A hybrid method for large-scale short-term scheduling of make-and-pack production processes

Due to the ongoing trend towards increased product variety, fast-moving consumer goods such as food and beverages, pharmaceuticals, and chemicals are typically manufactured through so-called make-and-pack processes. These processes consist of a make stage, a pack stage, and intermediate storage facilities that decouple these two stages. In operations scheduling, complex technological constraints must be considered, e.g., non-identical parallel processing units, sequence-dependent changeovers, batch splitting, no-wait restrictions, material transfer times, minimum storage times, and finite storage capacity. The short-term scheduling problem is to compute a production schedule such that a given demand for products is fulfilled, all technological constraints are met, and the production makespan is minimised. A production schedule typically comprises 500–1500 operations. Due to the problem size and complexity of the technological constraints, the performance of known mixed-integer linear programming (MILP) formulations and heuristic approaches is often insufficient.

[1]  Luis Puigjaner,et al.  MIP-based decomposition strategies for large-scale scheduling problems in multiproduct multistage batch plants: A benchmark scheduling problem of the pharmaceutical industry , 2010, Eur. J. Oper. Res..

[2]  Nilay Shah,et al.  RTN-based rolling horizon algorithms for medium term scheduling of multipur-pose plants , 1997 .

[3]  Luis Puigjaner,et al.  Production scheduling in multiproduct multistage semicontinuous food processes , 2011 .

[4]  Iiro Harjunkoski,et al.  Solving a large-scale industrial scheduling problem using MILP combined with a heuristic procedure , 2002, Eur. J. Oper. Res..

[5]  N. B. Raikar,et al.  Scheduling in the FMCG Industry: An Industrial Case Study , 2012 .

[6]  Jaime Cerdá,et al.  An MILP Continuous-Time Framework for Short-Term Scheduling of Multipurpose Batch Processes Under Different Operation Strategies , 2003 .

[7]  Christodoulos A. Floudas,et al.  Continuous-time versus discrete-time approaches for scheduling of chemical processes: a review , 2004, Comput. Chem. Eng..

[8]  Bilge Bilgen,et al.  Integrated production and distribution planning in the fast moving consumer goods industry: a block planning application , 2010, OR Spectr..

[9]  Ignacio E. Grossmann,et al.  Slot-based formulation for the short-term scheduling of multistage, multiproduct batch plants with sequence-dependent changeovers , 2008 .

[10]  Pedro M. Castro,et al.  New Continuous-Time MILP Model for the Short-Term Scheduling of Multistage Batch Plants , 2005 .

[11]  Martin Grunow,et al.  Realizing block planning concepts in make-and-pack production using MILP modelling and SAP APO © , 2006 .

[12]  Jaime Cerdá,et al.  An efficient MILP continuous-time formulation for short-term scheduling of multiproduct continuous facilities , 2002 .

[13]  Luis Puigjaner,et al.  Efficient mathematical frameworks for detailed production scheduling in food processing industries , 2012, Comput. Chem. Eng..

[14]  Christodoulos A. Floudas,et al.  Unit-specific event-based continuous-time approach for short-term scheduling of batch plants using RTN framework , 2008, Comput. Chem. Eng..

[15]  Jaime Cerdá,et al.  An MILP continuous-time approach to short-term scheduling of resource-constrained multistage flowshop batch facilities , 2001 .

[16]  Josef Kallrath,et al.  Planning and scheduling in the process industry , 2002, OR Spectr..

[17]  I. Grossmann,et al.  Optimal short-term scheduling of large-scale multistage batch plants , 2009 .

[18]  Iftekhar A. Karimi,et al.  A simpler better slot-based continuous-time formulation for short-term scheduling in multipurpose batch plants , 2005 .

[19]  Christos T. Maravelias,et al.  Modeling of Storage in Batching and Scheduling of Multistage Processes , 2008 .

[20]  Jaime Cerdá,et al.  Optimal scheduling of a resource-constrained multiproduct batch plant supplying intermediates to nearby end-product facilities , 2000 .

[21]  Pablo A. Marchetti,et al.  An approximate mathematical framework for resource-constrained multistage batch scheduling , 2009 .

[22]  Nilay Shah,et al.  Aggregate modelling of multipurpose plant operation , 1995 .

[23]  Iiro Harjunkoski,et al.  An MILP-Based reordering algorithm for complex industrial scheduling and rescheduling , 2000 .

[24]  Rubén Ruiz,et al.  A genetic algorithm for hybrid flowshops with sequence dependent setup times and machine eligibility , 2006, European Journal of Operational Research.

[25]  R. BELAID,et al.  STORAGE PROBLEM IN A SHAMPOO MAKING SYSTEM , 2010 .

[26]  Norbert Trautmann,et al.  A continuous-time MILP model for short-term scheduling of make-and-pack production processes , 2013 .

[27]  Vincent T'Kindt,et al.  Scheduling batches in flowshop with limited buffers in the shampoo industry , 2012, Eur. J. Oper. Res..

[28]  Christos T. Maravelias,et al.  Simultaneous Batching and Scheduling in Multistage Multiproduct Processes , 2008 .

[29]  Jaime Cerdá,et al.  Dynamic scheduling in multiproduct batch plants , 2003, Comput. Chem. Eng..

[30]  Philipp Baumann,et al.  Heuristic decomposition and LP-based scheduling in make-and-pack production , 2011, 2011 IEEE International Conference on Industrial Engineering and Engineering Management.

[31]  Ronald G. Askin,et al.  Scheduling flexible flow lines with sequence-dependent setup times , 2004, Eur. J. Oper. Res..

[32]  P. Castro,et al.  Two New Continuous-Time Models for the Scheduling of Multistage Batch Plants with Sequence Dependent Changeovers , 2006 .

[33]  Ignacio E. Grossmann,et al.  Decomposition techniques for multistage scheduling problems using mixed-integer and constraint programming methods , 2002 .

[34]  Pedro M. Castro,et al.  Scheduling multistage batch plants with sequence‐dependent changeovers , 2009 .

[35]  Jaime Cerdá,et al.  An MILP-based approach to the short-term scheduling of make-and-pack continuous production plants , 2002, OR Spectr..

[36]  Peter M.M. Bongers,et al.  Application of multi-stage scheduling , 2006 .

[37]  Dario Pacciarelli,et al.  A tabu search algorithm for scheduling pharmaceutical packaging operations , 2010, Eur. J. Oper. Res..

[38]  Gabriela P. Henning,et al.  A novel network-based continuous-time representation for process scheduling: Part II. General framework , 2009, Comput. Chem. Eng..

[39]  Christos T. Maravelias,et al.  A decomposition framework for the scheduling of single- and multi-stage processes , 2006, Comput. Chem. Eng..

[40]  Ignacio E. Grossmann,et al.  New General Continuous-Time State−Task Network Formulation for Short-Term Scheduling of Multipurpose Batch Plants , 2003 .

[41]  Gabriela P. Henning,et al.  A novel network-based continuous-time representation for process scheduling: Part I. Main concepts and mathematical formulation , 2009, Comput. Chem. Eng..

[42]  Hlynur Stefansson,et al.  Production , Manufacturing and Logistics Discrete and continuous time representations and mathematical models for large production scheduling problems : A case study from the pharmaceutical industry , 2011 .

[43]  Vipul Jain,et al.  A Disjunctive Model for Scheduling in a Manufacturing and Packing Facility with Intermediate Storage , 2000 .

[44]  Jaime Cerdá,et al.  State-of-the-art review of optimization methods for short-term scheduling of batch processes , 2006, Comput. Chem. Eng..

[45]  Han Hoogeveen,et al.  Scheduling multipurpose batch process industries with no-wait restrictions by simulated annealing , 2000, Eur. J. Oper. Res..

[46]  R. Sargent,et al.  A general algorithm for short-term scheduling of batch operations */I , 1993 .

[47]  Norbert Trautmann,et al.  Scheduling of make and pack plants: a case study , 2006 .

[48]  Carlos A. Méndez,et al.  An improvement-based MILP optimization approach to complex AWS scheduling , 2012, Comput. Chem. Eng..

[49]  Joseph F. Pekny,et al.  The curse of reality — why process scheduling optimization problems are difficult in practice , 2000 .

[50]  Rajagopalan Srinivasan,et al.  Novel genetic algorithm for short-term scheduling of sequence dependent changeovers in multiproduct polymer plants , 2011, Comput. Chem. Eng..

[51]  L. Puigjaner,et al.  An Efficient Mixed-Integer Linear Programming Scheduling Framework for Addressing Sequence-Dependent Setup Issues in Batch Plants , 2009 .

[52]  Ignacio E. Grossmann,et al.  New general continuous-time state-task network formulation for short-term scheduling of multipurpose batch plants , 2003 .

[53]  Augusto Q. Novais,et al.  A discrete time reactive scheduling model for new order insertion in job shop, make-to-order industries , 2010 .

[54]  I. Grossmann,et al.  A Mixed-Integer Linear Programming Model for Short-Term Scheduling of Single-Stage Multiproduct Batch Plants with Parallel Lines , 1997 .

[55]  Iftekhar A. Karimi,et al.  Scheduling a Two-Stage Multiproduct Process with Limited Product Shelf Life in Intermediate Storage , 2003 .