A Mathematical Programming Model for Tactical Planning with Set-up Continuity in a Two-stage Ceramic Firm

David Pérez Perales, M.M. Eva Alemany

Abstract

It is known that capacity issues in tactical production plans in a hierarchical context are relevant since its inaccurate determination may lead to unrealistic or simply non-feasible plans at the operational level. Semi-continuous industrial processes, such as ceramic ones, often imply large setups and their consideration is crucial for accurate capacity estimation. However, in most of production planning models developed in a hierarchical context at this tactical (aggregated) level, setup changes are not explicitly considered. Their consideration includes not only decisions about lot sizing of production, but also allocation, known as Capacitated Lot Sizing and Loading Problem (CLSLP). However, CLSLP does not account for set-up continuity, specially important in contexts with lengthy and costly set-ups and where product families minimum run length are similar to planning periods. In this work, a mixed integer linear programming (MILP) model for a two stage ceramic firm which accounts for lot sizing and loading decisions including minimum lot-sizes and set-up continuity between two consecutive periods is proposed. Set-up continuity inclusion is modelled just considering which product families are produced at the beginning and at the end of each period of time, and not the complete sequence. The model is solved over a simplified two-stage real-case within a Spanish ceramic firm. Obtained results confirm its validity.


Keywords

set-up continuity; ceramic firm; tactical planning; mixed integer linear programming

Full Text:

PDF

References

Alemany, M.M., Alarcón, F., Lario, F.C., Boj, J.J. (2009). Planificación agregada en cadenas de suministro del sector cerámico. III internacional conference on industrial engineering and industrial management. Barcelona, Spain 3-42.

Alemany, M.M., Boj, J.J., Mula, J., Lario, F.C. (2011). Mathematical programming model for centralised master planning in ceramic tile supply chains. International Journal of Production Research, 48, 5053-5074. http://dx.doi.org/10.1080/00207540903055701

Barany, I., Van Roy, T.J., Wolsey, L.A. (1984). Strong formulations for multi-item capacitated lot sizing. Management Science, 30(10), 1255–1261. http://dx.doi.org/10.1287/mnsc.30.10.1255

Belvaux, G., Wolsey, L.A. (2001). Modelling practical lot-sizing problems as mixed-integer programs. Management Science, 47(7), 724-38. http://dx.doi.org/10.1287/mnsc.47.7.993.9800

Chen, W.H., Thizy, J.M. (1990). Analysis of relaxations for the multi-item capacitated lot-sizing problem. Annals of Operations Research, 26, 29-72. http://dx.doi.org/10.1007/BF02248584

Chung, C., Flynn, J., Lin, C.M. (1994). An efective algorithm for the capacitated single item lot size problem. European Journal of Operational Research, 75(2), 427-40. http://dx.doi.org/10.1016/0377-2217(94)90086-8

De Toni, A., Meneghetti, A. (2000).The production planning process for a network of firms in the textile-apparel industry. International Journal of Production Economics, 65(1), 17-32. http://dx.doi.org/10.1016/S0925-5273(99)00087-0

Eppen, G.D., Martin, R.K. (1987). Solving multi-item capacitated lot sizing problems using variable redefinition. Operations Research, 35(6), 832–48. http://dx.doi.org/10.1287/opre.35.6.832

Fumero, Y., Montagna, J.M., Corsano, G. (2012). Simultaneous design and scheduling of a semicontinuous/batch plant for ethanol and derivatives production. Article Computers & Chemical Engineering, 36, 342-357. http://dx.doi.org/10.1016/j.compchemeng.2011.08.004

Gopalakrishnan, M., Ding, K., Bourjolly, J.M., Mohan, S. (2001). A tabu-search heuristic for the capacitated lot-sizing problem with set-up carryover. Management Science, 47(6), 851–863. http://dx.doi.org/10.1287/mnsc.47.6.851.9813

Grieco, S., Quirico, S., Tullio, T. (2001). A Review of Different Approaches to the FMS Loading Problem. International Journal of Flexible Manufacturing Systems, 13(4), 361-384. http://dx.doi.org/10.1023/A:1012290630540

Guo, Z.X., Wong, W.K., Leung, S.Y.S., Fan, J.T., Chan, S.F. (2006). Mathematical model and genetic optimization for the job shop scheduling problem in a mixed- and multi-product assembly environment: A case study based on the apparel industry. Computers & Industrial Engineering, 50(3), 202-219. http://dx.doi.org/10.1016/j.cie.2006.03.003

Haase, K. (1994). Lotsizing and scheduling for Production Planning. In: Lecture Notes in Economics and Mathematical Systems. Springer-Verlag, Berlin. http://dx.doi.org/10.1007/978-3-642-45735-7

Hindi, K.S. (1996) .Solving the CLSP by a tabu search heuristic. Journal of the Operational Research Society, 47(1), 151–61. http://dx.doi.org/10.1057/jors.1996.13

Ishikura, H. (1994). Study on the production planning of apparel products: Determining optimal production times and quantities. Computers & Industrial Engineering, 27(1/4), 19-22- http://dx.doi.org/10.1016/0360-8352(94)90227-5

Kang, S., Malik, K., Thomas, L.J. (1999). Lotsizing and scheduling on parallel machines with sequence dependent setup costs. Management Science, 45(2), 273-289. http://dx.doi.org/10.1287/mnsc.45.2.273

Karacapilidis, N., Pappis, C. (1996). Production planning and control in textile industry: A case study. Computers in Industry, 30(2), 127-144. http://dx.doi.org/10.1016/0166-3615(96)00038-3

Kopanos, G.M., Puigjaner, L., Georgiadis, M.C. (2012a). Simultaneous production and logistics operations planning in semicontinuous food industries. Omega, 40(5), 634-650. http://dx.doi.org/10.1016/j.omega.2011.12.002

Kopanos, G.M., Puigjaner, L., Georgiadis, M.C. (2012b). Single and multi-site production and distribution planning in food processing industries. Computer Aided Chemical Engineering, 31, 1030-1034. http://dx.doi.org/10.1016/B978-0-444-59506-5.50037-7

Maes, J., McClain, J.O., Van Wassenhove, L.N. (1991). Multilevel capacitated lot sizing complexity and LP-based heuristics. European Journal of Operational Research, 53(2), 131-48. http://dx.doi.org/10.1016/0377-2217(91)90130-N

Newson, E.F. (1975). Multi-item lot size scheduling by heuristic, part I: with fixed resources. Management Science, 21(10), 1186-1193. http://dx.doi.org/10.1287/mnsc.21.10.1086

Meijboom, B., Obel, B. (2007). Tactical coordination in a multi-location and multi-stage operations structure: A model and a pharmaceutical company case. Omega, 35(3), 258-273. http://dx.doi.org/10.1016/j.omega.2005.06.003

Min, L., Cheng, W. (2006). Genetic algorithms for the optimal common due date assignment and the optimal scheduling policy in parallel machine earliness/tardiness scheduling problems. Robotics and Computer-Integrated Manufacturing, 22(4), 279-287. http://dx.doi.org/10.1016/j.rcim.2004.12.005

Motta C.F., Resendo R., Morelato P. (2013). A hybrid multi-population genetic algorithm applied to solve the multi-level capacitated lot sizing problem with backlogging, Computers & Operations Research, 40 910–919. http://dx.doi.org/10.1016/j.cor.2012.11.002

Mustafa, K., Sinan, K., Nesim, E. (1999). A Generic Model to Solve Tactical Planning Problems in Flexible Manufacturing Systems. International Journal of Flexible Manufacturing Systems, 11(3), 215-243. http://dx.doi.org/10.1023/A:1008182411581

Ngaia, E.W.T., Penga, S., Alexander, P., Moon, K. (2014). Decision support and intelligent systems in the textile and apparel supply chain: An academic review of research articles. Expert Systems with Applications, 41(1), 81-91. http://dx.doi.org/10.1016/j.eswa.2013.07.013

Özdamar, L., Birbil, S.I. (1998). Hybrid Heuristics for the capacitated lot sizing and loading problem with setup times and overtime decisions. European Journal of Operational Research,110(3), 525-547. http://dx.doi.org/10.1016/S0377-2217(97)00269-5

Özdamar, L., Bozyel, A. (1998).Simultaneous lot sizing and loading of product families on parallel facilities of different classes. International Journal of Production Research, 36(5), 1305-1324. http://dx.doi.org/10.1080/002075498193336

Romsdal, A., Thomassen, M.K., Dreyer, H.C., Strandhagen, J.O. (2011). Fresh food supply chains; characteristics and supply chain requirements. 18th international annual EurOMA conference. Cambridge, UK, Cambridge University.

Pérez, D. (2013). Framework and methodology proposal for the modeling of the supply chain collaborative planning process based on mathematical programming. Application to the ceramic sector. Dissertation, Universitat Politècnica de València

Pérez, D., Alemany M.M.E., Lario, F.C., Fuertes, V.S. (2014).Set-up Continuity in Tactical Planning of Semi-Continuous Industrial Processes. Managing Complexity. Springer International Publishing, 165-173.

Porkka, P., Vepsalainen, A.P.J., Kuula, M. (2003). Multiperiod production planning carrying over set-up time. International Journal of Production Research, 41(6), 1133–1148. http://dx.doi.org/10.1080/0020754021000042995

Shabani, N., Sowlati, T. (2013). A mixed integer non-linear programming model for tactical value chain optimization of a wood biomass power plant. Applied Energy, 104, 353-361. http://dx.doi.org/10.1016/j.apenergy.2012.11.013

Soman, C.A., Van Donk, D.P., Gaalman, G.J.C. (2004). Combined make-to-order and make-to-stock in a food production system. International Journal of Production Economics, 90(2), 223–235. http://dx.doi.org/10.1016/S0925-5273(02)00376-6

Soman, C.A., Van Donk, D.P., Gaalman, G.J.C. (2007). Capacitated planning and scheduling for combined make-to-order and make-to-stock production in the food industry: An illustrative case study. International Journal of Production Economics, 108(1-2), 191–199. http://dx.doi.org/10.1016/j.ijpe.2006.12.042

Sox, C.R., Gao, Y.B. (1999). The capacitated lot sizing problem with setup carry-over. IIE Transactions, 31(2), 173–181. http://dx.doi.org/10.1080/07408179908969816

Suerie, C., Stadtler, H. (2003). The capacitated lot-sizing problem with linked lot sizes. Management Science, 49(8), 1039–1054. http://dx.doi.org/10.1287/mnsc.49.8.1039.16406

Teimoury, E., Modarres, M., Ghasemzadeh, F., Fathi, M. (2010). A queueing approach to production-inventory planning for supply chain with uncertain demands: Case study of PAKSHOO Chemicals Company. Journal of Manufacturing Systems, 29(2/3), 55-62. http://dx.doi.org/10.1016/j.jmsy.2010.08.003

Ulstein, N.L., Nygreen, B., Sagli, J.R. (2007). Tactical planning of offshore petroleum production. European Journal of Operational Research, 176(1), 550-564. http://dx.doi.org/10.1016/j.ejor.2005.06.060

Van Donk, D.P. (2001). Make to stock or make to order: The decoupling point in the food processing industries. International. Journal of Production Economics, 69(3), 297–306. http://dx.doi.org/10.1016/S0925-5273(00)00035-9

Van Elzakker, M.A.H., Zondervan, E., Raikar, N.B., Hoogland, H., Grossmann, I.E. (2014). An SKU decomposition algorithm for the tactical planning in the FMCG industry. Computers & Chemical Engineering, 62(5), 80-95. http://dx.doi.org/10.1016/j.compchemeng.2013.11.008

Wong, W.K., Leung, S.Y.S. (2008). Genetic optimization of fabric utilization in apparel manufacturing. International Journal of Production Economics, 114(1), 376-387. http://dx.doi.org/10.1016/j.ijpe.2008.02.01

Abstract Views

395
Metrics Loading ...

Metrics powered by PLOS ALM




Creative Commons License

This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License

Universitat Politècnica de València

e-ISSN: 2340-4876     ISSN: 2340-5317