Batching and Scheduling : Models and Methods for Several Problem Classes

In some manufacturing systems significant setups are required to change production from one type of products to another. The setups render the manufacturing system inflexible as for reacting to changes in demand patterns, hence inventories must be maintained to guarantee an acceptable customer service. In this environment, production scheduling faces a number of problems, and this work deals with mathematical models to support the scheduling decisions. Some more background and motivation is given in the following sections, as well as in a case description in Section 1. 3. The synopsis in Section 1. 4 outlines the topics of the work. 1. 1 Motivation of the Planning Problem Consider the production of metal sheets in a rolling mill. If the width of the next type of sheets is greater than the width of the preceding type, then the roll needs a setup: during the rolling process the edges of a sheet cause grooves on the rolls' surface, thus, the surface must be polished if a greater width is run next. Sheets with a smaller width can be run directly, without a setup. Another example in which setups are sequence dependent is a line where cars are sprayed: if the color of the paint changes, the cleaning of the tools requires a setup depending on the sequence of the colors. Only a small setup may be needed for changing from a light to a dark color, but a thorough cleaning of the tools is 2 CHAPTER 1.