Planning and Scheduling in
Manufacturing and Services
by:
Michael Pinedo
Materials provided by:
Academia:
Erwin Hans and Johann Hurink (Twente University, the Netherlands)
Siggi Olafsson (Iowa State University)
Sanja Petrovic (Nottingham University)
Fatma Sibel Salman (Carnegie-Mellon University)
Cees Duin and Erik van der Sluis (University of Amsterdam)
J. Christopher Beck (University of Toronto)
Tim Nieberg (University of Bonn)
Marco Chiarandini (University of Southern Denmark)
Corporations:
Alcan Inc. (Montreal, Canada)
Jeppesen Systems (Carmen Systems – Gothenburg, Sweden)
Cybertec (Trieste, Italy)
Fair Isaac (Dash Optimization – Northants, England)
Ilog (Paris, France)
SAP (Walldorf, Germany)
Oliver Wyman (MultiModal – Princeton, USA)
Contents of the CD
1. Slides from Academia:
Erwin Hans and Johan Hurink
Siggi Olafsson
Sanja Petrovic
Fatma Sibel Salman
Cees Duin and Erik van der Sluis
Christopher Beck
Tim Nieberg
Marco Chiarandini
2. Slides from Corporations:
Alcan Inc.
Jeppesen Systems (Carmen)
Cybertec
Fair Isaac (Dash Optimization)
Oliver Wyman (MultiModal)
SAP
3. Scheduling Systems:
Lekin
4. Optimization Software
Fair Isaac (Dash Optimization)
ILOG OPL Studio
5. Examples and Exercises
Aircraft Scheduling
Tanker Scheduling
6. Mini-Cases
Fair Isaac (Dash Optimization)
ILOG
7. Additional Reading Material
Jeppesen Systems (Carmen)
Oliver Wyman (MultiModal)
8. Movies:
Saiga (ILOG)
United Airlines
Planning and Scheduling in Manufacturing and Services
1. Slides from Academia
The textbook “Operations Scheduling with Applications in Manufacturing and Services” has
been adopted by more than 20 instructors worldwide. A number of these instructors have
developed elaborate websites and large number of power point transparencies. In this CD we
have compiled the material developed by four of them, namely
Erwin Hans & Johann Hurink (Twente University)
Siggi Olafsson (Iowa State University)
Sanja Petrovic (Nottingham University)
Fatma Sibel Salman (Carnegie-Mellon University)
Cees Duin & Erik van der Sluis (University of Amsterdam)
300 transparencies
500 transparencies
400 transparencies
100 transparencies
350 transparencies
Christopher Beck (University of Toronto)
650 transparencies
Tim Nieberg (University of Bonn)
Marco Chiarandini (University of Southern Denmark)
130 transparencies
180 transparencies
a. Twente-Holland
University of Twente-Enschede, The Netherlands – Dr. Erwin Hans and Johann Hurink
•
Course Title: Production planning: operations scheduling with applications in
manufacturing and services
•
Course Description: The objective of this course is to develop an acquaintance with
models and techniques for operations scheduling, with applications in manufacturing
and services. The course will focus on resource constrained project scheduling, job
shop scheduling, interval scheduling and reservation systems, workforce scheduling and
scheduling applications. It will concentrate on exact methods as well as heuristic
methods.
Planning and Scheduling in Manufacturing and Services
b. Iowa State
Iowa State University – Professor Sigurdur Olafsson
•
Course Title: Production Scheduling IE514
•
Course Description: As modern manufacturing moves towards manufacture-to-order
and virtual environments that both increase the complexity of the operation and demand
an increasing rapid response time, it becomes more important than ever that
manufacturing enterprises have Advanced Planning and Scheduling (APS) systems
that can reliably schedule complicated operations quickly. At the same time, scheduling
plays an increasing role in many service industries, such as the transportation, computer,
and communication industries. Against this background, this course presents a solid
background in the models and scheduling techniques that are the most useful in both
manufacturing and service industries and places these tools within the context of modern
enterprise-wide information systems such as Enterprise Resource Planning (ERP)
systems, where the APS module works interactively with other modules such as MRP,
inventory management, product and process design, product costing, and supply chain
management. Thus, although most of our lectures in this course will be spent on
scheduling models and solution techniques, after completing the course you should also
understand how these technical tools can be integrated into enterprise-wide computing
systems that improve the overall efficiency of the organization. In particular, by
incorporating the models and techniques from this course, an APS module can be used
to improve customer service and delivery promises, increase throughput, reduce work in
process, and minimize setup operations.
c. Nottingham
University of Nottingham - Dr. Sanja Petrovic
•
Course Title: Automated Scheduling G53ASD
•
Course Description: The aim of the course is to provide a sound understanding of the
fundamental techniques and algorithms for scheduling problems that arise in a range of
commercial and service sectors. The objectives of the course include the introduction of
a number of scheduling algorithms including General Purpose Procedures Applied to
Production Scheduling (Single Machine Deterministic Models, and Multiple Machines
Problems), University Timetabling, Employee Timetabling, Project Scheduling. The
course will also cover some modern approaches for dealing with scheduling problems
including treating uncertainties in scheduling by fuzzy sets and fuzzy logic, using
previous experiences in scheduling by case based reasoning, and multicriteria
approaches to scheduling.
Planning and Scheduling in Manufacturing and Services
d. CMU
Carnegie Mellon University – Professor Fatma Sibel Salman
•
Course Title: Sequencing and Scheduling: 45-865 – Spring 2000
•
Course Description: Every organization needs to schedule its operations effectively in
order to remain competitive in today's markets. This course gives an introduction to a
broad range of scheduling problems that arise in both manufacturing and service
organizations. We will examine a variety of scheduling techniques, starting from basic
principles and leading to algorithms and computerized scheduling systems. We will
apply these techniques to problems arising in production scheduling, project
management, transportation scheduling and workforce scheduling. The emphasis is on
practicality rather than depth and theory, with the goal of bringing the student up to the
position where he or she knows where to look and what to expect to be able to do when
faced with a situation that seems to involve some sort of scheduling problem. Instruction
will be through a mix of lectures, readings, cases and problem sets. Guest lectures by
practitioners, articles, videos and software demos on industrial applications will
complement the class material.
e. Amsterdam
University of Amsterdam, The Netherlands – Dr. Erik van der Sluis and Dr. Cees Duin
•
Course Title: Operations Scheduling, Spring 2004
•
Course Description: The objective of this course is to introduce a number of scheduling
problems arising in manufacturing and service environments. The course will focus on
single machine scheduling, resource constrained project scheduling, job shop and flow
shop scheduling, interval scheduling and reservation systems and workforce scheduling.
It will concentrate on mathematical formulations, exact methods as well as heuristic
methods and complexity results. Instruction will be through a mix of lectures and
problem sets.
Planning and Scheduling in Manufacturing and Services
f. University of Toronto
University of Toronto, Canada – Professor J. Christopher Beck
•
Course Title: MIE 562: Scheduling
•
Course Description: This course takes a practical approach to scheduling problems and
solution techniques, motivating the different mathematical definitions of scheduling
with real-world scheduling systems and problems. The linking theme for the course is
the use of search (partition, relaxations, and inference) to solve hard combinatorial
problems. Topics covered include: job shop scheduling, timetabling, project scheduling,
and the variety of solution approaches including constraint programming, local search,
heuristics, and dispatch rules. Also covered will be information engineering aspects of
building scheduling systems. A group project will require the creation a scheduling
system using the Warp Shoes database. Evaluation will be based on three terms tests, the
project, and the final exam. Students should have a basic knowledge of standard
optimization techniques as taught in second and third year MIE courses.
g. University of Bonn
University of Bonn, Germany – Professor Tim Nieberg
•
Course Title: Scheduling
•
Course Description: The term scheduling represents the assignment of resources over
time to perform some tasks, jobs or activities. Feasible schedules are compared with
respect to a given optimality criterion. Mostly, the optimization problem is
combinatorial and very complex. From a computational point of view these problems
are hard (NP-hard) and the classical techniques fail in practice. Therefore, an optimal
solution is often approximated. The following topics will be discussed:
• Classification of scheduling models
• Single-machine models
• Parallel-machine models
• Open shop, flow shop and job shop models
• Timetabling
• Transportation
• On-line models
Planning and Scheduling in Manufacturing and Services
h. SDU
University of Southern Denmark – Professor Marco Chiarandini
•
Course Title: Scheduling, Timetabling and Routing
•
Course Description: The course is application-oriented and is focused on three
optimization contexts: production planning, service timetabling, and transportation
routing. In the first context, application examples are project scheduling, job shop
scheduling and scheduling in flexible assembly systems. In the second context,
application examples are crew and workforce scheduling, education timetabling and
employee timetabling. In the third context, application examples are the vehicle routing
problems, with constraints that derives from capacities, time windows, pickup and
delivery or back-haul. For each case, the problem will be formulated, modeled and
solved. Cases under uncertainty of data will also be considered. The solution techniques
are mainly heuristics, such as local search methods and metaheuristics, but exact
methods, such as networks algorithms, integer programming and branch and bound, will
also be outlined when they are feasible for the given problem. The configuration and
tuning of these solvers on the specific application will be solved by means of a
systematic methology.
Planning and Scheduling in Manufacturing and Services
2. Slides from Corporations
a. Alcan Inc.
Alcan is the second largest aluminum company in the world headquartered in Montreal,
Canada. Their Industrial Engineering group has developed a number of planning and
scheduling systems for their smelters as well as for their converting facilities. Their
algorithms are based on genetic algorithms as well as integer programming techniques.
b. Jeppesen Systems (Carmen Systems)
Jeppesen Systems is a software house that specializes in systems for the airline industry.
They have systems that are designed to route and schedule the aircraft as well as systems
that do crew scheduling. Their applications are based on the latest research in optimization.
Jeppesen Systems also provides services to analyze, implement, support and improve.
c. Cybertec
Cybertec is the largest scheduling software development company in Italy. It has
implementations in virtually every major company in Italy. This slide show is one that was
prepared for Zanussi (the major Italian manufacturer of appliances). It clearly shows the
elaborate user interfaces of the Cyberplan system.
d. Fair Isaac (Dash Optimization)
Fair Isaac develops and markets Xpress-MP, the world's leading software product for
modeling and optimization. Xpress-MP solves large-scale optimization problems and
enables better business decisions and resulting financial benefits in areas such as supply
chain management, operations, logistics and asset management. It has been applied in
sectors as diverse as manufacturing, processing, distribution, retailing, transport, finance
and investment.
Planning and Scheduling in Manufacturing and Services
e. Oliver Wyman (MultiModal Applied Systems)
Oliver Wyman is the market leader in planning and service design software, consulting and
support for railway systems worldwide. Oliver Wyman builds MultiRail, the industrystandard system for operations and schedule planning for freight and passenger railways.
Other products and services focus on operating plan design, line capacity/dispatch planning,
real-time marshalling plan management, crew optimization, yield management, and a wide
variety of consulting and custom software development services.
f. SAP
SAP is one of the largest software developers in the world. It is based in Walldorf,
Germany. Its APO division developed an Integrated supply chain management system with
a demand management module, a medium term planning module and a detailed scheduling
module.
Planning and Scheduling in Manufacturing and Services
3. Scheduling Systems
•
LEKIN
This CD contains a copy of the LEKIN scheduling
system, which is being used at hundreds of
universities and companies worldwide.
Planning and Scheduling in Manufacturing and Services
4. Optimization Software
This CD contains a copy of Xpress-MP
Xpress-MP – the fast track from formulation to
solution
Xpress-MP is the preferred choice for end-user
applications
• Powerful yet flexible model building tools
• The fastest optimizers around
• Able to solve large problems
• Rapid development
Xpress-MP – the superior optimization software
component
Xpress-MP is the preferred optimization component
for software product developers
• Easy to integrate
• Reliable
• Powerful, flexible, industry standard interfaces
• Delivers state-of-the-art technology
This CD also contains sample programs for examples
8.41 and 11.2.1.
Planning and Scheduling in Manufacturing and Services
This CD contains a trial version of
ILOG OPL Studio
ILOG OPL Studio is a complete platform for
leveraging valuable resources with optimization
technology. Powered by ILOG's leading optimization
engines, this comprehensive modeling system
expedites development and deployment.
Fast development
Minimal computer programming is required to develop
optimization applications, thanks to ILOG OPL Studio's
intuitive optimization programming language (OPL):
•
•
•
Reduce development time for a wide range of
optimization problems, ranging from short-term
operational scheduling to long-term economic
planning
Experiment with both constraint programming
and mathematical programming to determine the
most effective method for solving optimization
problems
Descriptive OPL syntax produces substantially
simpler code than traditional programming
languages, reducing development time from
weeks to days
Smooth deployment
Optimization projects advance directly from concept to
implementation, drawing on OPL Component Libraries:
• Embed OPL models directly into business
applications after analysis and testing
• Connect optimization systems directly to data
sources, reading business information and
storing optimized solutions
• Solve large or complex optimization problems,
utilizing support for powerful computation
servers
Planning and Scheduling in Manufacturing and Services
5. Examples and Exercises
This section includes the details of examples and exercises which are covered in the book.
• Tanker Scheduling (Computational details of Example 11.2.1)
• Aircraft Routing and Scheduling (Computational details of Example 11.3.1)
Planning and Scheduling in Manufacturing and Services
6. Mini-Cases
The mini-cases in this section describe actual industrial implementations of planning
and scheduling systems in industry. Most of these cases have been provided by ILOG, a
software house based in Paris that markets various products including CPLEX. Some
cases have been provided by Fair Isaac (Dash Optimization). Fair Isaac (Dash
Optimization) markets the Xpress-MP software that is presented in Section 4 of this CD.
The mini-cases are organized according to the chapters in the book. There is one or more minicases for each chapter from 4 to 11.
Chapter 4: Project Planning and Scheduling
Mini-case: - Samho Heavy Industries (Shipbuilding Scheduling System)
Chapter 5: Job Shop Scheduling
Mini-Case: - Eurocopter (Workshop Planning for Helicopter Propellor Repair)
Chapter 6: Scheduling of Flexible Assembly Systems
Mini-Cases: - Automotive Industry (Enabling Technology for Success)
- PSA Peugeot Citroën (Solving the car sequencing problem using
combined CP/MIP for PSA Peugeot Citroën)
Chapter 7: Lot Sizing and Scheduling
Mini-Cases: - POSCO (Optimizing Steel Production to Better Meet Customer Demand)
- McDougalls Foods (Matching Production to Demand)
- BASF (Solving BASF’s plastics production planning and lot-sizing
problem using combined CP/MIP)
- Procter & Gamble (Production and planning in Procter & Gamble’s snacks
business)
Chapter 8: Planning and Scheduling in Supply Chains
Mini-Case: - MARS (Optimizing Production and Supporting Decisions)
Chapter 9: Interval Scheduling, Reservation Systems and Timetabling
Mini-Case: - FREMAP (Planning of Medical Appointments)
- British Army (Training Administration Financial Management
Information System)
Chapter 11: Transportation Planning and Scheduling
Mini-Cases: - Siemens (Railway Timetabling)
- SNCF (Train Station Resource Allocation)
Planning and Scheduling in Manufacturing and Services
- ADP (Reducing Congestion at Paris Airports)
- Navion (Oil Tanker Scheduling)
- Clarity Systems (Freight Container Scheduling)
Chapter 13: Workforce Scheduling
Mini-Case: - Long Island Lighting Co. (Corporate Resource Management System)
- Severn Trent Systems (Crew Scheduler)
- Banque Bruxelles Lambert (Staff Planner)
Planning and Scheduling in Manufacturing and Services
7. Additional Readings
This section includes papers that are useful additional reading. The papers are selected based on
the insights and perspectives they provide.
Chapter 11: Transportation Planning and Scheduling
Papers: • Using Constraint Propagation to Accelerate Column Generation in Aircraft
Scheduling
Mattias Groenkvist
Jeppesen Systems (Carmen Systems)
• MultiRail Passenger Edition System Description
• Fast Track II System Description
• Rail Crew Scheduling, Rostering and Management- Opcom White Paper
Oliver Wyman (MultiModal Applied Systems)
Chapter 13: Workforce Scheduling
Paper:
• Integrating operations Research and Constraint Programming Techniques in Crew
Scheduling
Niklas Kohl and Stefan E. Karish
Jeppesen Systems (Carmen Systems)
Planning and Scheduling in Manufacturing and Services
8. Movies
Double click on the movie. The movie should automatically open in either Windows Media
Player, or Real Player. If you cannot view the movie, go to the Microsoft website
(http://www.microsoft.com) and download Windows Media Player.
Saïga
Aéroports de Paris (A 14 minute film)
Presenting Saïga, an application developed with ILOG products
by Aéroports de Paris. Designed to optimize resource allocation
at airports, Saïga includes a graphical user interface, a planning
and allocation optimization module, and a real-time control
engine. ILOG products are used at many other airports
throughout the world as well. At London’s Heathrow Airport,
for example, British Airways is using an ILOG-based
application to design the proposed Terminal 5.
Airports are not the only operations that use ILOG products;
they are also widely used in the telecommunications, defense,
transportation and manufacturing industries. Also featured in the
film is an ILOG-based system used by Motorala to schedule the
satellites in IRIDIUM, a global communication system.
United Airlines
PEGASUS Software (A 10 minute film)
Managing flight schedules tends to be a complicated
process and involves many different variables, like aircraft
scheduling, maintenance, crew scheduling, and so on.
Moreover, it has to be flexible enough to meet the
changing expectations of the customers. PEGASUS, the
scheduling system developed by United Airlines, uses a
heuristic system, instead of a linear program, to develop
flight schedules that are both efficient and flexible.
I would like to acknowledge Berna Sifonte for her assistance in the design and creation of this CD.