Online Scheduling in Manufacturing: A Cumulative Delay Approach

156 Pages·2013·3.697 MB·English

by  Haruhiko Suwa, Hiroaki Sandoh (auth.)

Online Scheduling in Manufacturing
Haruhiko Suwa Hiroaki Sandoh
•
Online Scheduling
in Manufacturing
A Cumulative Delay Approach
123
Haruhiko Suwa Hiroaki Sandoh
Department of Mechanical Engineering Graduate School ofEconomics
SetsunanUniversity Osaka University
Neyagawa, Osaka Toyonaka,Osaka
Japan Japan
ISBN 978-1-4471-4560-8 ISBN 978-1-4471-4561-5 (eBook)
DOI 10.1007/978-1-4471-4561-5
SpringerLondonHeidelbergNewYorkDordrecht
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(cid:2)Springer-VerlagLondon2013
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Preface
This book provides results and findings from our research in online scheduling.
Online scheduling is recognized as the crucial decision-making process of pro-
ductioncontrolataphaseof‘‘beinginproduction’’accordingtothereleasedshop
floorschedule.Onlineschedulingcanalsobeconsideredasoneofkeyenablersto
realize prompt capable-to-promise as well as available-to-promise to customers
along with reducing production lead times under recent globalized competitive
markets.
Themainpartofthisbookistointroducenewapproachestoonlinescheduling
based on a concept of cumulative delay. The cumulative delay is regarded as
consolidated information of uncertainties under a dynamic environment in man-
ufacturing and can be collected constantly without much efforts at any points in
time during a schedule execution. In our approach, the cumulative delay of the
schedulehastheimportantroleofacriterionformakingadecisionwhetherornot
a schedule revision is carried out. We believe that the cumulative delay approach
to trigger schedule revisions has the following capabilities for the practical deci-
sion making:
1. To reduce frequent schedule revisions which do not necessarily improve a
current situation with much expense for its operation;
2. Toavoidoverreactingtodisturbancesdependentonstronglyanindividualshop
floor circumstance; and
3. To simplify the monitoring process of a schedule status.
This bookwillbeofinteresttoboth practitionersandresearcherswho workin
planningandschedulinginmanufacturing.Researcherswillfindtheimportanceof
when-to-revise policies during a schedule execution and their influences on
scheduling results which have been obtained by numerous computer simulations.
Practitioners will benefit from the broad range of topics in scheduling from the-
oretical issues to applications. We hope all readers of this book will achieve new
insights into techniques for scheduling.
v
vi Preface
ThisbookispartiallysupportedbytheGrants-in-AidforScientificResearchof
theJapanSocietyforthePromotionofScience.Finally,wearedeeplygratefulto
ourfriends,colleagues,andourfamily,inparticularAnthonyDoyle,SimonRees,
Claire Protherough, Grace Quinn, and Christine Velarde, who helped us with the
completion of the book.
Osaka, Japan, March 2012 Haruhiko Suwa
Hiroaki Sandoh
Contents
Part I Introduction
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Introduction to Online Scheduling. . . . . . . . . . . . . . . . . . . . . . 4
1.3 Key Issues in Online Scheduling. . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Outline of Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Outline of Scheduling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Overview of Frameworks and Methods . . . . . . . . . . . . . . . . . . 15
2.2 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Generic Models for Scheduling. . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Manufacturing Configurations. . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Characteristics and Restrictions. . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Performance Measure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7 Online Scheduling Problems. . . . . . . . . . . . . . . . . . . . . . . . . . 32
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Part II Online Scheduling Models
3 When-to-Revise Against Uncertainty?. . . . . . . . . . . . . . . . . . . . . . 41
3.1 Uncertainty in Scheduling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.1 Typology of Uncertainty . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.2 Known Uncertainties. . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Planning Horizon and Related Matters. . . . . . . . . . . . . . . . . . . 45
3.3 Inspection Points in Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4 Two Basic Policies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4.1 Periodic Schedule Revision Policy . . . . . . . . . . . . . . . . 50
3.4.2 Event-Driven Schedule Revision Policy. . . . . . . . . . . . . 51
vii
viii Contents
3.5 Advanced Policies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5.1 Hybrid Schedule Revision Policy . . . . . . . . . . . . . . . . . 51
3.5.2 Enhanced Event-Driven Schedule Revision Policy . . . . . 52
3.6 Literature Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Methods for Online Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Categories of Online Scheduling. . . . . . . . . . . . . . . . . . . . . . . 55
4.2 Procedure of Dispatching . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3 Scheduling Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3.1 Principle of Scheduling Rules. . . . . . . . . . . . . . . . . . . . 59
4.3.2 Static Dispatching Rules . . . . . . . . . . . . . . . . . . . . . . . 60
4.3.3 Dynamic Dispatching Rules. . . . . . . . . . . . . . . . . . . . . 61
4.3.4 Adaptive Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.4 Principle of Schedule Revision . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.1 Basic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.2 Right-Shift Operation . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4.3 Iterative Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.5 Knowledge-Based Reactive Scheduling . . . . . . . . . . . . . . . . . . 68
4.6 Literature Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5 Cumulative Delay-Based Schedule Revision Policy . . . . . . . . . . . . 75
5.1 Cumulative Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1.1 Actual Delay of Each Job/Task. . . . . . . . . . . . . . . . . . . 75
5.2 Definition of Cumulative Delay . . . . . . . . . . . . . . . . . . . . . . . 77
5.2.1 Counting Up Only Completed Jobs or Tasks . . . . . . . . . 77
5.2.2 Counting Up at Every Inspection Point . . . . . . . . . . . . . 80
5.3 Basic Properties of Cumulative Delay . . . . . . . . . . . . . . . . . . . 84
5.4 Configuration of Scheduling Policy. . . . . . . . . . . . . . . . . . . . . 87
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Part III Online Scheduling Based on Cumulative Delay
6 D(cid:2)-Driven Policy: Application to Job Shop Problems . . . . . . . . . . 93
6.1 Job Shop Scheduling with Disruptions. . . . . . . . . . . . . . . . . . . 93
6.2 Disjunctive Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.2.1 Basic Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.2.2 Disjunctive Model with Machine Breakdown. . . . . . . . . 95
6.3 Properties of Cumulative Delay. . . . . . . . . . . . . . . . . . . . . . . . 98
6.3.1 Simulation Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.3.2 Simulation Results and Discussion . . . . . . . . . . . . . . . . 102
6.4 Performance of D(cid:2)-Driven Policy . . . . . . . . . . . . . . . . . . . . . . 105
Contents ix
6.4.1 Design of D(cid:2)-Driven Policy. . . . . . . . . . . . . . . . . . . . . 105
6.4.2 Simulation Schemes for Performance Evaluation . . . . . . 107
6.4.3 Pareto Optimality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7 Hybrid D(cid:2)-Driven Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.1 Framework. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.2 Multiple Job Families on a Single Machine . . . . . . . . . . . . . . . 116
7.2.1 Description of the Problem. . . . . . . . . . . . . . . . . . . . . . 116
7.2.2 Problem Instances. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.3 Configuration of Scheduling Policy. . . . . . . . . . . . . . . . . . . . . 119
7.3.1 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.3.2 Scheduling Method in a Dynamic Environment . . . . . . . 120
7.4 Computational Experiments . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.4.1 Design Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.4.2 Behaviors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.5 Performance of Hybrid D(cid:2)-Driven Policy. . . . . . . . . . . . . . . . . 126
7.5.1 Comparison with Periodic Schedule Revision Policy. . . . 126
7.5.2 Comparison with a Conventional
Event-Driven Policy . . . . . . . . . . . . . . . . . . . . . . . . . . 130
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8 Enhanced D(cid:2)-Driven Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.1 Framework. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.2 Flexible Flow Shops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8.2.1 Definition of Flexible Flow Shop Problems . . . . . . . . . . 138
8.2.2 Methods for Schedule Revision . . . . . . . . . . . . . . . . . . 139
8.3 Configuration of Enhanced Policy. . . . . . . . . . . . . . . . . . . . . . 141
8.3.1 Definition of Cumulative Delay . . . . . . . . . . . . . . . . . . 141
8.3.2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.4 Properties of Cumulative Delays. . . . . . . . . . . . . . . . . . . . . . . 143
8.5 Performance of the Enhanced D(cid:2)-Driven Policy . . . . . . . . . . . . 144
8.5.1 Simulation Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8.5.2 Comparison with Periodic Revision. . . . . . . . . . . . . . . . 146
8.5.3 Comparison with Other Cumulative
Delay-Based Policies. . . . . . . . . . . . . . . . . . . . . . . . . . 148
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Part I
Introduction
Chapter 1
Introduction
1.1 Background
Production scheduling is essential in manufacturing to enable cost effective and
timely production, and thereby to meet the deadlines of individual products with
targetqualities.Intheactualenvironments,jobsareinitiallyassignedtothelimited
numberofresourcesoveraspecifiedtimehorizon,whichwillbemeasuredbyashift
oradayinmanycases.Thesequencesofthejobstobeprocessedontheindividual
resourcesarethendeterminedundersomesuitablecriterionassociatedwithatleast
oneperformancemeasure.Thescheduleobtainedinthismannerisreleasedtothe
shopfloorasreferentialinformationtocontroltheproductionactivitiesandtomanage
materialprocurement,shipmentsoforders,andtheotherexternalactivitiesaswell.
TherapidprogressofInformationandCommunicationTechnology(ICT)inthese
twodecadeshasmadeinformationsystemsoneofkeyenablerstorealizeflexibleand
adaptivemanufacturingsystems[30].Basicallyinformationtechnologyisacollec-
tivetermofinformationprocessing,informationcommunicationandaccumulation
of information to share. Information-sharing, among others, has led to realization
ofConcurrentEngineering(CE)whichemphasizesthequickresponsetocustomers
[14, 36].Concurrentengineering,whichisoccasionallyreferredtoassimultaneous
engineering[12,17],isasignificantparadigmand/orconceptinproductdevelopment
involvingseveralaspectsofproductdesignandplanning,andhasdirectlyinfluenced
uponschedulingstrategies.
In fact, there have been growing requirements in manufacturing for developing
new production control systems which can concurrently handle decision-makings
associated with scheduling on the shop floor and higher level decision-making
such as capacity planning [10, 19]. There exist scheduling systems which incor-
porateprocessplanningand/orproductionplanning.Hegdeetal.[18],forexample,
has reported a case study on the integrated scheduling systems with simultaneous
production planning for carbon products. A computer integrated system has also
beendeveloped,whichcanprovidethesystemuserswiththefeedbackinformation
from process planning and scheduling [2]. For large scale manufacturing systems,
H.SuwaandH.Sandoh,OnlineSchedulinginManufacturing, 3
DOI:10.1007/978-1-4471-4561-5_1,©Springer-VerlagLondon2013