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1

Modified Resource-Constrained Project Scheduling to minimize idle time for Banbury mixing process: a case study in the tire manufacturing industry

Butrat Anan, Supsomboon Srisawat

Management Systems in Production Engineering

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2023

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nr 3 (31)

263--270

EN

The Banbury mixing process (BMP) is to supplies the specific characteristic compounds for the tire manufacturing process. Idle time in the BMP was a problem caused by the aging process between mixing steps and the limited space for processing, measured in pallets. In this study, the resource-constrained project scheduling model (RCPS) is modified in case of the objective function and the input value of resource constraint to minimize idle time (SST). The complete minimization (Cmax) is changed from minimizing the starting time of the last job to the starting time of all jobs. In addition, the non-limited resource is defined as the input for the space capacity to reduce the idle time. As the results, the SST can provide the schedule that make less 5 time periods of idle time. Moreover, when considering the relationship between mixing and aging, aging process that is scheduled from SST starts immediately comparison to Cmax that some of aging process are not. Furthermore, the effect of the quantity of pallets was also examined. Although the non-limited resource does not make any delay to the schedule but the limited quantity is not. When pallets are limited, aging jobs were significantly impacted, with the last aging pallet being delayed. To reduce delays, it prepares an adequate supply of pallets that is close to or equal to its requirement that is defined by the non-limited resource. Further research combining the scheduling of the BMP with the tire manufacturing process and more techniques to modify RCPS are applied.

2

A Combination of Association Rules and Optimization Model to Solve Scheduling Problems in an Unstable Production Environment

Del Gallo Mateo, Ciarapica Filippo Emanuele, Mazzuto Giovanni, Bevilacqua Maurizio

Management and Production Engineering Review

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2023

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Vol. 14, No. 4

56--70

EN

Production problems have a significant impact on the on-time delivery of orders, resulting in deviations from planned scenarios. Therefore, it is crucial to predict interruptions during scheduling and to find optimal production sequencing solutions. This paper introduces a selflearning framework that integrates association rules and optimisation techniques to develop a scheduling algorithm capable of learning from past production experiences and anticipating future problems. Association rules identify factors that hinder the production process, while optimisation techniques use mathematical models to optimise the sequence of tasks and minimise execution time. In addition, association rules establish correlations between production parameters and success rates, allowing corrective factors for production quantity to be calculated based on confidence values and success rates. The proposed solution demonstrates robustness and flexibility, providing efficient solutions for Flow-Shop and Job-Shop scheduling problems with reduced calculation times. The article includes two Flow-Shop and Job-Shop examples where the framework is applied.

3

Production management system in a modern coal and coke company based on the demand and quality of the exploited raw material in the aspect of building a service-oriented architecture

Dyczko Artur

Journal of Sustainable Mining

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2023

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Vol. 22, iss. 1

1--19

EN

The paper deals with the implementation of the JSW Capital Group’s (Poland) Demand and Quality Driven Production Management System (SPPJ – System Zarządzania Produkcją oparty na Popycie i Jakości) using a service-oriented architecture (SOA). The main components of the SPPJ architecture have been characterized, and the scope of their integration has been defined. The individual parts in the first area, i.e. quality management, have been described in detail. Due to the extensive nature of the issue, components in other areas, i.e. planning and scheduling, coal extraction and processing, coke production, as well as sales and logistics, have only been signalled. Results of the analysis of the implementation of particular components of SPPJ areas have also been presented. The development of the system and the way of implementation in a mining environment is important from the perspective of achieving the superior objective of the JSW Capital Group’s Quality Programme, which is to increase the efficiency of management of the exploited deposit and the volume of commercial product supply.

4

Zastosowanie logiki rozmytej do szeregowania zleceń produkcyjnych

Jardzioch Andrzej, Witkowska Weronika

Zarządzanie Przedsiębiorstwem

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2022

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Vol. 25, nr 3-4

15--20

EN

The article presents an algorithm that allows using fuzzy logic to determine the effective arrangement of production orders in the production system. The main criterion used to rate was the total cost related to delayed implementation of production orders. In addition, the sum of delays of all orders and the total time of order execution were assessed. The elaborated algorithm uses fuzzy inference and allows us to estimate dynamically the effectiveness of selecting the next order from orders awaiting execution. As a result, the computational complexity of the proposed algorithm is linear. The research was conducted to assess the usefulness of the proposed algorithm. To illustrate the possibilities of the proposed algorithm, the obtained rankings were compared with those obtained using typical heuristic rules (FIFO, EDD, Johnson’s algorithm, and min changeover time). The obtained results confirmed the benefits of the proposed algorithm for scheduling production orders. The developed algorithm was implemented in Matlab and research was carried out for different series of production orders.

5

Scheduling of the Manufacturing Cell Work with the Use of a Genetic Algorithm on the Example of a Flexible Production System

Matuszny Marcin

Management and Production Engineering Review

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2022

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Vol. 13, No. 4

98--106

EN

The article is to present the application of genetic algorithm in production scheduling in a production company. In the research work the assumptions of the methodology were described and the operation of the proposed genetic algorithm was presented in details. Genetic algorithms are useful in complex large scale combinatorial optimisation tasks and in the engineering tasks with numerous limitations in the production engineering. Moreover, they are more reliable than the existing direct search algorithms. The research is focused on the effectivity improvement and on the methodology of scheduling of a manufacturing cell work. The genetic algorithm used in the work appeared to be robust and fast in finding accurate solutions. It was shown by experiment that using this method enables obtaining schedules suitable for a model. It gives a group of solutions that are at least as good as those created by the heuristic rules.

6

Sequencing and planning of packaging lines with reliability and digital twin concept considerations - a case study of a sugar production plant

Dąbrowska Alicja, Giel Robert, Winiarska Klaudia

LogForum

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2022

|

Vol. 18, no. 3

321--334

EN

Background: The study focuses on simplified make-and-pack production in the sugar industry as a case study. The analyzed system is characterized by parallel packing lines, which share one resource with a sequence-independent setup time. Additionally, the special characteristics that occur in many enterprises make scheduling difficult. The special characteristics of the system are the simultaneous occurrence of a variable input stream, scheduling of processes, and including the reliability of machines. Due to the variability of the input parameters, it is appropriate to consider the use of Digital Twin, which is a virtual representation of the real processes' performance. Therefore, this purpose of the paper is two-fold. First, an analysis of sequence determination of the stream-splitting machine was performed with taking into account the impact of logistics system reliability on system performance. Second, the concept of implementing Digital Twin in the analyzed production process is presented. Methods: The mathematical model for line efficiency was developed on the presented make-and-pack production presented in the selected sugar industry. Different sequences of stream-splitting machines were studied to examine the system's efficiency, availability, and utilization of packaging lines. Two scenarios were investigated with the use of computer simulation. Results: Computer simulation experiments were performed to investigate the sequencing and planning of packaging line problems. The results obtained for the case company indicated a significant dependence between the preferred packing sequence and the operational parameters. Conclusions: The simulations confirm the influence of internal and external factors on sugar line packaging processes. The main advantage of the developed simulation model is identifying the relationship between the size of the input stream and the system's availability level, as well as identifying the main constraints on the possibility of implementing the DT concept in the analyzed company.

7

Solving scheduling problems with integrated online sustainability observation using heuristic optimization

Burduk Anna, Musiał Kamil, Balashov Artem, Batako Andre, Safonyk Andrii

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2022

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Vol. 70, nr 6

art. no. e143830

EN

The paper deals with the issue of production scheduling for various types of employees in a large manufacturing company where the decision-making process was based on a human factor and the foreman’s know-how, which was error-prone. Modern production processes are getting more and more complex. A company that wants to be competitive on the market must consider many factors. Relying only on human factors is not efficient at all. The presented work has the objective of developing a new employee scheduling system that might be considered a particular case of the job shop problem from the set of the employee scheduling problems. The Neuro-Tabu Search algorithm and the data gathered by manufacturing sensors and process controls are used to remotely inspect machine condition and sustainability as well as for preventive maintenance. They were used to build production schedules. The construction of the Neuro-Tabu Search algorithm combines the Tabu Search algorithm, one of the most effective methods of constructing heuristic algorithms for scheduling problems, and a self-organizing neural network that further improves the prohibition mechanism of the Tabu Search algorithm. Additionally, in the paper, sustainability with the use of Industry 4.0 is considered. That would make it possible to minimize the costs of employees’ work and the cost of the overall production process. Solving the optimization problem offered by Neuro-Tabu Search algorithm and real-time data shows a new way of production management.

8

Comparison of the Classical Algorithm with the Training Algorithm in Scheduling Problem ADI Production

Wilk-Kołodziejczyk D., Chrzan K., Jaśkowiec K., Pirowski Z., Żuczek R., Bitka A., Machulec D.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 1

5--12

EN

A classical algorithm Tabu Search was compared with Q Learning (named learning) with regards to the scheduling problems in the Austempered Ductile Iron (ADI) manufacturing process. The first part comprised of a review of the literature concerning scheduling problems, machine learning and the ADI manufacturing process. Based on this, a simplified scheme of ADI production line was created, which a scheduling problem was described for. Moreover, a classic and training algorithm that is best suited to solve this scheduling problem was selected. In the second part, was made an implementation of chosen algorithms in Python programming language and the results were discussed. The most optimal algorithm to solve this problem was identified. In the end, all tests and their results for this project were presented.

9

Agárdi Anita, Nehéz Károly

Management and Production Engineering Review

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2021

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Vol. 13, No. 3

15--24

EN

Unrelated Parallel Machines Scheduling Problem (U-PMSP) is a category of discrete optimization problems in which various manufacturing jobs are assigned to identical parallel machines at particular times. In this paper, a specific production scheduling task the U-PMSP with Machine and Job Dependent Setup Times, Availability Constraint, Time Windows and Maintenance Times is introduced. Machines with different capacity limits and maintenance times are available to perform the tasks. After that our problem, the U-PMSP with Machine and Job Dependent Setup Times, Availability Constraints, Time Windows and Maintenance Times is detailed. After that, the applied optimization algorithm and their operators are introduced. The proposed algorithm is the genetic algorithm (GA), and proposed operators are the order crossover, partially matched crossover, cycle crossover and the 2-opt as a mutation operator. Then we prove the efficiency of our algorithm with test results. We also prove the efficiency of the algorithm on our own data set and benchmark data set. The authors conclude that this GA is effective for solving high complexity parallel machine problems.

10

Construction of a heuristic architecture of a production line management system in the JSW SA Mining Group in the context of output stabilization, quality improvement and the maximization of economic effects

Dyczko Artur

Gospodarka Surowcami Mineralnymi

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2021

|

T. 37, z. 4

219--238

EN

The effective implementation of new market strategies presents the mining enterprises with new challenges which require precise assessment instruments of the carried out business to be met at the level of mines, preparation plants, coking plants, and steelworks. These instruments include deposit, technological, and economic parameters, which together with a safety margin, determining the percentage reserve level of each parameter, shape the profitability of undertaken projects. The paper raises the issue of designing an IT architecture of the system for deposit modelling and mining production scheduling, implemented in the JSW SA. The development and application of the system was important with regard to the overriding objective of the Quality ProgramProgram of the JSW Capital Group, which is increasing the effectiveness of deposit and commercial product quality management. The paper also presents the required specification of the technical architecture necessary to implement systems and the actions required to integrate them with other IT systems of the JSW Group. The heuristic technical architecture of the JSW SA production line management system presented in the paper enables an analysis of the production process profitability in a carried account system in the area of mines, preparation plants, and coking plants of the mining group of the biggest European coal producer for metallurgical purposes.

PL

Skuteczna realizacja nowych strategii rynkowych stawia przed przedsiębiorstwami wydobywczymi nowe wyzwania, których realizacja wymaga precyzyjnych instrumentów oceny prowadzonej działalności na szczeblu kopalń, zakładów przeróbczych, koksowni, jak i hut. Instrumentami tymi są parametry złożowe, technologiczne i ekonomiczne, które wraz z marginesami bezpieczeństwa określającymi procentowy poziom rezerw każdego z parametrów kształtują rentowność podejmowanych przedsięwzięć. W artykule poruszono tematykę projektowania informatycznej architektury systemu do modelowania złoża oraz harmonogramowania produkcji górniczej, wdrożonego w JSW SA. Opracowanie i zastosowanie systemu było istotne z pespektywy realizacji nadrzędnego celu Programu Jakość Grupy Kapitałowej JSW, czyli zwiększenia efektywności zarządzania jakością złoża i produktu handlowego. Następnie w artykule przedstawiono opracowaną wymaganą specyfikację architektury technicznej, niezbędnej dla wdrożenia systemów oraz wymagane działania niezbędne do integracji z innymi systemami IT Grupy JSW. Prezentowana w artykule heurystyczna architektura techniczna systemu zarządzania ciągiem produkcyjnym JSW SA pozwala analizować rentowność procesu produkcyjnego w układzie rachunku ciągnionego w obszarze kopalń, zakładów przeróbczych i koksowni grupy górniczej największego europejskiego producenta węgla do celów metalurgicznych. Sytuacja rynku surowcowego staje się problematyczna dla przedsiębiorców, którzy muszą w sposób elastyczny dopasowywać swoje firmy do zmiennych warunków rynkowych, aby utrzymać tzw. biznesowość swoich projektów górniczych.

11

Flexible Job Shop Scheduling Problem with Sequence-Dependent Transportation Constraints and Setup Times

Varone Sacha, Schindl David, Beffa Corentin

Annals of Computer Science and Information Systems

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2021

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Vol. 26

97--102

EN

We study a production scheduling problem, which adresses on the one hand the usual operational constraints such as the precedence of operations, time windows, delays, uniqueness of treatment, availability of resources, and waiting times. On the other hand, the problem takes into account possible restricted movements according to production orders. This problem is a variant of a flexible job shop scheduling problem with several types of sequence-dependent constraints. We consider additional sequence-dependent setup times, as well as sequence-dependent transportation and assignment restrictions. We propose a mixed integer programming model (MIP). It is based on the MIP model of a flexible job shop scheduling problem, in which we add those sequence-dependent constraints. We solve it with a general purpose MIP solver.

12

Multi criteria decision making model for producing multiple products at the same time

Mokao Rami

Management and Production Engineering Review

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2020

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Vol. 11, No. 3

92--105

EN

The Decision Makers in the production organizations, which produce multiple different products at the same time, set the priorities for what the organization desires to produce. This priority is sorting the products in order to schedule the production based on these priorities. The production organizations receive a huge number of orders from different customers, each order contains many products with close delivery dates. The organization aims to produce multiple different products at the same time, in order to satisfy all customers by delivering all orders at the right time. This study will propose a method to prioritize the production to produce a multiple different products at the same time, the production lines will produce multiple different products. This method will prioritize the products using Multi Criteria Decision Making technique, and prioritize the production operations using a new algorithm called Algorithm for Prioritization of Production Operations. In addition, the study will provide an algorithm for production scheduling using the production priority calculated based on the proposed method. The study will also compare the scheduling based on the priority rules and based on the proposed method through total production time and the variety of products produced.

13

Zastosowanie modelu ARIMA do prognozowania wielkości produkcji w przedsiębiorstwie

Grzelak Małgorzata

Systemy Logistyczne Wojsk

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2019

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Vol. 50, no. 1

93--106

PL

Celem przedsiębiorstw produkcyjnych jest zaspokajanie potrzeb klientów, poprzez terminowe wytwarzanie wyrobów zgodnie z popytem występującym na rynku. Powyższe działania umożliwiane są przez prawidłowe sporządzanie prognoz potencjalnych zamówień. W poniższym artykule przedstawiono model ARIMA jako narzędzie wspierające planowanie wielkości produkcji w przedsiębiorstwie. Dokonano również oceny wiarygodności opracowanego modelu poprzez analizę reszt oraz ich autokorelacji i autokorelacji cząstkowych.

EN

The purpose of production companies is to meet the needs of customers by timely production of products in accordance with the demand on the market. The above activities are enabled by proper preparation of forecasts of potential orders. The following article presents a tool supporting production volume planning in an enterprise based on the ARIMA autoregressive model. The likelihood of the developed model was also evaluated by analyzing the residuals and their autocorrelations and partial autocorrelations.

14

Toward an Efficient Resolution for a Single-machine Bi-objective Scheduling Problem with Rejection

Moghaddam Atefeh, Teghem Jacques, Tuyttens Daniel, Yalaoui Farouk, Amodeo Lionel

Foundations of Computing and Decision Sciences

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2019

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Vol. 44, No. 2

179--211

EN

We consider a single-machine bi-objective scheduling problem with rejection. In this problem, it is possible to reject some jobs. Four algorithms are provided to solve this scheduling problem. The two objectives are the total weighted completion time and the total rejection cost. The aim is to determine the set of efficient solutions. Four heuristics are described; they are implicit enumeration algorithms forming a branching tree, each one having two versions according to the root of the tree corresponding either to acceptance or rejection of all the jobs. The algorithms are first illustrated by a didactic example. Then they are compared on a large set of instances of various dimension and their respective performances are analysed.

15

Koncepcja zastosowania narzędzi predykcji w projektowaniu harmonogramów odpornych

Sobaszek Ł, Świć A., Gola A.

Zarządzanie Przedsiębiorstwem

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2016

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Vol. 19, nr 2

20--26

EN

The development of competitiveness on world markets caused the need to increase production flexibility. An essential tool in achieving this purpose could be production scheduling. Unfortunately, the production process is associated with presence of numerous random events that negatively affect its course. Therefore, it is necessary to apply appropriate prediction methods which help to reduce its affect. The paper presents the conception of robust production scheduling. The typical scheduling problems and robust scheduling idea are described. Moreover, the current solutions of production scheduling under uncertainty are outlined. Finally, the idea of creating robust schedules based on previous production processes are presented. In the final part of the paper the author presented problems related to proposed idea.

16

Zmniejszenie udziału czasów przezbrajania w dostępnym czasie pracy maszyn

Żywicki K., Chabowski P., Dworczak P.

Zarządzanie Przedsiębiorstwem

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2015

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Vol. 18, nr 3

35--40

EN

The article presents an analysis of three options to reduce the share of changeovers time in the available time of working machines. The first option concerns the reduction of the number and share of changeover times by grouping them in the production schedule by technologically similarity. The similarity is understood as production of products using the same settings of machines or using the same equipment. For the purpose of such approach patterns of clustering and queuing production orders in work schedules machines are formed. This enables the rapid and substantial reduction in the share of changeovers in the available working time of machine without interfering with the retooling process itself. By only knowing the structure of retooling and extract these essential elements, which by pooling and templates queuing can be avoided. In this case, increase the efficiency of the machine is achieved, however, at the same time stocks of both semi-finished and finished products increases and extends the duration of the customer contracts internal or external. The second variant is related to the analysis of the effect of shortening changeover times on the availability of machines. This approach was applied to organizational changes of retooling of machines in accordance with SMED method. This requires the involvement of all people involved in the process and examine depth of the whole process of retooling. At the same time this allows for a significant improvement in the efficiency of the machine without increasing inventory and maximizing production orders. The third analysis includes the simultaneous application of queuing pattern of production orders for individual products in the schedules of the machine and to shorten setup times. This approach allows for rapid improvement of the equipment with relatively low effort and cost.

17

Dobór buforów czasowych oraz ich umiejscowienie w harmonogramie produkcji

Kozik M., Krystek J., Trznadel T.

Logistyka

|

2015

|

nr 2

408--413, CD1

PL

Artykuł dotyczy zasad doboru buforów czasowych wraz z ich umiejscowieniem w harmonogramie produkcji. Autorzy proponują wykorzystanie metody, która uwzględnia niedeterministyczny czas trwania zadań w harmonogramie, zgodnie z teorią łańcucha krytycznego.

EN

Article concerns the principles of selection time buffers along with their position in the production schedule. The authors propose the use of a method that takes into account the non - deterministic duration of the tasks in the schedule, according to the theory of critical chain.

18

An integrated model of production scheduling and maintenance planning under imperfect preventive maintenance

Chen X., Xiao L., Zhang X., Xiao W., Li J.

Eksploatacja i Niezawodność

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2015

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Vol. 17, no. 1

70--79

EN

For a successful company, machines are always required to work continuously to make more profit in a certain period. However, machines can be unavailable due to the scheduled maintenance activities or unexpected failures. Hence, a model connected production scheduling with maintenance planning for a production line which is composed of multiple machines is developed. Suppose preventive maintenance is imperfect and cannot renew all the machines. Age reduction factor and hazard rate increase factor are introduced to illustrate the imperfect character. Aperiodic preventive maintenance policy is adopted. Replacement as perfect maintenance could restore the machine “as good as new”. When and whether to perform replacement is based on a cost-time rate function which is defined to judge whether or not the preventive maintenance is economical. The objective of the joint model is to maximize the total profit which is composed of production value, production cost, maintenance cost (including the preventive maintenance cost and replacement cost), and tardiness cost (which is related to the job sequence and maintenance activities). To optimize the objective, immune clonal selection algorithm is utilized. The proposed model is validated by a numerical example.

PL

Aby firma mogła działać z powodzeniem i przynosić większe zyski w danym okresie czasu, zainstalowane w niej maszyny muszą pracować w sposób nieprzerwany. Niestety, z powodu planowych działań obsługowych lub nieoczekiwanych awarii, maszyny są czasami wyłączane z produkcji. Dlatego też w niniejszym artykule opracowano model łączący harmonogramowanie produkcji z planowaniem obsługi technicznej dla linii produkcyjnej złożonej z wielu maszyn. W pracy założono, że konserwacja zapobiegawcza jest niepełna i nie prowadzi do odnowy wszystkich maszyn. Aby zilustrować jej niepełny charakter, wprowadzono pojęcia czynnika redukcji wieku oraz czynnika wzrostu wskaźnika zagrożenia. Przyjęto politykę nieokresowej konserwacji zapobiegawczej. Wymiana jako forma pełnej konserwacji pozwala na przywrócenie maszyny do stanu "fabrycznej nowości". Kiedy i czy należy przeprowadzić wymianę zależy od funkcji wskaźnika kosztu w stosunku do czasu, który pozwala ocenić, czy konserwacja zapobiegawcza jest opłacalna. Model zintegrowany ma na celu maksymalizację całkowitego zysku, który jest wypadkową wartości produkcji, kosztów produkcji, kosztów obsługi (w tym kosztów konserwacji zapobiegawczej oraz kosztów wymiany) i kosztów nieterminowego zakończenia zadania (ang. lateness, związanych z kolejnością wykonywanych zadań i czynności obsługowych). Aby zoptymalizować opisany cel, wykorzystano algorytm odpornościowej selekcji klonalnej Proponowany model zweryfikowano na przykładzie liczbowym.

19

Production Scheduling under Fuzziness for the Furnace - Casting Line System

Duda J., Stawowy A.

Archives of Foundry Engineering

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2015

|

Vol. 15, iss. 4

29--32

EN

The problem considered in the paper is motivated by production planning in a foundry equipped with a furnace and a casting line, which provides a variety of castings in various grades of cast iron/steel for a large number of customers. The goal is to create the order of the melted metal loads to prevent delays in delivery of goods to customers. This problem is generally considered as a lot-sizing and scheduling problem. However, contrary to the classic approach, we assumed the fuzzy nature of the demand set for a given day. The paper describes a genetic algorithm adapted to take into account the fuzzy parameters of simultaneous grouping and scheduling tasks and presents the results achieved by the algorithm for example test problem.

20

Production Scheduling for the One Furnace – Two Casting Lines System

Basiura R., Duda J., Stawowy A.

Archives of Foundry Engineering

|

2015

|

Vol. 15, iss. 2 spec.

3--6

EN

The paper presents a scheduling production problem in foundry equipped with one furnace and two casting lines, which provides a number of different types of castings for a large number of clients. The amount of molten metal may not be greater than the capacity of the furnace and its load is a type of metal, from which the products are manufactured on automated casting lines. The purpose of planning is to create the processing order of metal, to prevent delays in the delivery of the ordered products to the customers. This problem is mixt of lot-sizing problem and scheduling problem on two machines (the lines) running in parallel. The article gives a mathematical model, which formally defines the optimization problem, and his relaxed version which is based on the concept of rolling-horizon planning. The proposed approaches were tested on the sample data.