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DOI 10.1007/s00170-012-4600-7
ORIGINAL ARTICLE
1 Introduction
Nowadays, because of the intensely competitive markets
and limited resources, many manufacturers have come to
appreciate the importance of production planning. So, designing the best strategy and policy in this scope is vital.
H. Khaledi
Department of Industrial Engineering,
Sharif University of Technology,
Tehran, Iran
M. Reisi-Nafchi (*)
Department of Industrial and Systems Engineering,
Isfahan University of Technology,
Isfahan, Iran
e-mail: mohamad.reisi@in.iut.ac.ir
Therefore, this papers method could have many applications because of generality and could be applied in cases
where the production planning problem is defined. The rest
of papers structure is as follows:
In Section 2, the problem is described and its parameters
and variables are introduced. A classic model based on
linear programming for the problem is presented in Section 3, and in Section 4, a new dynamic programming model
is proposed and proved it is equivalent to the proposed
2 Problem description
In this paper, the problem objective is attempting to prepare
orders and requests of customers by considering setup costs,
tardiness, and products shortage costs. In addition, producing
customers necessities according to forecasts is another objective now and in future. Therefore, there exists an optimal
control problem that its production planning strategy is a
digital controller and must be optimized. Since this is a random problem, because of stochastic values of sales in future,
in this paper it is modeled as a stochastic dynamic programming and is transformed to a linear programming model using
successive approximations. To understand the problem better,
first, transformed model, i.e., linear programming model, is
presented and then original model, i.e., dynamic programming
and stages of its linearization are described. For linear
programming model, its constraints are introduced at first
and then its objective function is presented.
All necessary parameters and variables are defined as
follows:
i, j01, , n1, , n2, , n: All types of materials, items
and products which should be considered in production
planning
i, j01, , n1: Raw materials, which are purchased and
consumed but are not produced
i, j0n1 +1, , n2: Work in process materials and products which are produced and consumed
i, j0n2 +1, , n: Final products which are produced
and sold
m: Total number of producing machines which have
capacity constraints
k01, , m: Indicates the producing machine k
T: Total periods of production planning horizon
t00, 1, , T: Periods of production planning horizon;
t00: previous period, t01: first period
A: Total number of warehouses.
tIi: Inventory level of item i at the end of period t, so
matrix I is defined as below:
3
2
. . . . . . T I1
0 I1
1 I1
.. 7
6
7
6
...
6 0 I2
. . . . . . .. 7
7
6
.
6
. 7
6
. 7
I 6
7
6...
. . . t Ii . . . .. 7
7
6
7
6
6 ..
.. 7
.. . . . .
4 .
. 5
.
. .
I
.
.
.
.
.
.
.
.
.
0 n
T In
tPi:
1 P1
6
6 P
61 2
6
6
6
P 6...
6
6
6 ..
6 .
4
1 Pn
2 P1
...
..
.
...
t Pi
...
..
.
..
... ...
T P1
..
.
..
.
..
.
..
.
3
7
7
7 2
3
7
Raw materials : Purchase
7
7 4
5
WIPs : Produce
7
7
End products : Produce
7
7
7
5
2 S1
...
6
..
6 S
.
...
61 2
6
6
S 6
6...
...
6
t Si
6 .
.. . .
4 ..
.
.
1 Sn . . . . . .
T S1
..
.
..
.
..
.
..
.
q11
6
6 q21
6
6
Q 6 ...
6
6 ..
4 .
qn;1
q12
..
.
...
...
qik . . .
.. . .
.
.
... ...
C11
6
6 C21
6
6
C 6...
6
6 ..
4 .
Cn1
C12
..
.
...
...
Cij . . .
.. . .
.
.
... ...
t t n;1
T Sn
3
2
q1;m
0
.. 7
6 ...
. 7
7 6
.. 7 6 qn ;1
6 1
. 7
7 6
.. 7 4 ...
. 5
0
q
nm
0
..
.
3
0
.. 7
. 7
0 7
7
.. 7
. 5
...
..
.
. . . qnm
3 2
C1n
0 C1n1
.. 7 6
..
. 7
.
7 60
.. 7 6
6
0
0
7
. 7 6
..
.. 7 6
40
.
. 5
0
0
Cnn
3
... 0
..
.. 7
.
. 7
7
. . . Cn2 n 7
7
..
.. ... 7
5
.
.
0 0 0
t t 11
6
6 t t 21
6
6
t 6 . . .
6 .
4 ..
7
7 2
3
7
Raw materials : Consumption
7
7 4
5
WIPs : Consumption
7
7
End products : Sales
7
7
5
t b ik
...
rn;1
...
...
..
.
...
3
2
r1;m
0
.. 7
.
7
6
. 7 6 ..
.. 7 6 rn ;1
6 1
. 7
7 6
.. 7 4 ...
. 5
0
rnm
0
..
.
...
..
.
...
3
0
.. 7
. 7
0 7
7
.. 7
. 5
rnm
t t 12
..
.
t t ik
..
.
...
...
t t 1m
..
.
..
.
..
.
...
...
..
.
...
3
7
7
7
7
7
7
5
t t nm
rik
..
.
...
r12
..
.
6
6 r21
6
6
R 6...
6
6 ..
4 .
T Pn
tSi:
r11
t d ik
To understand better the above definitions, some parameters and variables are shown in Fig. 1 in a schematic
diagram.
0 Ii
t Ii t1 Ii t Pi t Si
i 1 . . . n1 . . . n2 . . . n; t 1T
t Ii
0production supplies
i 1 . . . n1 . . . n2 ; t 1 . . . T
t Ii
1
2
3
i n21 . . . n;t 1 . . . T
4
rik: Production rate of item i in machine k, so matrix R
is defined as below:
i2La t Ii
Ua
a 1 . . . Awarehouse capacity
T-1I
TB , TP , TS
TI
|---------- t=T ----------|
t Si
6
Pn
t Si
jn1
Cij t Pj
i 1 . . . n1 . . . n2 . . . n; t 1 . . . T
Min W
m
X
q ik t b ik q i
k1
m
X
Z t I; t B;
in1 1
t b ik
Binary0=1
k 1...m
10
m
X
rik t t ik ri
k1
m
X
m
n
X
1 X
bi t Ii
lk
jt bik t1 bik j
2 k1
in2 1
in1 1
n
X
15
t t ik i n1 1 . . . n2 ; t 1 . . . T
k1
11
m
X
t1 B
k1
t b ik 1;
13
14
t b ik i n1 1 . . . n2 ; t 1 . . . T
9
n
P
t1 B
t1 Z t I; t B;
t1
t Pi
T
X
n
X
k1
n
X
2
g i t Ii or
g i t Ii
i1
16
i1
12
In the above relation, i is unit cost of inventory surplus
and t Ii is surplus amount of inventory of product i at the end
of period t.
Some other scenarios for changing production line could
be considered. These scenarios are presented as the
following:
Figure 2 shows the relationship between defined parameters and variables graphically. This figure demonstrates that in
each period there exist some inventories (I) and during the
period this inventory increases by producing products (P) and
at the end of the period some products may be sold (S) and the
rest amount of inventory will remain for the next period.
The objective function of the proposed model is to minimize the total cost of inventories according to the
&
1P*
4P
2P
1S*
1I
2S
0I
2I
4S
3P=0
4I
3S
3I=0
t=0
t=1
t=2
t=3
t=4
Z t I; t B;
t1 B
n
X
bi
in2 1
t Ii
m
n
X
1 X
lik jt bik t1 bik j
2 k1 in 1
t f ijk t b ik
t1 B
n
X
in2 1
bi t Ii
m
X
n
X
t1 B
n
X
in2 1
m X
n
X
b i t Ii
lik 1t bik t1 bik
1t b ik t1 b ik
n
X
in2 1
t1 B
m
n
n
X
X
X
b i t Ii
lijk t bjk t1 bik
Min W
(
T
X
at1
t1
n
X
bi
t Ii
t b ik
n
X
gi
i1
t Ii
m X
n
X
n
X
k1 in1 1 in1 1
27
(
k1 in1 1 in1 1
20
b t b jk t g ijk
t1 jk
2 t g ijk 1 t1 b jk t b ik
in2 1
Equivalent
26
in2 1
Z t I; t B;
t bjk t1
b ik t f ijk
2 t f ijk 1 t b jk t1 b ik
k1 in1 1
19
&
Equivalent
k1 in1 1
18
&
1t1 b ik
25
t g ijk
Z t I; t B;
24
17
&
t1
b ik t e ijk 1
2 t e ijk t b jk t1 b ik
tb
jk
t1 b ik t b jk and t1 b i k
1t1 b ik t b jk and not
t1 b ik
21
22
1t b ik t1 b ik not t b jk and t1 b ik
RRR
1;...;1
V I ;BMin
B0
23
...
fZ I P B 0 X ; B 0 ; B a:V I P B 0 X ; B 0 g : f X :d X
X0;...;0
28
V I ; B Min
Z I P B 0
B0 >
:
ZZZ
1;...;1
Z
...
X :f X :d X ; B 0 ; B a:V I P B 0
X0;...;0
ZZZ
1;...;1
Z
...
x0;...;0
X :f X :d X ; B 0
9
>
=
>
;
29
X : f X : d X EX !
X S Sn2 1 ; Sn2 2 ; . . . ; Sn
...
30
X 0;...;0
:
Where vector S is the expected values of forecasting
sales. Therefore, probability distributions of forecasting
sales are not important and it is enough to know their
average. Now, dynamic programming is as follows:
V1 T 1 I;T1 B
TB
35
31
V0 0
T !1
T!1
32
37
1B
33
a:V
T 21 I P2 B2 S ; 2 B
g
Z 1 I P 2 B* 2S ; 2B* ; 1 B
a:VT2 1 I P 2 B* 2 S ; 2 B*
36
t1
VT 0 I; 0 B MinfZ 0 I P1 B1 S ; 1 B ; 0 B
a:V
T 1 0 I P1 B1 S ; 1 Bg
Z 0 I P 1 B* 1 S ; 1 B* ; 0 B
a:VT 1 0 I P 1 B* 1 S ; 1 B*
T1 Bg
a:V
0 T 1 I PT BT S ; T Bg
Z T1 I P T B* T S; T B* ; T1B
a:V0 T 1 I P T B* T S ; T B*
V I ; B Min
fZ I P B 0 S ; B 0 ; B a:V I P B 0 S; B0 g
0
MinfZ T 1 I PT BT S ; T B ;
34
So, the optimal solution of the proposed linear programming in the previous section is exactly equal to the optimal
solution of original dynamic programming, which to solve
it, the problem should be solved for T01 and then the value
of T must increase successively until the solution of T+1
and T become equal. In this case, the optimal solution of
unlimited periods is obtained.
5 Conclusion
Production planning has become one of the most important
issues for manufacturers from several years ago. So, its related
problems have been studied by many researchers from different
point of views. In this paper, the problem is considered in a
general and applied manner and a new model is proposed to
achieve optimal decisions which are applicable in master production schedule, manufacturing resource planning, capacity
requirements planning, and job shop/shop floor scheduling. A
new stochastic dynamic programming model and its transformed
linear model are presented for the problem and then it is proved
that these two models are equivalent. For further studies, it is
suggested that these models are applied on real world data.
Besides, fuzzy concepts could be useful to model the problem.
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