IDEAS home Printed from https://ideas.repec.org/a/spr/flsman/v31y2019i1d10.1007_s10696-017-9303-9.html
   My bibliography  Save this article

A decomposition heuristic to solve the two-stage lot sizing and scheduling problem with temporal cleaning

Author

Listed:
  • Alyne Toscano

    (Federal University of Triângulo Mineiro)

  • Deisemara Ferreira

    (Federal University of São Carlos)

  • Reinaldo Morabito

    (Federal University of São Carlos)

Abstract

This paper presents a study on the fruit-based beverage lot sizing and scheduling problem. This is a two-stage lot-scheduling problem with some features, such as the presence of buffers between the production stages, mandatory temporal cleanings for the preparation tanks (stage I) and production lines (stage II), and production synchronization between the production stages. To solve this problem, we propose two variations of a two-phase heuristic algorithm by devising a production stage decomposition scheme coupled with a constructive procedure. In the first phase, a one-stage lot sizing is solved by a mixed integer programming model, and in the second phase, scheduling and the synchrony between the stages are carried out using a constructive algorithm. The two variations of the heuristic are: Stage I Heuristics (S1H) and Stage II Heuristics (S2H). In S1H, production stage I is solved by a mathematical model and in S2H, production stage II is solved by another mathematical model. Data from a typical beverage company of a large worldwide brand was used in the computational tests. The results showed that the heuristics are able to find competitive solutions very quickly and that the S2H heuristic performs better than S1H.

Suggested Citation

  • Alyne Toscano & Deisemara Ferreira & Reinaldo Morabito, 2019. "A decomposition heuristic to solve the two-stage lot sizing and scheduling problem with temporal cleaning," Flexible Services and Manufacturing Journal, Springer, vol. 31(1), pages 142-173, March.
    • Handle: RePEc:spr:flsman:v:31:y:2019:i:1:d:10.1007_s10696-017-9303-9
    DOI: 10.1007/s10696-017-9303-9
    as

    Download full text from publisher

    File URL: http://link.springer.com/10.1007/s10696-017-9303-9
    File Function: Abstract
    Download Restriction: Access to the full text of the articles in this series is restricted.
    File URL: https://libkey.io/10.1007/s10696-017-9303-9?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. William W. Trigeiro & L. Joseph Thomas & John O. McClain, 1989. "Capacitated Lot Sizing with Setup Times," Management Science, INFORMS, vol. 35(3), pages 353-366, March.
    2. José Roberto Dale Luche & Reinaldo Morabito & Vitória Pureza, 2009. "Combining Process Selection And Lot Sizing Models For Production Scheduling Of Electrofused Grains," Asia-Pacific Journal of Operational Research (APJOR), World Scientific Publishing Co. Pte. Ltd., vol. 26(03), pages 421-443.
    3. Ferreira, Deisemara & Clark, Alistair R. & Almada-Lobo, Bernardo & Morabito, Reinaldo, 2012. "Single-stage formulations for synchronised two-stage lot sizing and scheduling in soft drink production," International Journal of Production Economics, Elsevier, vol. 136(2), pages 255-265.
    4. Bouchriha, Hanen & Ouhimmou, Mustapha & D'Amours, Sophie, 2007. "Lot sizing problem on a paper machine under a cyclic production approach," International Journal of Production Economics, Elsevier, vol. 105(2), pages 318-328, February.
    5. Almeder, Christian & Klabjan, Diego & Traxler, Renate & Almada-Lobo, Bernardo, 2015. "Lead time considerations for the multi-level capacitated lot-sizing problem," European Journal of Operational Research, Elsevier, vol. 241(3), pages 727-738.
    6. Fabrizio Marinelli & Maria Nenni & Antonio Sforza, 2007. "Capacitated lot sizing and scheduling with parallel machines and shared buffers: A case study in a packaging company," Annals of Operations Research, Springer, vol. 150(1), pages 177-192, March.
    7. Ferreira, Deisemara & Morabito, Reinaldo & Rangel, Socorro, 2009. "Solution approaches for the soft drink integrated production lot sizing and scheduling problem," European Journal of Operational Research, Elsevier, vol. 196(2), pages 697-706, July.
    8. Meyr, H., 2002. "Simultaneous Lotsizing and Scheduling on Parallel Machines," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 36065, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    9. Fleischmann, Bernhard, 1990. "The discrete lot-sizing and scheduling problem," European Journal of Operational Research, Elsevier, vol. 44(3), pages 337-348, February.
    10. Fahimeh Shamsaei & Mathieu Vyve, 2017. "Solving integrated production and condition-based maintenance planning problems by MIP modeling," Flexible Services and Manufacturing Journal, Springer, vol. 29(2), pages 184-202, June.
    11. Brahimi, Nadjib & Dauzere-Peres, Stephane & Najid, Najib M. & Nordli, Atle, 2006. "Single item lot sizing problems," European Journal of Operational Research, Elsevier, vol. 168(1), pages 1-16, January.
    12. Fleischmann, B. & Meyr, H., 1997. "The General Lotsizing and Scheduling Problem," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 36068, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    13. Camargo, Victor C.B. & Toledo, Franklina M.B. & Almada-Lobo, Bernardo, 2014. "HOPS – Hamming-Oriented Partition Search for production planning in the spinning industry," European Journal of Operational Research, Elsevier, vol. 234(1), pages 266-277.
    14. Meyr, Herbert & Mann, Matthias, 2013. "A decomposition approach for the General Lotsizing and Scheduling Problem for Parallel production Lines," European Journal of Operational Research, Elsevier, vol. 229(3), pages 718-731.
    15. V C B Camargo & F M B Toledo & B Almada-Lobo, 2012. "Three time-based scale formulations for the two-stage lot sizing and scheduling in process industries," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 63(11), pages 1613-1630, November.
    16. Drexl, Andreas & Haase, Knut, 1995. "Proportional lotsizing and scheduling," International Journal of Production Economics, Elsevier, vol. 40(1), pages 73-87, June.
    17. Karimi, B. & Fatemi Ghomi, S. M. T. & Wilson, J. M., 2003. "The capacitated lot sizing problem: a review of models and algorithms," Omega, Elsevier, vol. 31(5), pages 365-378, October.
    18. Meyr, Herbert, 2002. "Simultaneous lotsizing and scheduling on parallel machines," European Journal of Operational Research, Elsevier, vol. 139(2), pages 277-292, June.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Dražen Popović & Nenad Bjelić & Milorad Vidović & Branislava Ratković, 2023. "Solving a Production Lot-Sizing and Scheduling Problem from an Enhanced Inventory Management Perspective," Mathematics, MDPI, vol. 11(9), pages 1-23, April.
    2. Mac Cawley, Alejandro & Maturana, Sergio & Pascual, Rodrigo & Tortorella, Guilherme Luz, 2022. "Scheduling wine bottling operations with multiple lines and sequence-dependent set-up times: Robust formulation and a decomposition solution approach," European Journal of Operational Research, Elsevier, vol. 303(2), pages 819-839.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Karina Copil & Martin Wörbelauer & Herbert Meyr & Horst Tempelmeier, 2017. "Simultaneous lotsizing and scheduling problems: a classification and review of models," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 39(1), pages 1-64, January.
    2. Martin Wörbelauer & Herbert Meyr & Bernardo Almada-Lobo, 2019. "Simultaneous lotsizing and scheduling considering secondary resources: a general model, literature review and classification," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 41(1), pages 1-43, March.
    3. Ferreira, Deisemara & Clark, Alistair R. & Almada-Lobo, Bernardo & Morabito, Reinaldo, 2012. "Single-stage formulations for synchronised two-stage lot sizing and scheduling in soft drink production," International Journal of Production Economics, Elsevier, vol. 136(2), pages 255-265.
    4. Mac Cawley, Alejandro & Maturana, Sergio & Pascual, Rodrigo & Tortorella, Guilherme Luz, 2022. "Scheduling wine bottling operations with multiple lines and sequence-dependent set-up times: Robust formulation and a decomposition solution approach," European Journal of Operational Research, Elsevier, vol. 303(2), pages 819-839.
    5. Camargo, Victor C.B. & Toledo, Franklina M.B. & Almada-Lobo, Bernardo, 2014. "HOPS – Hamming-Oriented Partition Search for production planning in the spinning industry," European Journal of Operational Research, Elsevier, vol. 234(1), pages 266-277.
    6. Meyr, Herbert & Mann, Matthias, 2013. "A decomposition approach for the General Lotsizing and Scheduling Problem for Parallel production Lines," European Journal of Operational Research, Elsevier, vol. 229(3), pages 718-731.
    7. Wolosewicz, Cathy & Dauzère-Pérès, Stéphane & Aggoune, Riad, 2015. "A Lagrangian heuristic for an integrated lot-sizing and fixed scheduling problem," European Journal of Operational Research, Elsevier, vol. 244(1), pages 3-12.
    8. Carvalho, Desiree M. & Nascimento, Mariá C.V., 2022. "Hybrid matheuristics to solve the integrated lot sizing and scheduling problem on parallel machines with sequence-dependent and non-triangular setup," European Journal of Operational Research, Elsevier, vol. 296(1), pages 158-173.
    9. K. A. G. Araujo & E. G. Birgin & M. S. Kawamura & D. P. Ronconi, 2023. "Relax-and-Fix Heuristics Applied to a Real-World Lot Sizing and Scheduling Problem in the Personal Care Consumer Goods Industry," SN Operations Research Forum, Springer, vol. 4(2), pages 1-30, June.
    10. Martínez, Karim Pérez & Morabito, Reinaldo & Toso, Eli Angela Vitor, 2018. "A coupled process configuration, lot-sizing and scheduling model for production planning in the molded pulp industry," International Journal of Production Economics, Elsevier, vol. 204(C), pages 227-243.
    11. Józefowska, J. & Zimniak, A., 2008. "Optimization tool for short-term production planning and scheduling," International Journal of Production Economics, Elsevier, vol. 112(1), pages 109-120, March.
    12. Lee, Younsoo & Lee, Kyungsik, 2022. "New integer optimization models and an approximate dynamic programming algorithm for the lot-sizing and scheduling problem with sequence-dependent setups," European Journal of Operational Research, Elsevier, vol. 302(1), pages 230-243.
    13. Masoumeh Mahdieh & Alistair Clark & Mehdi Bijari, 2018. "A novel flexible model for lot sizing and scheduling with non-triangular, period overlapping and carryover setups in different machine configurations," Flexible Services and Manufacturing Journal, Springer, vol. 30(4), pages 884-923, December.
    14. Melega, Gislaine Mara & de Araujo, Silvio Alexandre & Jans, Raf, 2018. "Classification and literature review of integrated lot-sizing and cutting stock problems," European Journal of Operational Research, Elsevier, vol. 271(1), pages 1-19.
    15. Junqueira, Rogerio de Ávila Ribeiro & Morabito, Reinaldo, 2019. "Modeling and solving a sugarcane harvest front scheduling problem," International Journal of Production Economics, Elsevier, vol. 213(C), pages 150-160.
    16. Tao Wu & Zhe Liang & Canrong Zhang, 2018. "Analytics Branching and Selection for the Capacitated Multi-Item Lot Sizing Problem with Nonidentical Machines," INFORMS Journal on Computing, INFORMS, vol. 30(2), pages 236-258, May.
    17. Wei, Wenchao & Guimarães, Luis & Amorim, Pedro & Almada-Lobo, Bernardo, 2017. "Tactical production and distribution planning with dependency issues on the production process," Omega, Elsevier, vol. 67(C), pages 99-114.
    18. Wolter, Anja & Helber, Stefan, 2013. "Simultaneous Production and Maintenance Planning for a Single Capacitated Resource facing both a Dynamic Demand and Intensive Wear and Tear," Hannover Economic Papers (HEP) dp-522, Leibniz Universität Hannover, Wirtschaftswissenschaftliche Fakultät.
    19. Dražen Popović & Nenad Bjelić & Milorad Vidović & Branislava Ratković, 2023. "Solving a Production Lot-Sizing and Scheduling Problem from an Enhanced Inventory Management Perspective," Mathematics, MDPI, vol. 11(9), pages 1-23, April.
    20. Gislaine Mara Melega & Silvio Alexandre de Araujo & Reinaldo Morabito, 2020. "Mathematical model and solution approaches for integrated lot-sizing, scheduling and cutting stock problems," Annals of Operations Research, Springer, vol. 295(2), pages 695-736, December.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:spr:flsman:v:31:y:2019:i:1:d:10.1007_s10696-017-9303-9. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Sonal Shukla or Springer Nature Abstracting and Indexing (email available below). General contact details of provider: http://www.springer.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.