• Title/Summary/Keyword: mixed-integer programming

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Integrating Machine Reliability and Preventive Maintenance Planning in Manufacturing Cell Design

  • Das, Kanchan;Lashkari, R.S.;Sengupta, S.
    • Industrial Engineering and Management Systems
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    • v.7 no.2
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    • pp.113-125
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    • 2008
  • This paper presents a model for designing cellular manufacturing systems (CMS) by integrating system cost, machine reliability, and preventive maintenance (PM) planning. In a CMS, a part is processed using alternative process routes, each consisting of a sequence of visits to machines. Thus, a level of 'system reliability' is associated with the machines along the process route assigned to a part type. Assuming machine reliabilities to follow the Weibull distribution, the model assigns the machines to cells, and selects, for each part type, a process route which maximizes the overall system reliability and minimizes the total costs of manufacturing operations, machine underutilization, and inter-cell material handling. The model also incorporates a reliability based PM plan and an algorithm to implement the plan. The algorithm determines effective PM intervals for the CMS machines based on a group maintenance policy and thus minimizes the maintenance costs subject to acceptable machine reliability thresholds. The model is a large mixed integer linear program, and is solved using LINGO. The results point out that integrating PM in the CMS design improves the overall system reliability markedly, and reduces the total costs significantly.

Sequencing for a mixed model assembly line in just-in-time production system (JIT 상황하에서 다품종 조립라인 작업물 투입 순서 결정 방안)

  • Hwang, Hark;Jeong, In-Jae;Lim, Joon-Mook
    • Korean Management Science Review
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    • v.11 no.1
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    • pp.91-106
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    • 1994
  • In mixed model assembly lines, products are assembled seqeuntially that have different combination of options specified by customers. In just in time (JIT) environment, production smoothing becomes an important issue for sub-lines which supply the necessary parts to each workstation of the assembly line. Another important issue is to avoid line stopping caused by work overload in workstations. To find a sequence which minimizes the costs associated with line stoppage and the option parts inventory level, a nonlinear mixed integer programming is formulated. Recognizing the limit of the Branch and Bound technique in large sized problems, a heuristic solution procedure is proposed. The performance of the heuristic is compared with the Branch and Bound technique through randomly generated test problems. The computational results indicate that on the average the heuristic solutions deviate approximately 3.6% from the optimal solutions.

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Optimal scheduling for multi-product batch processes under consideration of non-zero transfer times and set-up times

  • Jung, Jae-Hak;Lee, In-Beum;Yang, Dae-Ryook;Chang, Kun-Soo
    • 제어로봇시스템학회:학술대회논문집
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    • 1993.10b
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    • pp.30-35
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    • 1993
  • Simple recurrence relations for calculating completion times of various storage polices (unlimited, intermediate storages(FIS), finite intermediate storages(FIS), no intermediate storage(NIS), zero wait(ZW) for serial multi-product multi-unit processes are suggested. Not only processing times but also transfer times, set-up (clean-up) times of units and set-up times of storages are considered. Optimal scheduling strategies with zero transfer times and zero set-up times had been developed as a mixed integer linear programniing(MILP) formulation for several intermediate storage policies. In this paper those with non-zero transfer times, non-zero set-up times of units and set-up times of storages are newly proposed as a mixed integer nonlinear programming(MINLP) formulation for various storage polices (UIS, NIS, FIS, and ZW). Several examples are tested to evaluate the robustness of this strategy and reasonable computation times.

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Optimal Hourly Scheduling of Community-Aggregated Electricity Consumption

  • Khodaei, Amin;Shahidehpour, Mohammad;Choi, Jaeseok
    • Journal of Electrical Engineering and Technology
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    • v.8 no.6
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    • pp.1251-1260
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    • 2013
  • This paper presents the optimal scheduling of hourly consumption in a residential community (community, neighborhood, etc.) based on real-time electricity price. The residential community encompasses individual residential loads, communal (shared) loads, and local generation. Community-aggregated loads, which include residential and communal loads, are modeled as fixed, adjustable, shiftable, and storage loads. The objective of the optimal load scheduling problem is to minimize the community-aggregated electricity payment considering the convenience of individual residents and hourly community load characteristics. Limitations are included on the hourly utility load (defined as community-aggregated load minus the local generation) that is imported from the utility grid. Lagrangian relaxation (LR) is applied to decouple the utility constraint and provide tractable subproblems. The decomposed subproblems are formulated as mixed-integer programming (MIP) problems. The proposed model would be used by community master controllers to optimize the utility load schedule and minimize the community-aggregated electricity payment. Illustrative optimal load scheduling examples of a single resident as well as an aggregated community including 200 residents are presented to show the efficiency of the proposed method based on real-time electricity price.

A connection method of LPSolve and Excel for network optimization problem (네트워크 최적화 문제의 해결을 위한 LPSolve와 엑셀의 연동 방안)

  • Kim, Hu-Gon
    • Journal of Korea Society of Industrial Information Systems
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    • v.15 no.5
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    • pp.187-196
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    • 2010
  • We present a link that allows Excel to call the functions in the lp_solve system. lp_solve is free software licensed under the GPL that solves linear and mixed integer linear programs of moderate size. Our link manages the interface between Excel and lp_solve. Excel has a built-in add-in named Solver that is capable of solving mixed integer programs, but only with fewer than 200 variables. This link allows Excel users to handle substantially larger problems at no extra cost. Futhermore, we introduce that a network drawing method in Excel using arc adjacency lists of a network.

Development of Intelligent ATP System Using Genetic Algorithm (유전 알고리듬을 적용한 지능형 ATP 시스템 개발)

  • Kim, Tai-Young
    • Journal of Intelligence and Information Systems
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    • v.16 no.4
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    • pp.131-145
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    • 2010
  • The framework for making a coordinated decision for large-scale facilities has become an important issue in supply chain(SC) management research. The competitive business environment requires companies to continuously search for the ways to achieve high efficiency and lower operational costs. In the areas of production/distribution planning, many researchers and practitioners have developedand evaluated the deterministic models to coordinate important and interrelated logistic decisions such as capacity management, inventory allocation, and vehicle routing. They initially have investigated the various process of SC separately and later become more interested in such problems encompassing the whole SC system. The accurate quotation of ATP(Available-To-Promise) plays a very important role in enhancing customer satisfaction and fill rate maximization. The complexity for intelligent manufacturing system, which includes all the linkages among procurement, production, and distribution, makes the accurate quotation of ATP be a quite difficult job. In addition to, many researchers assumed ATP model with integer time. However, in industry practices, integer times are very rare and the model developed using integer times is therefore approximating the real system. Various alternative models for an ATP system with time lags have been developed and evaluated. In most cases, these models have assumed that the time lags are integer multiples of a unit time grid. However, integer time lags are very rare in practices, and therefore models developed using integer time lags only approximate real systems. The differences occurring by this approximation frequently result in significant accuracy degradations. To introduce the ATP model with time lags, we first introduce the dynamic production function. Hackman and Leachman's dynamic production function in initiated research directly related to the topic of this paper. They propose a modeling framework for a system with non-integer time lags and show how to apply the framework to a variety of systems including continues time series, manufacturing resource planning and critical path method. Their formulation requires no additional variables or constraints and is capable of representing real world systems more accurately. Previously, to cope with non-integer time lags, they usually model a concerned system either by rounding lags to the nearest integers or by subdividing the time grid to make the lags become integer multiples of the grid. But each approach has a critical weakness: the first approach underestimates, potentially leading to infeasibilities or overestimates lead times, potentially resulting in excessive work-inprocesses. The second approach drastically inflates the problem size. We consider an optimized ATP system with non-integer time lag in supply chain management. We focus on a worldwide headquarter, distribution centers, and manufacturing facilities are globally networked. We develop a mixed integer programming(MIP) model for ATP process, which has the definition of required data flow. The illustrative ATP module shows the proposed system is largely affected inSCM. The system we are concerned is composed of a multiple production facility with multiple products, multiple distribution centers and multiple customers. For the system, we consider an ATP scheduling and capacity allocationproblem. In this study, we proposed the model for the ATP system in SCM using the dynamic production function considering the non-integer time lags. The model is developed under the framework suitable for the non-integer lags and, therefore, is more accurate than the models we usually encounter. We developed intelligent ATP System for this model using genetic algorithm. We focus on a capacitated production planning and capacity allocation problem, develop a mixed integer programming model, and propose an efficient heuristic procedure using an evolutionary system to solve it efficiently. This method makes it possible for the population to reach the approximate solution easily. Moreover, we designed and utilized a representation scheme that allows the proposed models to represent real variables. The proposed regeneration procedures, which evaluate each infeasible chromosome, makes the solutions converge to the optimum quickly.

Design of military supply chain network using MIP & Simulation model (혼합정수계획법과 시뮬레이션 기법을 이용한 군 공급사슬망 설계)

  • Lee, Byeong-Ho;Jeong, Dong-Hwa;Seo, Yoon-Ho
    • Journal of the military operations research society of Korea
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    • v.34 no.3
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    • pp.1-12
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    • 2008
  • Design of supply chain network (SCN) is required to optimize every factor in SCN and to provide a long-term and strategic decision-making. A mathematical model can not reflect the real world because design of SCN contains variables and stochastic factors according to status of its system. This paper presents the designing methodology of military SCN using the mathematical model and the simulation model. It constructs SCN to minimize its total costs using the Mixed Integer Programming (MIP) model. And we solve problems of a vehicle assignment and routing through adaptation of experiment parameters repeatedly in the simulation model based on the results from the MIP model. We implement each model with CPLEX and AutoMod, and experiment to reconstruct SCN when the Logistic Support Unit is restricted to support military units. The results from these experiments show that the proposed method can be used for a design of military SCN.

An Improved Genetic Approach to Optimal Supplier Selection and Order Allocation with Customer Flexibility for Multi-Product Manufacturing

  • Mak, Kai-Ling;Cui, Lixin;Su, Wei
    • Industrial Engineering and Management Systems
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    • v.11 no.2
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    • pp.155-164
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    • 2012
  • As the global market becomes more competitive, manufacturing industries face relentless pressure caused by a growing tendency of greater varieties of products, shorter manufacturing cycles and more sophisticated customer requirements. Efficient and effective supplier selection and order allocation decisions are, therefore, important decisions for a manufacturer to ensure stable material flows in a highly competitive supply chain, in particular, when customers are willing to accept products with less desirable product attributes (e.g., color, delivery date) for economic reasons. This paper attempts to solve optimally the challenging problem of supplier selection and order allocation, taking into consideration the customer flexibility for a manufacturer producing multi-products to satisfy the customers' demands in a multi period planning horizon. A new mixed integer programming model is developed to describe the behavior of the supply chain. The objective is to maximize the manufacturer's total profit subject to various operating constraints of the supply chain. Due to the complexity and non-deterministic polynomial-time (NP)-hard nature of the problem, an improved genetic approach is proposed to solve the problem optimally. This approach differs from a canonical genetic algorithm in three aspects: a new selection method to reduce the chance of premature convergence and two problem-specific repair heuristics to guarantee feasibility of the solutions. The results of applying the proposed approach to solve a set of randomly generated test problems clearly demonstrate its excellent performance. When compared with applying the canonical genetic algorithm to locate optimal solutions, the average improvement in the solution quality amounts to as high as ten percent.

Study for the Plant Layout Optimization for the Ethylene Oxide Process based on Mathematical and Explosion Modeling (수학적 모델과 폭발사고 모델링을 통한 산화에틸렌 공정의 설비 배치 최적화에 관한 연구)

  • Cha, Sanghoon;Lee, Chang Jun
    • Journal of the Korean Society of Safety
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    • v.35 no.1
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    • pp.25-33
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    • 2020
  • In most plant layout optimization researches, MILP(Mixed Integer Linear Programming) problems, in which the objective function includes the costs of pipelines connecting process equipment and cost associated with safety issues, have been employed. Based on these MILP problems, various optimization solvers have been applied to investigate the optimal solutions. To consider safety issues on the objective function of MILP problems together, the accurate information about the impact and the frequency of potential accidents in a plant should be required to evaluate the safety issues. However, it is really impossible to obtain accurate information about potential accidents and this limitation may reduce the reliability of a plant layout problem. Moreover, in real industries such as plant engineering companies, the plant layout is previously fixed and the considerations of various safety instruments and systems have been performed to guarantee the plant safety. To reflect these situations, the two step optimization problems have been designed in this study. The first MILP model aims to minimize the costs of pipelines and the land size as complying sufficient spaces for the maintenance and safety. After the plant layout is determined by the first MILP model, the optimal locations of blast walls have been investigated to maximize the mitigation impacts of blast walls. The particle swarm optimization technique, which is one of the representative sampling approaches, is employed throughout the consideration of the characteristics of MILP models in this study. The ethylene oxide plant is tested to verify the efficacy of the proposed model.

Development of Transmission Expansion Planning Optimization Software Considering Integration of Generation and Transmission Facilities (발·송전설비 통합성을 고려한 전력계통계획 전산모형 프로그램 개발)

  • Hur, Don;Jung, Hae-Sung;Ryu, Heon-Su;Cho, Kong-Wook
    • Journal of the Korean Institute of Illuminating and Electrical Installation Engineers
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    • v.24 no.2
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    • pp.16-26
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    • 2010
  • The transmission valuation methodology we propose here captures the interaction between generation and transmission investment decisions recognizing that a transmission expansion can impact the profitability of new resources investment, so that a methodology should consider both the objectives of investors in resources and the transmission planner. In this perspective, this paper purports to develop the mixed-integer programming based transmission expansion planning optimization software, which is well designed to determine the construction time and place of new generators, transmission lines, and substations as well as their capacities to minimize total expenditures related to their investment and operations while meeting technical constraints such as capacity margin, constitution ratio of power resources, spinning reserves, energy and fuel constraints, transmission line outages and losses, pi-type branching, and so on. Finally, Garver's simple system is adopted to validate not simply the accuracy but the efficiency of the proposed model in this paper.