Planning and Scheduling in Manufacturing and Services

499 Pages·2005·4.656 MB·English

by  Michael L. Pinedo (auth.)

Springer Series in Operations Research
Editors:
Peter W. Glynn Stephen M. Robinson
Michael L. Pinedo
Planning and Scheduling in
Manufacturing and Services
Includes CD-ROM
MichaelL.Pinedo
DepartmentofOperationsManagement
SternSchoolofBusiness
NewYorkUniversity
40West4thStreet,Suite700
NewYork,NY10012-1118
USA
[email protected]
SeriesEditors:
PeterW.Glynn StephenM.Robinson
DepartmentofManagementScience DepartmentofIndustrialEngineering
andEngineering UniversityofWisconsin–Madison
TermanEngineeringCenter 1513UniversityAvenue
StanfordUniversity Madison,WI53706-1572
Stanford,CA94305-4026 USA
USA [email protected]
[email protected]
MathematicsSubjectClassification(2000):90-xx
LibraryofCongressCataloging-in-PublicationData
Pinedo,Michael.
Planningandschedulinginmanufacturingservices/MichaelL.Pinedo.
p. cm.
Includesbibliographicalreferencesandindex.
ISBN0-387-22198-0
1.Productionscheduling. 2.Productionplanning. I.Title.
TS157.5.P558 2005
658.5′3—dc22 2004062622
ISBN0-387-22198-0 Printedonacid-freepaper.
©2005SpringerScience+BusinessMedia,Inc.
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Preface
Thisbookisanoutgrowthofanearliertextthatappearedin1999undertheti-
tle“OperationsSchedulingwithApplicationsinManufacturingandServices”,
coauthored with Xiuli Chao from North Carolina State. This new version has
beencompletelyreorganizedandexpandedinseveraldirectionsincludingnew
application areas and solution methods.
The application areas are divided into two parts: manufacturing applica-
tions and services applications. The book covers five areas in manufacturing,
namely, project scheduling, job shop scheduling, scheduling of flexible assem-
bly systems, economic lot scheduling, and planning and scheduling in supply
chains. It covers four areas in services, namely, reservations and timetabling,
tournamentscheduling,planningandschedulingintransportation,andwork-
force scheduling. Of course, this selection does not represent all the applica-
tions of planning and scheduling in manufacturing and services. Some areas
thathavereceivedafairamountofattentionintheliterature,e.g.,scheduling
of robotic cells, have not been included. Scheduling problems in telecommu-
nication and computer science have not been covered either.
It seems to be harder to write a good applications-oriented book than a
good theory-oriented book. In the writing of this book one question came up
regularly: what should be included and what should not be included? Some
difficult decisions had to be made with regard to some of the material cov-
ered. For example, should this book discuss Johnson’s rule, which minimizes
the makespan in a two machine flow shop? Johnson’s rule is described in
virtually every scheduling book and even in many books on operations man-
agement.Itismathematicallyelegant;butitisnotclearhowimportantitisin
practice.Wefinallyconcludedthatitdidnotdeservesomuchattentioninan
applications-orientedbooksuchasthisone.However,wedidincorporateitas
anexerciseinthechapteronjobshopschedulingandaskthestudenttocom-
pare its performance to that of the well-known shifting bottleneck heuristic
(which is one of the better known heuristics used in practice).
vi Preface
The fundamentals concerning the methodologies that are used in the ap-
plication chapters are covered in the appendixes. They contain the basics of
mathematicalprogramming,dynamicprogramming,heuristics,andconstraint
programming.
It is not necessary to have a detailed knowledge of computational com-
plexity in order to go through this book. However, at times some complexity
terminologyisused.Thatis,aschedulingproblemmaybereferredtoaspoly-
nomially solvable (i.e., easy) or as NP-hard (i.e., hard). However, we never go
into any NP-hardness proofs.
Because of the diversity and the complexity of the models it turned out
to be difficult to develop a notation that could be kept uniform throughout
the book. A serious attempt has been made to maintain some consistency of
notation. However, that has not always been possible (but, of course, within
each chapter the notation is consistent). Another issue we had to deal with
wasthelevelofthemathematicalnotationused.Wedecidedthatwedidhave
to adopt at times the set notation and use the ∈ symbol. So j ∈ S implies
that job j belongs to a set of jobs called S and S1∪S2 denotes the union of
the two sets S1 and S2.
ThebookcomeswithaCD-ROMthatcontainsvarioussetsofpowerpoint
slides. Five sets of slides were developed by instructors who had adopted the
earlierversionofthisbook,namelyErwinHansandJohannHurinkatTwente
University of Technology in the Netherlands, Siggi Olafsson at Iowa State,
SanjaPetrovicinNottingham,SibelSalmanatCarnegie-Mellon(Sibeliscur-
rently at Koc¸ University in Turkey), and Cees Duin and Erik van der Sluis
at the University of Amsterdam. Various collections of slides were also made
available by several companies, including Alcan, Carmen Systems, Cybertec,
Dash Optimization, Ilog, Multimodal, and SAP. Both Ilog and Dash Opti-
mization provided a substantial amount of additional material in the form of
software,minicases,andamovie.TheCD-ROMcontainsalsovariousplanning
and scheduling systems that have been developed in academia. The LEKIN
system has been especially designed for the machine scheduling and job shop
modelsdiscussedinChapter5.OthersystemsontheCD-ROMincludeacrew
schedulingsystem,anemployeeschedulingsystem,andatimetablingsystem.
Thisnewversionhasbenefitedenormouslyfromnumerouscommentsmade
bymanycolleagues.Firstofall,thistextowesalottoXiuliChaofromNorth
CarolinaState;hiscommentshavealwaysbeenextremelyuseful.Manyothers
have also gone through the manuscript and provided constructive criticisms.
The list includes Ying-Ju Chen (NYU), Jacques Desrosiers (GERAD, Mon-
treal), Thomas Dong (ILOG), Andreas Drexl (Kiel, Germany), John Fowler
(Arizona), Guillermo Gallego (Columbia), Nicholas Hall (Ohio State), Jack
Kanet (Clemson), Chung-Yee Lee (HKUST), Joseph Leung (NJIT), Haib-
ing Li (NJIT), Irv Lustig (ILOG), Kirk Moehle (Maersk Line), Detlef Pabst
(Arizona),DenisSaure(UniversidaddeChile),ErikvanderSluis(University
ofAmsterdam),MariusSolomon(NortheasternUniversity),ChelliahSriskan-
darajah(UTDallas),MichaelTrick(Carnegie-Mellon),RehaUzsoy(Purdue),
Preface vii
Alkis Vazacopoulos (Dash Optimization), Nitin Verma (Dash Optimization),
and Benjamin Yen (Hong Kong University).
The technical production of this book and CD-ROM would not have been
possible without the help of Berna Sifonte and Adam Lewenberg. Thanks are
also due to the National Science Foundation; without its support this project
would not have been completed.
A website for this book will be maintained at
http://www.stern.nyu.edu/~mpinedo
Thissitewillkeepanup-to-datelistoftheinstructorswhoareusingthebook
(including those who used the 1999 version). In addition, the site will contain
relevant material that becomes available after the book has gone to press.
New York Michael Pinedo
Fall 2004
Contents
Preface ........................................................ v
Contents of CD-ROM ......................................... xv
Part I Preliminaries
1 Introduction............................................... 3
1.1 Planning and Scheduling: Role and Impact ................. 3
1.2 Planning and Scheduling Functions in an Enterprise ......... 8
1.3 Outline of the Book...................................... 11
2 Manufacturing Models..................................... 19
2.1 Introduction ............................................ 19
2.2 Jobs, Machines, and Facilities ............................. 21
2.3 Processing Characteristics and Constraints ................. 24
2.4 Performance Measures and Objectives...................... 28
2.5 Discussion .............................................. 32
3 Service Models ............................................ 37
3.1 Introduction ............................................ 37
3.2 Activities and Resources in Service Settings................. 40
3.3 Operational Characteristics and Constraints ................ 41
3.4 Performance Measures and Objectives...................... 43
3.5 Discussion .............................................. 45
x Contents
Part II Planning and Scheduling in Manufacturing
4 Project Planning and Scheduling .......................... 51
4.1 Introduction ............................................ 51
4.2 Critical Path Method (CPM) ............................. 54
4.3 Program Evaluation and Review Technique (PERT) ......... 58
4.4 Time/Cost Trade-Offs: Linear Costs ....................... 61
4.5 Time/Cost Trade-Offs: Nonlinear Costs .................... 68
4.6 Project Scheduling with Workforce Constraints.............. 69
4.7 ROMAN: A Project Scheduling System for the Nuclear
Power Industry.......................................... 72
4.8 Discussion .............................................. 76
5 Machine Scheduling and Job Shop Scheduling ............. 81
5.1 Introduction ............................................ 81
5.2 Single Machine and Parallel Machine Models................ 82
5.3 Job Shops and Mathematical Programming................. 84
5.4 Job Shops and the Shifting Bottleneck Heuristic............. 87
5.5 Job Shops and Constraint Programming.................... 93
5.6 LEKIN: A Generic Job Shop Scheduling System.............102
5.7 Discussion ..............................................109
6 Scheduling of Flexible Assembly Systems ..................115
6.1 Introduction ............................................115
6.2 Sequencing of Unpaced Assembly Systems ..................116
6.3 Sequencing of Paced Assembly Systems ....................122
6.4 Scheduling of Flexible Flow Systems with Bypass............127
6.5 Mixed Model Assembly Sequencing at Toyota ...............132
6.6 Discussion ..............................................135
7 Economic Lot Scheduling ..................................141
7.1 Introduction ............................................141
7.2 One Type of Item and the Economic Lot Size ...............142
7.3 Different Types of Items and Rotation Schedules ............146
7.4 Different Types of Items and Arbitrary Schedules............150
7.5 More General ELSP Models ..............................159
7.6 Multiproduct Planning and Scheduling at Owens-Corning
Fiberglas ...............................................162
7.7 Discussion ..............................................164
8 Planning and Scheduling in Supply Chains ................171
8.1 Introduction ............................................171
8.2 Supply Chain Settings and Configurations ..................173
8.3 Frameworks for Planning and Scheduling in Supply Chains ...178
Contents xi
8.4 A Medium Term Planning Model for a Supply Chain ........184
8.5 A Short Term Scheduling Model for a Supply Chain .........190
8.6 Carlsberg Denmark: An Example of a System Implementation 193
8.7 Discussion ..............................................197
Part III Planning and Scheduling in Services
9 Interval Scheduling, Reservations, and Timetabling........205
9.1 Introduction ............................................205
9.2 Reservations without Slack ...............................207
9.3 Reservations with Slack ..................................210
9.4 Timetabling with Workforce Constraints ...................213
9.5 Timetabling with Operator or Tooling Constraints...........216
9.6 Assigning Classes to Rooms at U.C. Berkeley ...............221
9.7 Discussion ..............................................224
10 Scheduling and Timetabling in Sports and Entertainment .229
10.1 Introduction ............................................229
10.2 Scheduling and Timetabling in Sport Tournaments ..........230
10.3 Tournament Scheduling and Constraint Programming........237
10.4 Tournament Scheduling and Local Search...................240
10.5 Scheduling Network Television Programs ...................243
10.6 Scheduling a College Basketball Conference .................245
10.7 Discussion ..............................................248
11 Planning, Scheduling, and Timetabling in Transportation..253
11.1 Introduction ............................................253
11.2 Tanker Scheduling .......................................254
11.3 Aircraft Routing and Scheduling ..........................258
11.4 Train Timetabling .......................................272
11.5 Carmen Systems: Designs and Implementations .............279
11.6 Discussion ..............................................283
12 Workforce Scheduling......................................289
12.1 Introduction ............................................289
12.2 Days-Off Scheduling .....................................290
12.3 Shift Scheduling.........................................296
12.4 The Cyclic Staffing Problem ..............................299
12.5 Applications and Extensions of Cyclic Staffing ..............301
12.6 Crew Scheduling ........................................303
12.7 Operator Scheduling in a Call Center ......................307
12.8 Discussion ..............................................311
xii Contents
Part IV Systems Development and Implementation
13 Systems Design and Implementation.......................319
13.1 Introduction ............................................319
13.2 Systems Architecture ....................................320
13.3 Databases, Object Bases, and Knowledge-Bases .............322
13.4 Modules for Generating Plans and Schedules................327
13.5 User Interfaces and Interactive Optimization................330
13.6 Generic Systems vs. Application-Specific Systems............336
13.7 Implementation and Maintenance Issues....................339
14 Advanced Concepts in Systems Design ....................345
14.1 Introduction ............................................345
14.2 Robustness and Reactive Decision Making .................346
14.3 Machine Learning Mechanisms ............................351
14.4 Design of Planning and Scheduling Engines and Algorithm
Libraries ...............................................357
14.5 Reconfigurable Systems ..................................360
14.6 Web-Based Planning and Scheduling Systems ..............362
14.7 Discussion ..............................................365
15 What Lies Ahead?.........................................371
15.1 Introduction ............................................371
15.2 Planning and Scheduling in Manufacturing .................372
15.3 Planning and Scheduling in Services .......................373
15.4 Solution Methods........................................375
15.5 Systems Development ....................................377
15.6 Discussion ..............................................378
Appendices
A Mathematical Programming: Formulations
and Applications ..........................................383
A.1 Introduction ............................................383
A.2 Linear Programming Formulations.........................383
A.3 Nonlinear Programming Formulations......................386
A.4 Integer Programming Formulations ........................388
A.5 Set Partitioning, Set Covering, and Set Packing .............390
A.6 Disjunctive Programming Formulations ....................391