Maristela Oliveira Santos

Integrated pulp and paper mill planning and scheduling

This article describes a real-world production planning and scheduling problem occurring at an integrated pulp and paper mill (P&P) which manufactures paper for cardboard out of produced pulp. During the cooking of wood chips in the digester, two by-products are produced: the pulp itself (virgin fibers) and the waste stream known as black liquor. The former is then mixed with recycled fibers and processed in a paper machine. Here, due to significant sequence-dependent setups in paper type changeovers, sizing and sequencing of lots have to be made simultaneously in order to efficiently use capacity. The latter is converted into electrical energy using a set of evaporators, recovery boilers and counter-pressure turbines. The planning challenge is then to synchronize the material flow as it moves through the pulp and paper mills, and energy plant, maximizing customer demand (as backlogging is allowed), and minimizing operation costs. Due to the intensive capital feature of P&P, the output of the digester must be maximized. As the production bottleneck is not fixed, to tackle this problem we propose a new model that integrates the critical production units associated to the pulp and paper mills, and energy plant for the first time. Simple stochastic mixed integer programming based local search heuristics are developed to obtain good feasible solutions for the problem. The benefits of integrating the three stages are discussed. The proposed approaches are tested on real-world data. Our work may help P&P companies to increase their competitiveness and reactiveness in dealing with demand pattern oscillations.

A lot-sizing problem in an automated foundry

Abstract This work consists of the study of a foundry which has only one furnace and several moulding machines producing a known demand of different types of items which can be made of different alloys. There are two important and linked decision levels in this foundry: (1) what alloys should be produced in the furnace in each period, and (2) the quantity of items to be produced in each moulding machine. Two different cases are highlighted here: a single alloy can produce all the items, and different alloys are needed to produce the items. Assuming that the production bottleneck is the furnace, efficient problem-specific solution methods are proposed.

A hybrid VNS approach for the short-term production planning and scheduling: A case study in the pulp and paper industry

Mathematical formulations for production planning are increasing complexity, in order to improve their realism. In short-term planning, the desirable level of detail is particularly high. Exact solvers fail to generate good quality solutions for those complex models on medium- and large-sized instances within feasible time. Motivated by a real-world case study in the pulp and paper industry, this paper provides an efficient solution method to tackle the short-term production planning and scheduling in an integrated mill. Decisions on the paper machine setup pattern and on the production rate of the pulp digester (which is constrained to a maximum variation) complicate the problem. The approach is built on top of a mixed integer programming (MIP) formulation derived from the multi-stage general lotsizing and scheduling problem. It combines a Variable Neighbourhood Search procedure which manages the setup-related variables, a specific heuristic to determine the digesters production speeds and an exact method to optimize the production and flow movement decisions. Different strategies are explored to speed-up the solution procedure and alternative variants of the algorithm are tested on instances based on real data from the case study. The algorithm is benchmarked against exact procedures.

An optimization approach for the lot sizing and scheduling problem in the brewery industry

Abstract This study considers a production lot sizing and scheduling problem in the brewery industry. The underlying manufacturing process can be basically divided into two main production stages: preparing the liquids including fermentation and maturation inside the fermentation tanks; and bottling the liquids on the filling lines, making products of different liquids and sizes. This problem differs from other problems in beverage industries due to the relatively long lead times required for the fermentation and maturation processes and because the “ready” liquid can remain in the tanks for some time before being bottled. The main planning challenge is to synchronize the two stages (considering the possibility of a “ready” liquid staying in the tank until bottling), as the production bottlenecks may alternate between these stages during the planning horizon. This study presents a novel mixed integer programming model that represents the problem appropriately and integrates both stages. In order to solve real-world problem instances, MIP-based heuristics are developed, which explore the model structure. The results show that the model is able to comprise the problem requirements and the heuristics produce relatively good-quality solutions.

The constrained compartmentalized knapsack problem: mathematical models and solution methods

The constrained compartmentalized knapsack problem can be seen as an extension of the constrained knapsack problem. However, the items are grouped into different classes so that the overall knapsack has to be divided into compartments, and each compartment is loaded with items from the same class. Moreover, building a compartment incurs a fixed cost and a fixed loss of the capacity in the original knapsack, and the compartments are lower and upper bounded. The objective is to maximize the total value of the items loaded in the overall knapsack minus the cost of the compartments. This problem has been formulated as an integer non-linear program, and in this paper, we reformulate the non-linear model as an integer linear master problem with a large number of variables. Some heuristics based on the solution of the restricted master problem are investigated. A new and more compact integer linear model is also presented, which can be solved by a branch-and-bound commercial solver that found most of the optimal solutions for the constrained compartmentalized knapsack problem. On the other hand, heuristics provide good solutions with low computational effort.

Infeasibility handling in genetic algorithm using nested domains for production planning

In this paper we present a genetic algorithm with new components to tackle capacitated lot sizing and scheduling problems with sequence dependent setups that appear in a wide range of industries, from soft drink bottling to food manufacturing. Finding a feasible solution to highly constrained problems is often a very difficult task. Various strategies have been applied to deal with infeasible solutions throughout the search. We propose a new scheme of classifying individuals based on nested domains to determine the solutions according to the level of infeasibility, which in our case represents bands of additional production hours (overtime). Within each band, individuals are just differentiated by their fitness function. As iterations are conducted, the widths of the bands are dynamically adjusted to improve the convergence of the individuals into the feasible domain. The numerical experiments on highly capacitated instances show the effectiveness of this computational tractable approach to guide the search toward the feasible domain. Our approach outperforms other state-of-the-art approaches and commercial solvers.

Unequal individual genetic algorithm with intelligent diversification for the lot-scheduling problem in integrated mills using multiple-paper machines

This paper addresses the lot-sizing and scheduling problem of pulp and paper mills involving multiple paper machines. The underlying multi-stage integrated production process considers the following critical units: continuous digester, intermediate stocks of pulp and liquor, multiple paper machines and a recovery line to treat by-products. This work presents a mixed integer programming (MIP) model to represent the problem, as well as a solution approach based on a customized genetic algorithm (GA) with an embedded residual linear programming model. Some GA tools are explored, including literature and new operators, a novel diversification process and other features. In particular, the diversification process uses a new allele frequency measure to change between diversification and intensification procedures. Computational results show the effectiveness of the method to solve relatively large instances of the single paper machine problem when compared to other single paper machine solution methods found in the literature. For multiple paper machine settings, in most runs the GA solutions are better than those obtained for the MIP model using an optimization software.

BFO: a hybrid bees algorithm for the multi-level capacitated lot-sizing problem

This paper presents a hybrid heuristic based on the bees algorithm combined with the fix-and-optimize heuristic to solve the multi-level capacitated lot-sizing problem. The bees algorithm can be used as a new method to determine the sequence in which to apply the partition in the fix-and-optimize approach. This new manner of choosing the partition adds diversity to the solution pool and yields different local optima solutions after some iterations. The bees-and-fix-and-optimize (BFO) algorithm attempts to avoid these local optima by performing random search in accordance with the concept of bees algorithm. The BFO has yielded good results for instances from the literature and, in most cases, the results are superior to the best results provided by approaches presented in recent literature. They show that this construction concept is advantageous and illustrate the efficiency of hybrid methods composed of matheuristics and metaheuristics. Furthermore, the BFO approach is a general-purpose heuristic that can be applied to solve other types of production planning problems.

Asynchronous teams for joint lot-sizing and scheduling problem in flow shops

The integrated production scheduling and lot-sizing problem in a flow shop environment consists of establishing production lot sizes and allocating machines to process them within a planning horizon in a production line with machines arranged in series. The problem considers that demands must be met without backlogging, the capacity of the machines must be respected, and machine setups are sequence-dependent and preserved between periods of the planning horizon. The objective is to determine a production schedule to minimise the setup, production and inventory costs. A mathematical model from the literature is presented, as well as procedures for obtaining feasible solutions. However, some of the procedures have difficulty in obtaining feasible solutions for large-sized problem instances. In addition, we address the problem using different versions of the Asynchronous Team (A-Team) approach. The procedures were compared with literature heuristics based on Mixed Integer Programming. The proposed A-Team procedures outperformed the literature heuristics, especially for large instances. The developed methodologies and the results obtained are presented.

Logística de distribuição de água em redes urbanas: racionalização energética

The aim of the problem studied in this paper is to minimize the electrical energy cost necessary to manage water distribution networks. We consider water distribution systems that are designed to deliver water from pump stations suitably distributed in a city, to the final water consumers. Since the cost of the electrical energy varies during the day, it is necessary to plan the operation of the pumps and water inventory in the system. An integer linear optimization model is proposed for the problem, when considering a fixed cost for the starting of the pumps. On the other hand, when we do not consider this cost, the binary variables are eliminated and the problem can be formulated as a linear optimization model. Some randomly generated instances are solved and corresponding solutions evaluated. The examples show that the proposed models offer consistent managerial support for their use in the real problem.