Ramya / Rajendran / Ziegler Capacitated Lot Sizing Problems in Process Industries

1. Auflage 2019
ISBN: 978-3-030-01222-9
Verlag: Springer International Publishing
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 227 Seiten

This book examines the Capacitated Lot Sizing Problem (CLSP) in process industries. In almost all process industries, there are situations where products have short/long setup times, and the setup of the product and its subsequent production are carried over, across consecutive periods. The setup of a product is carried over across more than one successive period in the case of products having long setup times. A product having short setup has its setup time less than the capacity of the period in which it is setup. The setup is immediately followed by its production of the product and it may also be carried over, across successive time period(s). Many process industries require production of a product to occur immediately after its setup (without the presence of idle time between the setup and production of the product), and they also require the product to be continuously produced without any interruption. This book considers a single-machine, single-level and multiple-item CLSP problem. This book introduces the Capacitated Lot Sizing Problem with Production Carryover and Setup Crossover across periods (CLSP-PCSC). Mathematical models are proposed which are all encompassing that they can handle continuous manufacturing (as in process industries), and also situations where the setup costs and holding costs are product dependent and time independent/time dependent, with possible backorders, and with other appropriate adaptations.  Comprehensive heuristics are proposed based on these mathematical models to solve the CLSP-PCSC. The performance of the proposed models and heuristics are evaluated using problem instances of various sizes. This book also covers mathematical models developed for the Capacitated Lot Sizing Problem with Production Carryover and Setup Crossover across periods, and with Sequence-Dependent Setup Times and Setup Costs (CLSP-SD-PCSC). These models allow the presence of backorders and also address real-life situations present in process industries such as production of a product starting immediately after its setup and its uninterrupted production carryover across periods, along with the presence of short/long setup times. Heuristics proposed for the CLSP-PCSC can be extended to address the CLSP problem with sequence dependent setup costs and setup times. All the models and heuristics proposed in this book address some real-life considerations present in process industries.


Ramya Ravi currently works in Caterpillar India Private Limited at Chennai, India. She completed Bachelor of Engineering in Electrical and Electronics Engineering at Sri Chandrasekharendra Saraswati Viswa Mahavidhyala University in 2008. She completed Master of Engineering in Industrial Engineering at Thiagarajar College of Engineering, Madurai (Anna University) in 2011. Thereafter, she received Ph.D. in Operations Management from IIT Madras in 2017. Her research interests include Supply Chain Management, Inventory Optimization, Production Planning and Scheduling, and Analytics. She has a publication in International Journal of Production Research, and she has attended international conferences, both in India and abroad. 
Chandrasekharan Rajendran is a Professor in the Department of Management Studies at IIT Madras, India. He holds RAGS Family Foundation Institute Chair in IIT Madras. He has been serving on the faculty of IIT Madras since 1987. His research interests include Operations and Supply Chain Management, Logistics and Distribution Management, Scheduling in Manufacturing and Service Systems, Optimization and Heuristic Techniques, Simulation Modeling, and Quality Management. He is a recipient of Alexander von Humboldt Research Fellowship of Germany and he is also a Visiting Professor in University of Passau, Germany. He has been conferred Dr. rer. pol. h.c. (Doctor of Business Administration and Economics (Honoris Causa)) by University of Passau for his outstanding achievements and contributions to research. He has been ranked among the best researchers, both in India and world-wide, in Operations Management. 
Hans Ziegler has his Diploma from University of Karlsruhe (TH) (now called Karlsruhe Institute of Technology), and PhD and Post-doctoral Habilitation from University of Paderborn. He had been on the faculty of Universities of Paderborn and Darmstadt, before moving to University of Passau where he holds the Chair for Production, Operations and Logistics Management (since 1991). He has research interests in Operations Research, Production and Operations Management, Supply Chain and Logistics Management, Scheduling in Manufacturing and Service Systems, and Inventory Management. Prof. Ziegler has publications in many renowned international journals such as Computers and Industrial Engineering, Computers and Operations Research, Engineering Costs and Production Economics, European Journal of Operational Research, International Journal of Advanced Manufacturing and Technology, International Journal of Production Research, Production Planning and Control, Operations Research Letters, OR Spektrum, and Zeitschrift fuer Operations Research.
Sanjay Mohapatra received his B.E. from NIT Rourkela, M.Tech from IIT Madras, PGDBM XIMB, India and has finished his Ph.D. from Utkal University, India under Management Department. At present, he is an Associate Professor in Information Systems in XIMB, India. Professor Mohapatra has more than 21 years of industry experience. He has worked in various capacities in organizations like Hindustan Aeronautics Limited, Larsen & Toubro, PricewaterHouse, Infosys, Polaris & J&B Software. His teaching interests are in IT Strategy and Management Information Systems and research interests are in the area of IT enabled processes. He has authored/co-authored nine books and more than twenty papers in peer reviewed international journals.
Dr. K.Ganesh is Senior Knowledge Expert and Global Lead of 'supply chain management center of competence' at McKinsey & Company, Chennai, India. He has graduated in Production Engineering from Annamalai University with the university first rank. He pursued his Masters' degree in Industrial Engineering at NIT Trichy and secured college first. He then moved to IIT Madras where he obtained his doctoral degree in Supply Chain. He is having total 14 years of research and consulting experience in the supply chain consulting and worked with top consulting firms such as TCS and IBM. He has published more than 100 papers in leading international research and written 10 international books. He is himself a lyricist and has written several poems in both English and Tamil.

Autoren/Hrsg.

Ramya, Ravi

Rajendran, Chandrasekharan

Ziegler, Hans

Mohapatra, Sanjay

Ganesh, K.

Inhaltsverzeichnis

1;Preface;6
2;Contents;8
3;List of Tables;11
4;List of Figures;13
5;Abbreviations;17
6;Notations;19
7;1 Introduction;34
7.1;1.1 Preamble to the Production Planning Problem;34
7.2;1.2 Basic Characteristics and Attributes of Lot Sizing Models;35
7.2.1;1.2.1 Time Based Characteristics and Attributes;35
7.2.1.1;Planning Horizon;36
7.2.1.2;Time Scale;36
7.2.1.3;Parameters/Data;36
7.2.1.4;Objective Function;36
7.2.1.5;Cost Components;36
7.2.1.6;Capacity;36
7.2.1.7;Number of Resources;37
7.2.1.8;Setup Operation;37
7.2.2;1.2.2 Product Based Characteristics and Attributes;37
7.2.2.1;Number of Products;37
7.2.2.2;Inventory Restrictions;37
7.2.2.3;Service Policy;38
7.3;1.3 Classification of Lot Sizing Models;38
7.3.1;1.3.1 Continuous Lot Sizing Problem: Economic Lot Scheduling Problem (ELSP);38
7.3.2;1.3.2 Dynamic Lot Sizing Problem;38
7.3.2.1;Uncapacitated Lot Sizing Problem;38
7.3.2.2;Capacitated Lot Sizing Problem;39
7.3.2.3;Small Bucket Lot Sizing Models;39
7.3.2.4;Big Bucket Lot Sizing Models;40
7.4;1.4 An Analysis of Lot Sizing Literature;43
7.4.1;1.4.1 Literature on CLSP Without Production Carryover Across Periods and Without Sequence Dependent Setups;44
7.4.2;1.4.2 Literature on CLSP Without Production Carryover Across Periods and with Sequence Dependent Setups;50
7.4.3;1.4.3 Literature on CLSP with Production Carryover Across Periods and Without Sequence Dependent Setups;52
7.4.3.1;CLSP with Production Carryover Across Periods and Setup Splitting Between Two Periods;56
7.4.3.2;CLSP with Production Carryover Across Periods and Setup Crossover Across Many Periods;59
7.4.4;1.4.4 Literature on CLSP with Production Carryover Across Periods and with Sequence Dependent Setups;59
7.5;1.5 Integrated Decision Making in Supply Chains;63
7.6;1.6 Summary;64
8;2 CLSP: Real Life Applications and Motivation to Study Lot Sizing Problems in Process Industries;65
8.1;2.1 Production Planning in Discrete Manufacturing Industries and Continuous Manufacturing Industries;65
8.1.1;2.1.1 Discrete Manufacturing Industries;65
8.1.2;2.1.2 Continuous Manufacturing Industries;65
8.1.2.1;Batch Process Industries;66
8.1.2.2;Die Casting Industry;66
8.1.2.3;Rubber Accessories Manufacturing Industry;67
8.1.2.4;Flow/Continuous Process Industries;67
8.1.2.5;Paper and Pulp Industry;67
8.1.2.6;Planning of Beverage Production;68
8.1.2.7;Cement Manufacturing Process;68
8.1.2.8;Food Processing Industry;69
8.1.2.9;Continuous Casting of Steel Plates;70
8.1.2.10;Planning of Production of Glass Containers;70
8.1.2.11;Process of Sugar Manufacturing;70
8.2;2.2 Further Motivation from a Real-Life Case Study;72
8.3;2.3 Scope of the Book in the Context of Process Industries;73
8.4;2.4 Summary;77
9;3 Capacitated Lot Sizing Problem with Production Carryover and Setup Crossover Across Periods (CLSP:PCSC): Mathematical Model 1 (MM1) and a Heuristic for Process Industries;78
9.1;3.1 Introduction and Problem Definition;78
9.2;3.2 Basic Assumptions of the Proposed Mathematical Model (MM1:CLSP-PCSC);83
9.3;3.3 Mathematical Model (MM1:CLSP-PCSC) for the Capacitated Lot Sizing Problem with Production Carryover and Setup Crossover Across Periods;84
9.3.1;3.3.1 Parameters/Indices;84
9.3.2;3.3.2 Decision Variables;85
9.3.3;3.3.3 Mathematical Model 1 (MM1:CLSP-PCSC);86
9.3.4;3.3.4 Method of Tracking Setups in MM1:CLSP-PCSC;95
9.4;3.4 Special Cases of CLSP-PCSC with Respect to MM1:CLSP-PCSC;95
9.4.1;3.4.1 Setup Cost of a Product Calculated with Respect to the Period of Its Setup Completion;95
9.4.2;3.4.2 Setup Cost and Holding Cost of a Product Being Time Independent;96
9.5;3.5 Numerical Illustrations and Discussion with Respect to MM1:CLSP-PCSC;96
9.5.1;3.5.1 Setup Cost of a Product Calculated with Respect to the Period of Its Setup Initiation;97
9.5.2;3.5.2 Setup Cost of a Product Calculated with Respect to the Period of Its Setup Completion;97
9.5.3;3.5.3 Setup Cost and Holding Cost of a Product Being Time Independent;98
9.5.4;3.5.4 Observations from an Existing Model;98
9.6;3.6 Proposed Heuristic for CLSP-PCSC with Respect to MM1:CLSP-PCSC;104
9.7;3.7 Computational Experience;111
9.7.1;3.7.1 Comparing Solution Times of the Proposed Mathematical Models (MM1:CLSP-PCSC);111
9.7.2;3.7.2 Comparison of Exact and Heuristic Approaches of MM1:CLSP-PCSC;112
9.8;3.8 Summary;133
10;4 Further Development: Mathematical Model 2 (MM2) and a Comprehensive Heuristic for Capacitated Lot Sizing Problem with Production Carryover and Setup Crossover Across Periods for Process Industries;134
10.1;4.1 Introduction and Problem Definition;134
10.2;4.2 Basic Assumptions of the Proposed Mathematical Model (MM2:CLSP-PCSC);136
10.3;4.3 Mathematical Model 2 (MM2:CLSP-PCSC) for the Capacitated Lot Sizing Problem with Production Carryover and Setup Crossover Across Periods;137
10.3.1;4.3.1 Parameters/Indices;137
10.3.2;4.3.2 Decision Variables;138
10.3.3;4.3.3 Mathematical Model 2 (CLSP-PCSC);139
10.3.4;4.3.4 Method of Tracking Setups in MM2:CLSP-PCSC;147
10.4;4.4 Special Cases of CLSP-PCSC with Respect to MM2:CLSP-PCSC;147
10.4.1;4.4.1 Setup Cost of a Product Calculated with Respect to the Period of Its Setup Completion;147
10.4.2;4.4.2 Setup Cost and Holding Cost of a Product Being Time Independent;149
10.5;4.5 Numerical Illustrations and Discussion with Respect to MM2:CLSP-PCSC;149
10.5.1;4.5.1 Setup Cost of a Product Calculated with Respect to the Period of Its Setup Initiation;151
10.5.2;4.5.2 Setup Cost of a Product Calculated with Respect to the Period of Its Setup Completion;151
10.5.3;4.5.3 Setup Cost and Holding Cost of a Product Being TimeIndependent;151
10.6;4.6 Proposed Heuristic for CLSP-PCSC with Respect to MM2:CLSP-PCSC;154
10.7;4.7 Computational Experience;157
10.8;4.8 Summary;161
11;5 Capacitated Lot Sizing Problem with Production Carryover and Setup Crossover Across Periods Assuming Sequence-Dependent Setup Times and Setup Costs (CLSP-SD-PCSC): Mathematical Models for Process Industries;162
11.1;5.1 Introduction and Problem Definition;162
11.2;5.2 Basic Assumptions of the Proposed Mathematical Models (MM1:CLSP-SD-PCSC and MM2:CLSP-SD-PCSC);165
11.3;5.3 Mathematical Model 1 (MM1:CLSP-SD-PCSC);166
11.3.1;5.3.1 Parameters/Indices;166
11.3.2;5.3.2 Decision Variables;167
11.3.3;5.3.3 Mathematical Model 1 (MM1:CLSP-SD-PCSC);169
11.4;5.4 Mathematical Model 2 (MM2:CLSP-SD-PCSC);181
11.4.1;5.4.1 Parameters/Indices;181
11.4.2;5.4.2 Decision Variables;181
11.4.3;5.4.3 Mathematical Model 2 (MM2:CLSP-SD-PCSC);186
11.5;5.5 A Numerical Illustration and Discussion;206
11.6;5.6 Computational Experience;211
11.7;5.7 Summary;213
12;6 Summary Concerning Theoretical Developments;214
13;References;218