Showing papers on "Flow shop scheduling published in 2022"

A Self-Learning Discrete Jaya Algorithm for Multiobjective Energy-Efficient Distributed No-Idle Flow-Shop Scheduling Problem in Heterogeneous Factory System

Abstract: In this study, a self-learning discrete Jaya algorithm (SD-Jaya) is proposed to address the energy-efficient distributed no-idle flow-shop scheduling problem (FSP) in a heterogeneous factory system (HFS-EEDNIFSP) with the criteria of minimizing the total tardiness (TTD), total energy consumption (TEC), and factory load balancing (FLB). First, the mixed-integer programming model of HFS-EEDNIFSP is presented. An evaluation criterion of FLB combining the energy consumption and the completion time is introduced. Second, a self-learning operators selection strategy, in which the success rate of each operator is summarized as knowledge, is designed for guiding the selection of operators. Third, the energy-saving strategy is proposed for reducing the TEC. The energy-efficient no-idle FSP is transformed to be an energy-efficient permutation FSP to search the idle times. The speed of operations which adjacent are idle times is reduced. The effectiveness of SD-Jaya is tested on 60 benchmark instances. On the quality of the solution, the experimental results reveal that the efficacy of the SD-Jaya algorithm outperforms the other algorithms for addressing HFS-EEDNIFSP.

A Pareto-based collaborative multi-objective optimization algorithm for energy-efficient scheduling of distributed permutation flow-shop with limited buffers

Abstract: Energy-efficient scheduling of distributed production systems has become a common practice among large companies with the advancement of economic globalization and green manufacturing. Nevertheless, energy-efficient scheduling of distributed permutation flow-shop problem with limited buffers (DPFSP-LB) does not receive adequate attention in the relevant literature. This paper is therefore the first attempt to study this DPFSP-LB with objectives of minimizing makespan and total energy consumption ( T E C ). To solve this energy-efficient DPFSP-LB, a Pareto-based collaborative multi-objective optimization algorithm (CMOA) is proposed. In the proposed CMOA, first, the speed scaling strategy based on problem property is designed to reduce T E C . Second, a collaborative initialization strategy is presented to generate a high-quality initial population. Third, three properties of DPFSP-LB are utilized to develop a collaborative search operator and a knowledge-based local search operator. Finally, we verify the effectiveness of each improvement component of CMOA and compare it against other well-known multi-objective optimization algorithms on instances. Experiment results demonstrate the effectiveness of CMOA in solving this energy-efficient DPFSP-LB. Especially, the CMOA is able to obtain excellent results on all problems regarding the comprehensive metric, and is also competitive to its rivals regarding the convergence metric.

A Pareto-based collaborative multi-objective optimization algorithm for energy-efficient scheduling of distributed permutation flow-shop with limited buffers

Abstract: Energy-efficient scheduling of distributed production systems has become a common practice among large companies with the advancement of economic globalization and green manufacturing. Nevertheless, energy-efficient scheduling of distributed permutation flow-shop problem with limited buffers (DPFSP-LB) does not receive adequate attention in the relevant literature. This paper is therefore the first attempt to study this DPFSP-LB with objectives of minimizing makespan and total energy consumption ( T E C ). To solve this energy-efficient DPFSP-LB, a Pareto-based collaborative multi-objective optimization algorithm (CMOA) is proposed. In the proposed CMOA, first, the speed scaling strategy based on problem property is designed to reduce T E C . Second, a collaborative initialization strategy is presented to generate a high-quality initial population. Third, three properties of DPFSP-LB are utilized to develop a collaborative search operator and a knowledge-based local search operator. Finally, we verify the effectiveness of each improvement component of CMOA and compare it against other well-known multi-objective optimization algorithms on instances. Experiment results demonstrate the effectiveness of CMOA in solving this energy-efficient DPFSP-LB. Especially, the CMOA is able to obtain excellent results on all problems regarding the comprehensive metric, and is also competitive to its rivals regarding the convergence metric. • A green criterion is considered in the studied problem. • A new constraint of the limited buffers is introduced into this problem. • A multi-objective optimization algorithm is presented to solve this problem. • An effective energy saving strategy is proposed. • An initialization strategy and local search strategy are proposed.

Iterated Greedy Algorithms for Flow-Shop Scheduling Problems: A Tutorial

Abstract: An iterated greedy algorithm (IGA) is a simple and powerful heuristic algorithm. It is widely used to solve flow-shop scheduling problems (FSPs), an important branch of production scheduling problems. IGA was first developed to solve an FSP in 2007. Since then, various FSPs have been tackled by using IGA-based methods, including basic IGA, its variants, and hybrid algorithms with IGA integrated. Up until now, over 100 articles related to this field have been published. However, to the best of our knowledge, there is no existing tutorial or review paper of IGA. Thus, we focus on FSPs and provide a tutorial and comprehensive literature review of IGA-based methods. First, we introduce a framework of basic IGA and give an example to clearly show its procedure. To help researchers and engineers learn and apply IGA to their FSPs, we provide an open platform to collect and share related materials. Then, we make classifications of the solved FSPs according to their scheduling scenarios, objective functions, and constraints. Next, we classify and introduce the specific methods and strategies used in each phase of IGA for FSPs. Besides, we summarize IGA variants and hybrid algorithms with IGA integrated, respectively. Finally, we discuss the current IGA-based methods and already-solved FSP instances, as well as some important future research directions according to their deficiency and open issues. Note to Practitioners —Many practical scheduling problems can be transformed into flow-shop scheduling problems (FSPs), most of which are NP-hard. In order to solve them in an industrial system setting, designing effective heuristics is important and practically useful and has, thus, attracted much attention from both researchers and engineers. As an easy and high-performance heuristic, an iterated greedy algorithm (IGA) is widely used and adapted to solve numerous FSPs. Its simple framework makes it easy to be implemented by practitioners, and its high performance implies its great potential to solve industrial scheduling problems. In this work, we aim to give practitioners a comprehensive overview of IGA and help them apply IGA to solve their particular industrial scheduling problems. We review the papers that solve FSPs with IGA-based methods, including basic IGA, its variants, and hybrid algorithms with IGA integrated. First, we provide practitioners with a tutorial on IGA, where an example for solving an FSP is introduced and an open platform is constructed. The platform collects and shares the related materials, e.g., open-source code, benchmarks, and website links of important papers. Then, we introduce various FSPs and specific designs of IGA-based methods. Finally, we discuss the current research and point out future research issues.

A Hybrid Iterated Greedy Algorithm for a Crane Transportation Flexible Job Shop Problem

Abstract: In this study, we propose an efficient optimization algorithm that is a hybrid of the iterated greedy and simulated annealing algorithms (hereinafter, referred to as IGSA) to solve the flexible job shop scheduling problem with crane transportation processes (CFJSP). Two objectives are simultaneously considered, namely, the minimization of the maximum completion time and the energy consumptions during machine processing and crane transportation. Different from the methods in the literature, crane lift operations have been investigated for the first time to consider the processing time and energy consumptions involved during the crane lift process. The IGSA algorithm is then developed to solve the CFJSPs considered. In the proposed IGSA algorithm, first, each solution is represented by a 2-D vector, where one vector represents the scheduling sequence and the other vector shows the assignment of machines. Subsequently, an improved construction heuristic considering the problem features is proposed, which can decrease the number of replicated insertion positions for the destruction operations. Furthermore, to balance the exploration abilities and time complexity of the proposed algorithm, a problem-specific exploration heuristic is developed. Finally, a set of randomly generated instances based on realistic industrial processes is tested. Through comprehensive computational comparisons and statistical analyses, the highly effective performance of the proposed algorithm is favorably compared against several efficient algorithms. Note to Practitioners —The flexible job shop scheduling problem (FJSP) can be extended and applied to many types of practical manufacturing processes. Many realistic production processes should consider the transportation procedures, especially for the limited crane resources and energy consumptions during the transportation operations. This study models a realistic production process as an FJSP with crane transportation, wherein two objectives, namely, the makespan and energy consumptions, are to be simultaneously minimized. This study first considers the height of the processing machines, and therefore, the crane lift operations and lift energy consumptions are investigated. A hybrid iterated greedy algorithm is proposed for solving the problem considered, and several problem-specific heuristics are embedded to balance the exploration and exploitation abilities of the proposed algorithm. In addition, the proposed algorithm can be generalized to solve other types of scheduling problems with crane transportations.

Deep reinforcement learning for dynamic scheduling of a flexible job shop

Abstract: The ability to handle unpredictable dynamic events is becoming more important in pursuing agile and flexible production scheduling. At the same time, the cyber-physical convergence in production system creates massive amounts of industrial data that needs to be mined and analysed in real-time. To facilitate such real-time control, this research proposes a hierarchical and distributed architecture to solve the dynamic flexible job shop scheduling problem. Double Deep Q-Network algorithm is used to train the scheduling agents, to capture the relationship between production information and scheduling objectives, and make real-time scheduling decisions for a flexible job shop with constant job arrivals. Specialised state and action representations are proposed to handle the variable specification of the problem in dynamic scheduling. Additionally, a surrogate reward-shaping technique to improve learning efficiency and scheduling effectiveness is developed. A simulation study is carried out to validate the performance of the proposed approach under different scenarios. Numerical results show that not only does the proposed approach deliver superior performance as compared to existing scheduling strategies, its advantages persist even if the manufacturing system configuration changes.

KMOEA: A Knowledge-Based Multiobjective Algorithm for Distributed Hybrid Flow Shop in a Prefabricated System

Abstract: In this article, a distributed hybrid flow shop scheduling problem with variable speed constraints is considered. To solve it, a knowledge-based adaptive reference points multiobjective algorithm (KMOEA) is developed. In the proposed algorithm, each solution is represented with a 3-D vector, where the factory assignment, machine assignment, operation scheduling, and speed setting are encoded. Then, four problem-specific lemmas are proposed, which are used as the knowledge to guide the main components of the algorithm, including the initialization, global, and local search procedures. Next, an efficient initialization approach is presented, which is embedded with several problem-related initialization rules. Furthermore, a novel Pareto-based crossover heuristic is designed to learn from more promising solutions. To enhance the local search abilities, a speed adjustment local search method is investigated. Finally, a set of instances generated based on the realistic prefabricated production system is tested to verify the efficiency and effectiveness of the proposed algorithm.

An improved iterated greedy algorithm for the energy-efficient blocking hybrid flow shop scheduling problem

Abstract: With the continuous development of national economies, problems of various energy consumption levels and pollution emissions in manufacturing have attracted attention from researchers. Most existing research has focused on reducing economic costs and energy consumption. However, the Hybrid Flow Shop Scheduling Problem with energy-efficient criteria has not yet been well studied, especially with blocking constraints. This paper is the first to present a mathematical model of the blocking hybrid flow shop problem with an energy-efficient criterion and a modified Iterative Greedy algorithm based on a swap strategy designed to optimize the constructed model. In the proposed algorithm, first, a heuristic is adopted to generate the initial solution. Second, a local perturbation strategy based on a swap operator is designed to ensure the convergence of the algorithm. Third, a simple global perturbation strategy based on a half-swap operator is proposed as a means to further search for the potentially best solution with the traditional simulated annealing criterion. The proposed algorithm is applied to 150 test instances at different scales and compared to state-of-the-art algorithms. The experimental results demonstrate that the proposed algorithm outperforms the compared algorithms and can obtain a better solution.

Real-time data-driven dynamic scheduling for flexible job shop with insufficient transportation resources using hybrid deep Q network

Abstract: With the extensive application of automated guided vehicles in manufacturing system, production scheduling considering limited transportation resources becomes a difficult problem. At the same time, the real manufacturing system is prone to various disturbance events, which increase the complexity and uncertainty of shop floor. To this end, this paper addresses the dynamic flexible job shop scheduling problem with insufficient transportation resources (DFJSP-ITR) to minimize the makespan and total energy consumption. As a sequential decision-making problem, DFJSP-ITR can be modeled as a Markov decision process where the agent should determine the scheduling object and allocation of resources at each decision point. So this paper adopts deep reinforcement learning to solve DFJSP-ITR. In this paper, the multiobjective optimization model of DFJSP-ITR is established. Then, in order to make agent learn to choose the appropriate rule based on the production state at each decision point, a hybrid deep Q network (HDQN) is developed for this problem, which combines deep Q network with three extensions. Moreover, the shop floor state model is established at first, and then the decision point, generic state features, genetic-programming-based action space and reward function are designed. Based on these contents, the training method using HDQN and the strategy for facing new job insertions and machine breakdowns are proposed. Finally, comprehensive experiments are conducted, and the results show that HDQN has superiority and generality compared with current optimization-based approaches, and can effectively deal with disturbance events and unseen situations through learning.

Modelling and optimization of integrated distributed flow shop scheduling and distribution problems with time windows

Abstract: Production and distribution are two essential activities in supply chain management. Currently, integrated production and distribution problems receive much attention because decision-makers devote to improving the operation efficiency of both stages and try to achieve an optimal solution. This work proposes an integrated distributed production and distribution problem with consideration of time windows, in which a set of jobs (i.e., customer orders) needs to be assigned among factories and the jobs are processed on flow shop environments at their associated factories. Then, the completed jobs are delivered by capacitated vehicles to customers in different regions while satisfying given time windows as much as possible. Accordingly, to optimally solve the proposed problem, a mixed integer programming model with minimizing total weighted earliness and tardiness has been established. For the optimization task, an enhanced brain storm optimization algorithm with some particular strategies is designed to handle the considered problem. To assess the performance of the proposed optimization method, several experiments by adopting a set of benchmark test problems are performed, and state-of-the-art optimizers are chosen for comparisons. The obtained optimization results exhibit that the designed algorithm significantly outperforms its rivals and can be considered as an excellent optimizer for solving the studied problem. Besides, compared with the CPLEX solver, the designed optimizer also performs much better for solving large-size problems.

A collaborative iterative greedy algorithm for the scheduling of distributed heterogeneous hybrid flow shop with blocking constraints

Abstract: The hybrid flow shop and distributed flow shop problems have been extensively studied due to their wide industrial applications. However, the distributed heterogeneous hybrid flow shop problems (DHHFSP) with blocking constraints have not yet been well studied up to date. This paper considers how to arrange a variety of jobs to different heterogeneous factories, and each factory has a minimal makespan. The innovations of this paper lie in presenting a mathematical model of the DHHFSP with blocking constraints and designing a collaborative iterative greedy (CIG) algorithm. The CIG contains the problem-specific initialization strategy, the neighborhood search strategy, the destruction-reconstruction strategy, and the local intensification strategy. The cross-factory and inner-factory neighborhood search strategies based on two swap operators are adopted to reduce the blocking time. The local intensification strategy is developed to optimize the scheduling sequence of each factory. The proposed algorithm is empirically compared with five state-of-the-art algorithms on 60 different instance sets. The experimental results show that the proposed algorithm significantly outperforms the compared ones in terms of objective values and relative percentage deviation values.

An Effective Iterated Greedy Algorithm for a Robust Distributed Permutation Flowshop Problem With Carryover Sequence-Dependent Setup Time

Abstract: A new scheduling problem, the distributed permutation flowshop scheduling problem with uncertain processing times and carryover sequence-dependent setup time (DPUC), is addressed. The DPUC is an important application problem in modern electronics manufacturing. A robust model is established for the DPUC with makespan criterion. A counter-intuitive paradox is found, that is, adding a new job to one of the production lines can reduce the completion time of the production line. Two acceleration methods are provided to save computational efforts. An iterated greedy algorithm called IG_FS is proposed to solve the DPUC. A heuristic based on the well-known NEH is proposed to generate the initial solution for the IG_FS. In the destruction phase of the IG_FS, dynamic sizes based on both adaptability and randomness are provided to improve the exploration capability. During the local search phase of the IG_FS, a hybrid local search method consisting of shift and swap operators is presented to exploit more diverse search areas. Extensive experiments show that the proposed IG_FS performs significantly better than the six competing algorithms adapted from the closely related scheduling literature.

Intelligent optimization under blocking constraints: A novel iterated greedy algorithm for the hybrid flow shop group scheduling problem

Abstract: This paper introduces a new flow shop combinatorial optimization problem, called the blocking hybrid flow shop group scheduling problem (BHFGSP). In the problem, no buffers exist between any adjacent machines, and a set of jobs with different sequence-dependent setup times needs to be scheduled and processed at organized manufacturing cells. We verify the correctness of the mathematical model of BHFGSP by using CPLEX. In this paper, we proposed a novel iterated greedy algorithm to solve the problem. The proposed algorithm has two key techniques. One is the decoding procedure that calculates the makespan of a job sequence, and the other is the neighborhood probabilistic selection strategies with families and blocking-based jobs. The performance of the proposed algorithm is investigated through a large number of numerical experiments. Comprehensive results show that the proposed algorithm is effective in solving BHFGSP.

Dynamic scheduling method for integrated process planning and scheduling problem with machine fault

Abstract: • A pre-reactive scheduling method is designed to deal with the integrated process planning and scheduling problem with machine fault. • The process adjustment method based on jobs classification is proposed to improve the stability of rescheduling. • Two hybrid algorithms combining genetic algorithm and variable neighborhood algorithm are proposed to solve the initial scheduling scheme and the rescheduling scheme respectively. The integration of process planning and job shop scheduling is of great significance to improve the performance of manufacturing system. Many studies on integrating process planning and scheduling problem focused on static workshop environment. However, there are a lot of uncertain factors in the workshop that need to be dealt with. Therefore, this paper studies the dynamic scheduling method of dynamic integrated process planning and scheduling problem under machine fault. To solve the dynamic integrated process planning and scheduling problem, two hybrid algorithms combining genetic algorithm with neighborhood search algorithm are designed. To improve the stability of rescheduling scheme, according to the characteristics of sequencing flexibility, processing flexibility and machine flexibility of the integrated process planning and scheduling problem, a process adjustment method based on job classification is proposed. To dynamically adjust the diversity and convergence of population, an adaptive hierarchical migration strategy is proposed. To decode dynamic scheduling scheme, the greedy decoding method is improved. The designed dynamic scheduling method is applied to the famous benchmark to verify the effectiveness of the proposed method in solving the dynamic integrated process planning and scheduling problem with machine fault.

Deep Reinforcement Learning for Distributed Flow Shop Scheduling with Flexible Maintenance

Abstract: A common situation arising in flow shops is that the job processing order must be the same on each machine; this is referred to as a permutation flow shop scheduling problem (PFSSP). Although many algorithms have been designed to solve PFSSPs, machine availability is typically ignored. Healthy machine conditions are essential for the production process, which can ensure productivity and quality; thus, machine deteriorating effects and periodic preventive maintenance (PM) activities are considered in this paper. Moreover, distributed production networks, which can manufacture products quickly, are of increasing interest to factories. To this end, this paper investigates an integrated optimization of the distributed PFSSP with flexible PM. With the introduction of machine maintenance constraints in multi-factory production scheduling, the complexity and computation time of solving the problem increases substantially in large-scale arithmetic cases. In order to solve it, a deep Q network-based solution framework is designed with a diminishing greedy rate in this paper. The proposed solution framework is compared to the DQN with fixed greedy rate, in addition to two well-known metaheuristic algorithms, including the genetic algorithm and the iterated greedy algorithm. Numerical studies show that the application of the proposed approach in the studied production-maintenance joint scheduling problem exhibits strong solution performance and generalization abilities. Moreover, a suitable maintenance interval is also obtained, in addition to some managerial insights.

Collaborative Multifidelity-Based Surrogate Models for Genetic Programming in Dynamic Flexible Job Shop Scheduling

Abstract: Dynamic flexible job shop scheduling (JSS) has received widespread attention from academia and industry due to its practical application value. It requires complex routing and sequencing decisions under unpredicted dynamic events. Genetic programming (GP), as a hyperheuristic approach, has been successfully applied to evolve scheduling heuristics for JSS due to its flexible representation. However, the simulation-based evaluation is computationally expensive since there are many calculations based on individuals for making decisions in the simulation. To improve training efficiency, this article proposes a novel multifidelity-based surrogate-assisted GP. Specifically, multifidelity-based surrogate models are first designed by simplifying the problem expected to be solved. In addition, this article proposes an effective collaboration mechanism with knowledge transfer for utilizing the advantages of multifidelity-based surrogate models to solve the desired problems. This article examines the proposed algorithm in six different scenarios. The results show that the proposed algorithm can dramatically reduce the computational cost of GP without sacrificing the performance in all scenarios. With the same training time, the proposed algorithm can achieve significantly better performance than its counterparts in most scenarios while no worse in others.

Q-Learning-Based Teaching-Learning Optimization for Distributed Two-Stage Hybrid Flow Shop Scheduling with Fuzzy Processing Time

Abstract: Two-stage hybrid flow shop scheduling has been extensively considered in single-factory settings. However, the distributed two-stage hybrid flow shop scheduling problem (DTHFSP) with fuzzy processing time is seldom investigated in multiple factories. Furthermore, the integration of reinforcement learning and metaheuristic is seldom applied to solve DTHFSP. In the current study, DTHFSP with fuzzy processing time was investigated, and a novel Q-learning-based teaching-learning based optimization (QTLBO) was constructed to minimize makespan. Several teachers were recruited for this study. The teacher phase, learner phase, teacher's self-learning phase, and learner's self-learning phase were designed. The Q-learning algorithm was implemented by 9 states, 4 actions defined as combinations of the above phases, a reward, and an adaptive action selection, which were applied to dynamically adjust the algorithm structure. A number of experiments were conducted. The computational results demonstrate that the new strategies of QTLBO are effective; furthermore, it presents promising results on the considered DTHFSP.

A Pareto-Based Discrete Jaya Algorithm for Multiobjective Carbon-Efficient Distributed Blocking Flow Shop Scheduling Problem

Abstract: Carbon peaking and carbon neutrality, which are significant strategies for national sustainable development, have attracted enormous attention from researchers in the manufacturing domain. A Pareto-based discrete Jaya algorithm (PDJaya) is proposed to solve the carbon-efficient distributed blocking flow shop scheduling problem (CEDBFSP) with the criteria of total tardiness and total carbon emission in this paper. The mixed-integer linear programming model is presented for the CEDBFSP. An effective constructive heuristic is produced to generate the initial population. The new individual is generated by the update mechanism of PDJaya. The self-adaptive operator local search strategy is designed to enhance the exploitation capability of PDJaya. A critical-path-based carbon saving strategy is introduced to further reduce carbon emissions. The effectiveness of each strategy in the PDJaya is verified and compared with the state-of-the-art algorithms in the benchmark suite. The numerical results demonstrate that the PDJaya is the efficient optimizer for solving the CEDBFSP.

Network-based dynamic dispatching rule generation mechanism for real-time production scheduling problems with dynamic job arrivals

Abstract: Although the concept of Industrial 4.0 has been well accepted, only few studies have dealt with real-time production scheduling of smart factories. Due to the advantages of simplicity, efficiency and quick response, heuristic rules have become the most promising technology to solve such problems. However, they suffer some drawbacks, such as high development and maintenance costs, low solution quality, and excessive emphasis on local information. To design heuristics from the perspective of system optimization and ensure the performance of heuristics in real-time production scheduling environments, this study develops a network-based dynamic dispatching rule generation mechanism. The complex network theory is introduced to extract a series of low-level heuristics from the perspective of system optimization, while the automatic heuristic generation problem is formulated as a multiple attribute decision making problem. Given that the dispersity of local features indicates their value for decision-making, the entropy weighting method is employed to automatically produce an adequate combination of the provided easy-to-implement low-level heuristics. Finally, the open shop scheduling problem with dynamic job arrivals is taken as an example to evaluate the effectiveness of the proposed algorithm. Numerical results demonstrate the excellent performance of the proposed algorithm in terms of algorithm effectiveness and computational time.