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Single-stage formulations for synchronised two-stage lot sizing and scheduling in soft drink production

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  • Ferreira, Deisemara
  • Clark, Alistair R.
  • Almada-Lobo, Bernardo
  • Morabito, Reinaldo

Abstract

This study deals with industrial processes that produce soft drink bottles in different flavours and sizes, carried out in two synchronised production stages: liquid preparation and bottling. Four single-stage formulations are proposed to solve the synchronised two-stage lot sizing and scheduling problem in soft drink production synchronising the first stage's syrup lots in tanks with the second stage's soft drink lots on bottling lines. The first two formulations are variants of the General Lot Sizing and Scheduling Problem (GLSP) with sequence-dependent setup times and costs, while the other two are based on the Asymmetric Travelling Salesman Problem (ATSP) with different subtour elimination constraints. All models are computationally tested and compared to the original two-stage formulation introduced in Ferreira et al. (2009), using data based on a real-world bottling plant. The results show not only the superiority of the single-stage models if compared to the two-stage formulation, but also the much faster solution times of the ATSP-based models.

Suggested Citation

  • Ferreira, Deisemara & Clark, Alistair R. & Almada-Lobo, Bernardo & Morabito, Reinaldo, 2012. "Single-stage formulations for synchronised two-stage lot sizing and scheduling in soft drink production," International Journal of Production Economics, Elsevier, vol. 136(2), pages 255-265.
    • Handle: RePEc:eee:proeco:v:136:y:2012:i:2:p:255-265
    DOI: 10.1016/j.ijpe.2011.11.028
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    3. Dražen Popović & Nenad Bjelić & Milorad Vidović & Branislava Ratković, 2023. "Solving a Production Lot-Sizing and Scheduling Problem from an Enhanced Inventory Management Perspective," Mathematics, MDPI, vol. 11(9), pages 1-23, April.
    4. Gicquel, C. & Lisser, A. & Minoux, M., 2014. "An evaluation of semidefinite programming based approaches for discrete lot-sizing problems," European Journal of Operational Research, Elsevier, vol. 237(2), pages 498-507.
    5. Karina Copil & Martin Wörbelauer & Herbert Meyr & Horst Tempelmeier, 2017. "Simultaneous lotsizing and scheduling problems: a classification and review of models," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 39(1), pages 1-64, January.
    6. Alyne Toscano & Deisemara Ferreira & Reinaldo Morabito, 2019. "A decomposition heuristic to solve the two-stage lot sizing and scheduling problem with temporal cleaning," Flexible Services and Manufacturing Journal, Springer, vol. 31(1), pages 142-173, March.
    7. Mac Cawley, Alejandro & Maturana, Sergio & Pascual, Rodrigo & Tortorella, Guilherme Luz, 2022. "Scheduling wine bottling operations with multiple lines and sequence-dependent set-up times: Robust formulation and a decomposition solution approach," European Journal of Operational Research, Elsevier, vol. 303(2), pages 819-839.
    8. Gislaine Mara Melega & Silvio Alexandre de Araujo & Reinaldo Morabito, 2020. "Mathematical model and solution approaches for integrated lot-sizing, scheduling and cutting stock problems," Annals of Operations Research, Springer, vol. 295(2), pages 695-736, December.
    9. Yajaira Cardona-Valdés & Samuel Nucamendi-Guillén & Rodrigo E. Peimbert-García & Gustavo Macedo-Barragán & Eduardo Díaz-Medina, 2020. "A New Formulation for the Capacitated Lot Sizing Problem with Batch Ordering Allowing Shortages," Mathematics, MDPI, vol. 8(6), pages 1-16, June.
    10. Meyr, Herbert & Mann, Matthias, 2013. "A decomposition approach for the General Lotsizing and Scheduling Problem for Parallel production Lines," European Journal of Operational Research, Elsevier, vol. 229(3), pages 718-731.
    11. Martin Wörbelauer & Herbert Meyr & Bernardo Almada-Lobo, 2019. "Simultaneous lotsizing and scheduling considering secondary resources: a general model, literature review and classification," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 41(1), pages 1-43, March.
    12. Markus Mickein & Matthes Koch & Knut Haase, 2022. "A Decision Support System for Brewery Production Planning at Feldschlösschen," Interfaces, INFORMS, vol. 52(2), pages 158-172, March.
    13. Nabajyoti Bhattacharjee & Nabendu Sen, 2023. "A Sustainable Inventory Model to Study the Mixing and Bottling Plant of Single Item for Cost Minimization," SN Operations Research Forum, Springer, vol. 4(4), pages 1-18, December.
    14. Martínez, Karim Pérez & Morabito, Reinaldo & Toso, Eli Angela Vitor, 2018. "A coupled process configuration, lot-sizing and scheduling model for production planning in the molded pulp industry," International Journal of Production Economics, Elsevier, vol. 204(C), pages 227-243.

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