Research

year 1999 
author Daeyoung Chung 
Keyword job shop scheduling, production planning, operation subcontract, overtime, decomposition 
Abstract Reliable and timely delivery is an important factor determining the competitive strength of a manufacturing company. In some environment, keeping due date is considered as a constraint whose violation is not permitted. However, a production plan and promised due dates usually cannot be accomplished owing to diverse reasons including insufficient production capacity and unexpected events. To cope with such problems, loads are modified using alternative routing, subcontracting, overtime work, etc. Capacity adjustments are usually considered in production planning, but the plan cannot correctly reflect the limited capacities of production resources. So the intervention of human planner is inevitable to rectify the plan, but the performance of the resulting plan is usually inferior with respect to costs because the human planner does not have proper decision support tools. To make a cost efficient plan, the capacity adjustment should be considered at scheduling level.

This paper deals with a job shop scheduling problem considering operation subcontract and overtime work. The problem has more decision variables and complex constraints than the pure job shop scheduling problem, which traditionally has been regarded as one of the most difficult combinatorial optimization problems. Due to the characteristic of the problem, decomposition and synthesis method is proposed to get the solution. First, the solution method starts with a traditional job shop scheduling problem with an objective of minimizing the violation of due date constraints. Second, the subcontract operations are repeatedly selected to reduce the remaining violation while minimizing the costs. At each iteration step, the overtime plans are modified to minimize the total cost of adjusting production capacities. Incidentally, the proposed solution methodology could also be utilized to solve an independent sub-problems of this type.

Next, a job shop scheduling problem with an objective of minimizing maximum lateness is addressed, and an optimization method and a heuristic algorithm are developed. The optimization method transforms the problem into a series of constraint satisfaction problems (CSP), and solves the CSP until an optimal solution is found. In this research, a new variable ordering / value ordering method and an improved dichotomous search method are introduced. Being implemented with an efficient constraint propagation technique, the suggested method shows superior performance than the other existing methods. The heuristic algorithm aims to find good solutions by improving the schedules obtained by widely used dispatching rules. The algorithm is designed to incrementally reduce the maximum lateness by repeatedly re-sequencing the jobs on bottleneck machines with Carlier´s algorithm. Perceiving that the jobs spend much waiting time owing to poor sequencing decisions, the algorithm is designed to select the bottleneck machine by relaxing the capacity constraint. The suggested method was shown to improve the quality of the solution more than the critical pair-wise exchange method in a very short time.

Next, a job shop scheduling problem considering operation subcontract is defined, and its solution method is suggested. The problem is decomposed into two sub-problems that are much related with each other, and so we would better not to use a sequential approach. Reflecting the relationship of the sub-problems, a solution method that deals with the sub-problems in an integrated manner is developed. In short, re-sequencing of the jobs and the selection of subcontracting operations are repeatedly conducted on bottleneck machines. To select the subcontracting operations with minimum cost, a branch and bound algorithm was developed. However, during the actual application of the algorithm, it was discovered that the maximum lateness cannot be decreased sometimes. To clear the cause of the stall and to make a way out, an algorithm that transforms the problem into a maximum flow problem is also developed. Through experiments, it is shown that the suggested solution method outperforms the conventional method and the sequential approaches.

Overtime scheduling is a difficult problem that must consider the time availability of production resources. An implicit representation method that relaxes the time availability constraint and a time-based decomposition method are used to circumvent the difficulties. As a result, the original problem can be solved by successive determination of overtime production quantity in each period. To determine the overtime quantity of a period, a linear programming model is used. The LP model considers the constraints occurred by the release time of a job and the operations planned to be subcontract.

The results of this study can be utilized to support the decision making of a human planner by generating a plan with minimum cost. Also this study may be considered as one of the first attempts to integrate the production planning problems and production scheduling problems. 
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번호 c year 제목 author
61 PhD  2003  Process Modeling and Performance Analysis Methodology toward Optimal Design of Manufacturing Systems [30] Kichang Lee 
60 MS  1998  Design of Integrated BOM Management System supporting Multiple Views Keumseok Kang 
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56 MS  2003  Design of a BOF Blowing Control Model Using Artificail Intelligence Jungjoon Park 
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54 MS  2012  Flight and Maintenance Planning of Miliary Aircraft considering Preventive Maintenance Period [13] Jun-Ho Park 
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52 MS  2005  A Study on Product Development Methodology in Reverse Supply Chain [77] Joon Kim 
51 PhD  2010  Framework for Integrative SRM System and Collaboration Scorecard [26] Jongkyoung Park 
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40 MS  1993  A Study on the FMS Shop Floor Control by Bidding among Autonomous Objects Jangsuk Moon 
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38 MS  1988  A Study on The Machine-Part Group Formation for FMS Planning and Operation Jaeyoon Kim 
37 MS  2004  A study on due-date assignment method in wafer fabrication facility producing multiple product types [3] Jaewon Park 
36 MS  1995  A Study on the Group Scheduling Problem with Sequence-dependent Set-up Times in a Multi-stage Cellular Manufacturing Systems Jaesoo Shim 
35 PhD  2009  A Study for Business Process Improvement Using Real-time Information of Unbalanced Work [19] Jaehyun Kong 
34 MS  1994  A Finitely Recursive Processes Approach to Modeling and Control of an FMC Jaeheuk Choi 
33 MS  2013  Design of an inspection system for reducing quality deterioration under VMI supply chain management system [16] Jaebong Lee 
32 MS  2006  A Study on the Assessment Method of Installation and Operation Cost in a Reverse Supply Chain [2] file Hyunjong Jeong 
31 MS  2007  A Study on Project Risk Management based on Earned Value Management [25] file Hyunil Noh 
30 PhD  2007  A Study on MRP Process Improvement in a Grid Enabled APS [2] file Hyoung-Gon Lee 
29 MS  1991  A Study on the Layered Architecture for the Control of FMS Cells Hosub Shin 
28 PhD  1997  A Study on FMS Design Justification Considering Part Type Selection and Performance Evaluation Hosub Shin 
27 PhD  2014  Multi-level job scheduling in a flexible discrete-part production environment Hong Bum Na 
26 MS  1991  A Study on Scheduling Problem of Hierarchically Structured Products in FMS [1] Hanil Jeong 
25 PhD  1996  An Improved Scheduling Heuristic Based on Batch Splitting Method for The Job Shop Scheduling Problem [4] Hanil Jeong 
24 PhD  2008  A study on integrated production planning and strategic framework in supply chain [15] Haejoong Kim 
23 MS  2013  Developing integrated key performance indicators and measurement scheme for MES [19] file Gyusun Hwang 
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21 MS  2008  Integration of RFID and Web Service Technology in Manufacturing Systems [20] file Gunnam Ong 
20 MS  2004  A Design on Cost-Estimation Support System for Injection Mold Using AI Method [12] Gunhee Kim 
19 MS  1999  A Study on the Implementation of the Speech Recognition System for the Real-Time Decision Support of Manufacturing Cells [18] Eoksu Sim 
18 PhD  2005  Performance Analysis and Network Design of Supply Chain for Strategic Decision Making [14] Eoksu Sim 
17 MS  2000  A Study on Integrated Production Planning of Distributed Manufacturing Systems on Supply Chain Dosung Go 
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14 MS  2005  A Study on RFID application in Reverse Supply Chain [3] Dongjoon Lim 
13 MS  2014  A study on operational models for electric vehicle battery switch stations in smart grid environment Dong Hyun Kim 
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