BİR OTOMOTİV YAN SANAYİ FİRMASI İÇİN PARTİ BÜYÜKLÜĞÜ BELİRLEME VE ÇİZELGELEME SİSTEMİNİN GELİŞTİRİLMESİ
Abstract
Bu çalışmada, bir otomotiv yan sanayi firmasındaki parti büyüklüğü belirleme ve çizelgeleme problemi ele alınmıştır. Mevcut sistemin analizi sonucunda, kalıp-pres atamalarında uygunsuzluklar, buna bağlı oluşan kalite kayıpları, gerçekleşen ile planlanan üretim miktarları arasında farklar, operatör sayısında dengesizlikler, hazırlık sayılarında ve envanter miktarlarında fazlalıklar gözlenmiştir. Bu problem, kısıtlandırılmış parti büyüklüğüne sahip ilişkisiz paralel makine çizelgeleme problemi şeklinde ele alınmış ve çözümü için karışık tamsayılı programlama modeli geliştirilmiştir. Problemin NP-zor olması nedeniyle, makul sürede optimale yakın bir çözüm elde edebilmek için optimizasyon tabanlı sezgisel bir algoritma olan gevşet ve sabitle algoritması kullanılmıştır. Önerilen algoritma, problemi alt problemlere ayrıştırarak çözülmesini sağlamaktadır. Elde edilen üretim planı, firmanın mevcut çizelgeleme sistemiyle hazırlanan üretim planı ile karşılaştırıldığında, hazırlık sayısı ve envanter miktarının iyileştirildiği, uygun kalıp-pres atamaları nedeniyle kalite kayıplarının azaltıldığı ve operatör sayılarının dengeli olarak belirlendiği görülmüştür. Ayrıca, önerilen yaklaşımın firmada kullanımını kolaylaştırmak için bir çizelgeleme yazılımı geliştirilmiştir.
Supporting Institution
TÜBİTAK
Project Number
2209B (2241A)
Thanks
Projeyi 2209B (2241A) Sanayi Odaklı Lisans Bitirme Tezi Destekleme Programı kapsamında destekleyen TÜBİTAK’a ve bu çalışmanın firmalarında gerçekleştirilmesi için gösterdikleri ilgi ve destekleri için firma çalışanları Evren GEÇGİL ve Mehmet KALAY’a sonsuz teşekkürlerimizi sunarız.
References
- 1. Baker, K. R., Trietsch, D. 2009. Principles of Scheduling and Sequencing, John Wiley & Sons, Hoboken, New Jersey.
- 2. Beraldi, P., Ghiani, G., Grieco, A., Guerriero, E. 2008. “Rolling-horizon and Fix-and-relax Heuristics for the Parallel Machine Lot-sizing and Scheduling Problem with Sequence-dependent Set-up Costs,” Computers & Operations Research, vol. 35 (11), p. 3644-3656.
- 3. Carreno, J. J. 1990. “Economic Lot Scheduling for Multiple Products on Parallel Identical Processors,” Management Science, vol. 36 (3), p. 348-358.
- 4. Clark, A. R., Clark, S. J. 2000. “Rolling-horizon Lot-sizing When Set-up Times are Sequence-Dependent,” International Journal of Production Research, vol. 38 (10), p. 2287-2307.
- 5. Dastidar, S. G., Nagi, R. 2005. “Scheduling Injection Molding Operations with Multiple Resource Constraints and Sequence Dependent Setup Times and Costs,” Computers & Operations Research, vol. 32 (11), p. 2987-3005.
- 6. Jans, R. 2009. “Solving Lot-sizing Problems on Parallel Identical Machines Using Symmetry-breaking Constraints,” INFORMS Journal on Computing, vol. 21 (1), p. 123-136.
- 7. James, R. J. W., Almada-Lobo, B. 2011. “Single and Parallel Machine Capacitated Lotsizing and Scheduling: New Iterative MIP-based Neighborhood Search Heuristics,” Computers & Operations Research, vol. 38 (12), p. 1816-1825.
- 8. Kang, S., Malik, K., Thomas, L. J. 1999. “Lotsizing and Scheduling on Parallel Machines with Sequence-Dependent Setup Costs,” Management Science, vol. 45 (2), p. 273-289.
- 9. Koçanlı, M. M., Aydınbeyli, Y. E., Saraç, T. 2012. “Eti Şirketler Grubu’nda Üretim Çizelgeleme Problemi için Bir Hedef Programlama Modeli ve Genetik Algoritma,” Endüstri Mühendisliği Dergisi, vol. 23 (3), p. 12-26.
- 10. Marinelli, F., Nenni, M. E., Sforza, A. 2007. “Capacitated Lot Sizing and Scheduling with Parallel Machines and Shared Buffers: A Case Study in a Packaging Company,” Annals of Operations Research, vol. 150 (1), p. 177-192.
- 11. Meyr, H. 2002. “Simultaneous Lotsizing and Scheduling on Parallel Machines,” European Journal of Operational Research, vol. 139 (2), p. 277-292.
- 12. Maximal Software, Inc., MPL Modeling System, Arlington, VA, USA. http://www.maximalsoftware.com/mpl/, son erişim tarihi: 11 Haziran 2015.
- 13. Gurobi Optimization, Inc., Gurobi Optimization. http://www.gurobi.com/, son erişim tarihi: 11 Haziran 2015.
- 14. Quadt, D., Kuhn, H. 2009. “Capacitated Lot-Sizing and Scheduling with Parallel Machines, Back-Orders, and Setup Carry-Over,” Naval Research Logistics (NRL), vol. 56 (4), p. 366-384.
- 15. Xiao, J., Zhang, C., Zheng, L., Gupta, J. N. D. 2013. “MIP-based Fix-and-optimise Algorithms for the Parallel Machine Capacitated Lot-sizing and Scheduling Problem,” International Journal of Production Research, vol. 51 (16), p. 5011–5028.
Abstract
In this study, lot sizing and scheduling problem is considered in an automotive supplier. As a result of the current system analysis, inappropriate mold-press machine assignments, quality losses due to these inappropriate assignments, differences between the planned and actual production amounts, unbalanced number of operators, excess number of setups and excess amount of inventory are observed. This problem is considered as an unrelated parallel machine capacitated lot-sizing and scheduling problem, and a mixed integer programming model is developed for its solution. As the problem is NP-hard, the relax and fix algorithm, an optimization-based heuristic, is used to obtain a near-optimal solution in a reasonable time. The proposed algorithm provides a solution by decomposing the problem into subproblems. When the resulting production plan was compared with the production plan prepared by the current scheduling system; it is shown that there were improvements in the number of setups and amount of inventory, decreases in the quality losses due to appropriate mold-press machine assignments, and balanced number of operators. Moreover, a scheduling software package was developed to facilitate the use of the proposed approach in the company.
Project Number
2209B (2241A)
References
- 1. Baker, K. R., Trietsch, D. 2009. Principles of Scheduling and Sequencing, John Wiley & Sons, Hoboken, New Jersey.
- 2. Beraldi, P., Ghiani, G., Grieco, A., Guerriero, E. 2008. “Rolling-horizon and Fix-and-relax Heuristics for the Parallel Machine Lot-sizing and Scheduling Problem with Sequence-dependent Set-up Costs,” Computers & Operations Research, vol. 35 (11), p. 3644-3656.
- 3. Carreno, J. J. 1990. “Economic Lot Scheduling for Multiple Products on Parallel Identical Processors,” Management Science, vol. 36 (3), p. 348-358.
- 4. Clark, A. R., Clark, S. J. 2000. “Rolling-horizon Lot-sizing When Set-up Times are Sequence-Dependent,” International Journal of Production Research, vol. 38 (10), p. 2287-2307.
- 5. Dastidar, S. G., Nagi, R. 2005. “Scheduling Injection Molding Operations with Multiple Resource Constraints and Sequence Dependent Setup Times and Costs,” Computers & Operations Research, vol. 32 (11), p. 2987-3005.
- 6. Jans, R. 2009. “Solving Lot-sizing Problems on Parallel Identical Machines Using Symmetry-breaking Constraints,” INFORMS Journal on Computing, vol. 21 (1), p. 123-136.
- 7. James, R. J. W., Almada-Lobo, B. 2011. “Single and Parallel Machine Capacitated Lotsizing and Scheduling: New Iterative MIP-based Neighborhood Search Heuristics,” Computers & Operations Research, vol. 38 (12), p. 1816-1825.
- 8. Kang, S., Malik, K., Thomas, L. J. 1999. “Lotsizing and Scheduling on Parallel Machines with Sequence-Dependent Setup Costs,” Management Science, vol. 45 (2), p. 273-289.
- 9. Koçanlı, M. M., Aydınbeyli, Y. E., Saraç, T. 2012. “Eti Şirketler Grubu’nda Üretim Çizelgeleme Problemi için Bir Hedef Programlama Modeli ve Genetik Algoritma,” Endüstri Mühendisliği Dergisi, vol. 23 (3), p. 12-26.
- 10. Marinelli, F., Nenni, M. E., Sforza, A. 2007. “Capacitated Lot Sizing and Scheduling with Parallel Machines and Shared Buffers: A Case Study in a Packaging Company,” Annals of Operations Research, vol. 150 (1), p. 177-192.
- 11. Meyr, H. 2002. “Simultaneous Lotsizing and Scheduling on Parallel Machines,” European Journal of Operational Research, vol. 139 (2), p. 277-292.
- 12. Maximal Software, Inc., MPL Modeling System, Arlington, VA, USA. http://www.maximalsoftware.com/mpl/, son erişim tarihi: 11 Haziran 2015.
- 13. Gurobi Optimization, Inc., Gurobi Optimization. http://www.gurobi.com/, son erişim tarihi: 11 Haziran 2015.
- 14. Quadt, D., Kuhn, H. 2009. “Capacitated Lot-Sizing and Scheduling with Parallel Machines, Back-Orders, and Setup Carry-Over,” Naval Research Logistics (NRL), vol. 56 (4), p. 366-384.
- 15. Xiao, J., Zhang, C., Zheng, L., Gupta, J. N. D. 2013. “MIP-based Fix-and-optimise Algorithms for the Parallel Machine Capacitated Lot-sizing and Scheduling Problem,” International Journal of Production Research, vol. 51 (16), p. 5011–5028.
Details
| Primary Language | Turkish |
|---|---|
| Journal Section | Research Articles |
| Authors | |
| Project Number | 2209B (2241A) |
| Publication Date | January 29, 2016 |
| Acceptance Date | December 20, 2015 |
| Published in Issue | Year 2015 Volume: 26 Issue: 4 |
