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Integrated Sequencing and Scheduling in Coil Coating

  • Wiebke Höhn

    ()

    (Institut für Mathematik, Technische Universität Berlin, 10623 Berlin, Germany)

  • Felix G. König

    ()

    (Institut für Mathematik, Technische Universität Berlin, 10623 Berlin, Germany)

  • Rolf H. Möhring

    ()

    (Institut für Mathematik, Technische Universität Berlin, 10623 Berlin, Germany)

  • Marco E. Lübbecke

    ()

    (Department of Operations Research, RWTH Aachen University, 52056 Aachen, Germany)

Registered author(s):

    We consider a complex planning problem in integrated steel production. A sequence of coils of sheet metal needs to be color coated in consecutive stages. Different coil geometries and changes of colors necessitate time-consuming setup work. In most coating stages one can choose between two parallel color tanks. This can either reduce the number of setups needed or enable setups concurrent with production. A production plan comprises the sequencing of coils and the scheduling of color tanks and setup work. The aim is to minimize the makespan for a given set of coils. We present an optimization model for this integrated sequencing and scheduling problem. A core component is a graph theoretical model for concurrent setup scheduling. It is instrumental for building a fast heuristic that is embedded into a genetic algorithm to solve the sequencing problem. The quality of our solutions is evaluated via an integer program based on a combinatorial relaxation, showing that our solutions are within 10% of the optimum. Our algorithm is implemented at Salzgitter Flachstahl GmbH, a major German steel producer. This has led to an average reduction in makespan by over 13% and has greatly exceeded expectations. This paper was accepted by Dimitris Bertsimas, optimization.

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    File URL: http://dx.doi.org/10.1287/mnsc.1100.1302
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    Article provided by INFORMS in its journal Management Science.

    Volume (Year): 57 (2011)
    Issue (Month): 4 (April)
    Pages: 647-666

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    Handle: RePEc:inm:ormnsc:v:57:y:2011:i:4:p:647-666
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