Skip to main content
SpringerLink
Log in

Integrated Production Planning, Shift Planning, and Detailed Scheduling in a Tissue Paper Manufacturer

  • Conference paper
  • First Online:
Models, Algorithms, and Technologies for Network Analysis

Part of the book series: Springer Proceedings in Mathematics & Statistics ((PROMS,volume 32))

  • 1172 Accesses

Abstract

In this study, we report an integrated planning system that we developed for a large tissue paper manufacturer in Turkey. The system is composed of three integrated models to solve the capacity planning, shift planning, and scheduling problems. All three problems are solved by a combination of optimization methods and heuristics. We also report the implementation process of the system in the manufacturing organization, and discuss observed benefits of the system in terms of the competitive position of the company.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 129.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 169.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 169.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. Aghezzaf, E.H.: Lot-sizing Problem With Setup Times in Labor-based Capacity Production Systems. Int. J. Prod. Econ. 64(1–3), 1–9 (2000). DOI 10.1016/S0925-5273(99)00029-8

    Article  Google Scholar 

  2. Akartunal, K., Miller, A.J.: A Heuristic Approach for Big Bucket Multi-level Production Planning Problems. Eur. J. Oper. Res. 193(2), 396–411 (2009). DOI 10.1016/j.ejor.2007.11.033

    Article  Google Scholar 

  3. Alain, G.: A Primal-dual Approach for Capacity-constrained Production Planning With Variable and Fixed Costs. Comput. Ind. Eng. 37(1–2), 93–96 (1999). DOI 10.1016/S0360-8352(99)00030-3

    Article  Google Scholar 

  4. Allahverdi, A., Ng, C., Cheng, T., Kovalyov, M.: A Survey of Scheduling Problems With Setup Times or Costs. Eur. J. Oper. Res. 187(3), 985–1032 (2008). DOI 10.1016/j.ejor.2006.06.060

    Article  MathSciNet  MATH  Google Scholar 

  5. Beaumont, N.: Scheduling Staff Using Mixed Integer Programming. Eur. J. Oper. Res. 98(3), 473–484 (1997). DOI 10.1016/S0377-2217(97)00055-6

    Article  MATH  Google Scholar 

  6. Bhatnagar, R., Mehta, P., Chong Teo, C.: Coordination of Planning and Scheduling Decisions in Global Supply Chains With Dual Supply Modes. Int. J. Prod. Econ. 131(2), 473–482 (2011). DOI 10.1016/j.ijpe.2011.01.011

    Google Scholar 

  7. Chen, K., Ji, P.: A mixed integer programming model for advanced planning and scheduling (APS). Eur. J. Oper. Res. 181(1), 515–522 (2007). DOI 10.1016/j.ejor.2006.06.018

    Article  MathSciNet  MATH  Google Scholar 

  8. Chu, S.: Generating, scheduling and rostering of shift crew-duties: Applications at the Hong Kong international airport. Eur. J. Oper. Res. 177(3), 1764–1778 (2007). DOI 10.1016/j.ejor.2005.10.008

    Article  MATH  Google Scholar 

  9. Ernst, A.T., Jiang, H., Krishnamoorthy, M., Sier, D.: Staff scheduling and rostering: A review of applications, methods and models. Eur. J. Oper. Res. 153(1), 3–27 (2004)

    Article  MathSciNet  MATH  Google Scholar 

  10. Fumero, F.: Integrating distribution, machine assignment and lot-sizing via Lagrangean relaxation. Int. J. Prod. Econ. 49(1), 45–54 (1997). DOI 10.1016/S0925-5273(96)00098-9

    Article  Google Scholar 

  11. Georgiadis, M., Levis, A., Tsiakis, P., Sanidiotis, I., Pantelides, C., Papageorgiou, L.: Optimisation-based scheduling: A discrete manufacturing case study. Comput. Ind. Eng. 49(1), 118–145 (2005). DOI 10.1016/j.cie.2005.02.004

    Article  Google Scholar 

  12. Guyon, O., Lemaire, P., Pinson, E., Rivreau, D.: Cut generation for an integrated employee timetabling and production scheduling problem. Eur. J. Oper. Res. 201(2), 557–567 (2010)

    Article  MathSciNet  MATH  Google Scholar 

  13. Harjunkoski, I., Grossmann, I.: Decomposition techniques for multistage scheduling problems using mixed-integer and constraint programming methods. Comput. Chem. Eng. 26(11), 1533–1552 (2002). DOI 10.1016/S0098-1354(02)00100-X

    Article  Google Scholar 

  14. Hertz, A., Lahrichi, N., Widmer, M.: A flexible MILP model for multiple-shift workforce planning under annualized hours. Eur. J. Oper. Res. 200(3), 860–873 (2010) DOI 10.1016/j.ejor.2009.01.045

    Article  MATH  Google Scholar 

  15. ICRON Technologies: ICRON Supply Chain Optimization System (2011). Software company that provides advance planning and scheduling solutions. URL http://www.icrontech.com

  16. Jolayemi, J., Olorunniwo, F.: A Deterministic Model for Planning Production Quantities in a Multi-plant, Multi-warehouse Environment With Extensible Capacities. Int. J. Prod. Econ. 87(2), 99–113 (2004). DOI 10.1016/S0925-5273(03)00095-1

    Google Scholar 

  17. Kim, B., Kim, S.: Extended model for a hybrid production planning approach. Int. J. Prod. Econ. 73(2), 165–173 (2001). DOI 10.1016/S0925-5273(00)00172-9

    Article  Google Scholar 

  18. Kopanos, G.M., Méndez, C.A., Puigjaner, L.: MIP-based decomposition strategies for large-scale scheduling problems in multiproduct multistage batch plants: A benchmark scheduling problem of the pharmaceutical industry. Eur. J. Oper. Res. 207(2), 644–655 (2010). DOI 10.1016/j.ejor.2010.06.002

    Article  MATH  Google Scholar 

  19. Lagodimos, A., Mihiotis, A.: Overtime vs. regular shift planning decisions in packing shops. Int. J. Prod. Econ. 101(2), 246–258 (2006). DOI 10.1016/j.ijpe.2004.12.028

    Google Scholar 

  20. Lagodimos, A.G., Leopoulos, V.: Greedy heuristic algorithms for manpower shift planning. Int. J. Prod. Econ. 68(1), 95–106 (2000)

    Article  Google Scholar 

  21. Lasserre, J.B.: An integrated model for job-shop planning and scheduling. Manage. Sci. 38, 1201–1211 (1992)

    Article  MATH  Google Scholar 

  22. Leung, S.C., Chan, S.S.: A goal programming model for aggregate production planning with resource utilization constraint. Comput. Ind. Eng. 56(3), 1053–1064 (2009). DOI 10.1016/j.cie.2008.09.017

    Article  Google Scholar 

  23. Li, Z., Ierapetritou, M.G.: Production planning and scheduling integration through augmented lagrangian optimization. Comput. Chem. Eng. 34(6), 996–1006 (2010)

    Article  Google Scholar 

  24. Maravelias, C.T., Sung, C.: Integration of production planning and scheduling: Overview, challenges and opportunities. Comput Chem. Eng. 33(12), 1919–1930 (2009)

    Article  Google Scholar 

  25. Mendez, C., Henning, G., Cerda, J.: An MILP continuous-time approach to short-term scheduling of resource-constrained multistage flowshop batch facilities. Comput. Chem. Eng. 25(4–6), 701–711 (2001). DOI 10.1016/S0098-1354(01)00671-8

    Article  Google Scholar 

  26. Mendez, C.A., Cerda, J., Grossmann, I.E., Harjunkoski, I., Fahl, M.: State-of-the-art review of optimization methods for short-term scheduling of batch processes. Comput. Chem. Eng. 30(6–7), 913–946 (2006)

    Article  Google Scholar 

  27. Mula, J., Peidro, D., Díaz-Madroñero, M., Vicens, E.: Mathematical programming models for supply chain production and transport planning. Eur. J. Oper. Res. 204(3), 377–390 (2010). DOI 10.1016/j.ejor.2009.09.008

    Article  MATH  Google Scholar 

  28. Omar, M., S.C, T., Suppiah, Y.: Mixed integer programming formulation for hybrid flow shop scheduling problem. In: Industrial Engineering and Engineering Management (IEEM), 2010 IEEE International Conference on, pp. 385–389. IEEE (2010)

    Google Scholar 

  29. Pochet, Y., Wolsey, L.A.: Production Planning by Mixed Integer Programming. Springer, New York (2006)

    MATH  Google Scholar 

  30. Prasad, P., Maravelias, C.: Batch selection, assignment and sequencing in multi-stage multi-product processes. Comput. Chem. Eng. 32(6), 1106–1119 (2008). DOI 10.1016/ j.compchemeng.2007.06.012

    Article  Google Scholar 

  31. Riane, F., Artiba, A., Iassinovski, S.: An integrated production planning and scheduling system for hybrid flowshop organizations. Int. J. Prod. Econ. 74(1–3), 33–48 (2001). DOI 10.1016/S0925-5273(01)00105-0

    Article  Google Scholar 

  32. Ruiz, R., Serifoglu, F., urlings, T.: Modeling realistic hybrid flexible flowshop scheduling problems. Comput. Oper. Res. 35(4), 1151–1175 (2008). DOI 10.1016/j.cor.2006.07.014

    Google Scholar 

  33. Ruiz, R., Vázquez-Rodríguez, J.A.: The hybrid flow shop scheduling problem. Eur. J. Oper. Res. 205(1), 1–18 (2010). DOI 10.1016/j.ejor.2009.09.024

    Article  MATH  Google Scholar 

  34. Sawik, T.: Mixed integer programming for scheduling flexible flow lines with limited intermediate buffers. Math. Comput. Model. 31(13), 39–52 (2000). DOI 10.1016/S0895-7177(00)00110-2

    Article  MathSciNet  MATH  Google Scholar 

  35. Spitter, J., Hurkens, C., de Kok, A., Lenstra, J., Negenman, E.: Linear programming models with planned lead times for supply chain operations planning. Eur. J. Oper. Res. 163(3), 706–720 (2005). DOI 10.1016/j.ejor.2004.01.019

    Article  MATH  Google Scholar 

  36. Topaloglu, S.: A shift scheduling model for employees with different seniority levels and an application in healthcare. Eur. J. Oper. Res. 198(3), 943–957 (2009). DOI 10.1016/ j.ejor.2008.10.032

    Article  MathSciNet  MATH  Google Scholar 

  37. Wang, R., Liang, T.: Application of fuzzy multi-objective linear programming to aggregate production planning. Comput. Ind. Eng. 46(1), 17–41 (2004). DOI 10.1016/j.cie.2003.09.009

    Article  Google Scholar 

  38. Xue, G., Felix Offodile, O., Zhou, H., Troutt, M.D.: Integrated production planning with sequence-dependent family setup times. Int. J. Prod. Econ. 131(2), 674–681 (2011). DOI 10.1016/j.ijpe.2011.02.012

    Article  Google Scholar 

  39. Yura, K.: Production scheduling to satisfy worker’s preferences for days off and overtime under due-date constraints. Int. J. Prod. Econ. 33(1–3), 265–270 (1994)

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. University of Florida, Gainesville, FL, 32611, USA

    Zehra Melis Teksan

  2. Boğaziçi University, 34342, Bebek, Istanbul, Turkey

    Ali Tamer Ünal & Z. Caner Taşkın

Authors
  1. Zehra Melis Teksan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ali Tamer Ünal
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Z. Caner Taşkın
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zehra Melis Teksan .

Editor information

Editors and Affiliations

  1. Higher School of Economics, Dept. of Applied Math. & Informatics, National Research University, B. Pecherskaya 25/12, Nizhny Novgorod, 603155, Russia

    Boris Goldengorin

  2. Higher School of Economics, Department of Applied Mathematics, National Research University, Nizhny, Novgorod, 603155, Russia

    Valery A. Kalyagin

  3. , Department of Industrial and Systems Eng, University of Florida, Weil Hall 401, Gainesville, 32611, Florida, USA

    Panos M. Pardalos

Rights and permissions

Reprints and permissions

Copyright information

© 2013 Springer Science+Business Media New York

About this paper

Cite this paper

Teksan, Z.M., Ünal, A.T., Taşkın, Z.C. (2013). Integrated Production Planning, Shift Planning, and Detailed Scheduling in a Tissue Paper Manufacturer. In: Goldengorin, B., Kalyagin, V., Pardalos, P. (eds) Models, Algorithms, and Technologies for Network Analysis. Springer Proceedings in Mathematics & Statistics, vol 32. Springer, New York, NY. https://doi.org/10.1007/978-1-4614-5574-5_9

Download citation

Publish with us

Policies and ethics

Search

Navigation