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Motivated by a practical problem, this paper investigates the integrated planning of maintenance operations and workload allocation on a set of machines in a workshop. Given quantities of products to be produced per period on a planning horizon must be processed on unrelated flexible machines. Moreover, each machine has to undergo one or more maintenance operations that must be planned within a given time window and impact products differently. The main goal is to find a feasible plan that satisfies the machine capacity by allocating the production quantities to machines and assigning maintenance operations as late as possible in their time windows. Various original mathematical models are presented. In particular, we propose models that allow maintenance operations and some production quantities to overlap two consecutive periods. Computational experiments based on industrial data show that allowing this overlapping helps the earliness of maintenance operations to be significantly reduced in the most difficult instances, going for example from a total of 14 periods to only 1 period, and by more than 35% on average. [ABSTRACT FROM AUTHOR]

The complexity of decision-making for companies buying transportation services has increased due to the presence of more options and pricing schedules for transportation. Many companies make transportation and inventory decisions in an uncoordinated way and select only one transportation mode, missing opportunities for logistics cost savings. The experimental study in this paper is based on a real-world decision problem faced by a Scandinavian company that distributes fast-moving consumer goods and wants to determine its transportation strategy. We propose a novel multi-mode lot-sizing model with dynamic deterministic demand to illustrate the cost impact of accurately modelling piecewise-linear transportation costs and allowing a more flexible usage of transportation modes when planning order replenishments. We compare three transportation strategies with increasing degrees of flexibility: two single mode strategies, where one strategy is more flexible than the other, and a multi-mode strategy. We conclude that managers can significantly reduce costs by increasing the flexibility of mode selection in transportation strategies. [ABSTRACT FROM AUTHOR]

In this paper, a practical relevant operational production planning problem in complex manufacturing systems is addressed. In this problem, lots are planned individually to provide a more detailed plan than approaches that only consider production quantities. A three-step approach, which is currently fully integrated and used in a Decision Support System, is then introduced. This work follows the one of Mhiri et al. [2018. "Heuristic Algorithm for a WIP Projection Problem at Finite Capacity in Semiconductor Manufacturing." IEEE Transactions on Semiconductor Manufacturing 31 (1): 62–75] who addressed this problem. We push the approach a step further by introducing new optimisation possibilities through new smoothing rules, whose performance is studied according to different indicators. Furthermore, we present the production planning process in which the decision support tool is embedded and how it bridges the gap between the upper and lower planning levels. [ABSTRACT FROM AUTHOR]

This paper proposes a novel global scheduling approach for cycle time control strategy in large complex manufacturing systems with multiple workcentres, such as semiconductor manufacturing systems. The interaction between workcentres is taken into account by using global information such as release quantities, the Work-In-Process (WIP), cycle time targets and machine capacities. Local scheduling decisions in workcentres are steered by production targets, i.e. quantities of products to complete in each operation and each period on a scheduling horizon. These global production targets are determined by a mathematical model (global scheduling model), which optimises the satisfaction of cycle time targets. One of the major innovations of the proposed model is that it relies on the temporal trace of the WIP. The mathematical model is coupled with a generic multi-method simulation model for evaluation purpose. Computational experiments conducted on industrial data show that our global scheduling approach efficiently controls the cycle times of products. [ABSTRACT FROM AUTHOR]

Motivated by real challenges on energy management faced by industrial firms, we propose a novel way to reduce production costs by including the pricing of electricity in a multi-product lot-sizing problem. In incentive-based programs, when electric utilities face power consumption peaks, they request electricity-consuming firms to curtail their electric load, rewarding the industrial firms with incentives if they comply with the curtailment requests. Otherwise, industrial firms must pay financial penalties for an excessive electricity consumption. A two-stage stochastic formulation is presented to cover the case where a manufacturer wants to satisfy any curtailment request. A chance-constrained formulation is also proposed, and its relevance in practice is discussed. Finally, computational studies are conducted to compare mathematical models and highlight critical parameters and show potential savings when subscribing incentive-based programs. We show that the setup cost ratio, the capacity utilisation rate, the number of products and the timing of curtailment requests are critical parameters for manufacturers. [ABSTRACT FROM AUTHOR]

This document is a special issue of the International Journal of Production Research focused on collaborative production and maintenance in the context of big data and Industry 4.0. It discusses the impact of the fourth industrial revolution on manufacturing, highlighting the importance of interconnectedness, automation, and data-driven decision-making. The document emphasizes the need for proper analysis of the vast amount of data collected through smart sensors and the potential for collaboration between humans, machines, and data to improve production and maintenance processes. The special issue includes seven selected papers that address various aspects of collaborative production and maintenance, such as fault diagnosis, maintenance scheduling, and maintenance policy evaluation. The papers offer valuable insights, innovative approaches, and practical applications in the field. The editors hope that this special issue will inspire further research and collaboration in the era of big data and Industry 4.0. [Extracted from the article]

For the sake of product yield and quality considerations, time constraints (TCs) are imposed between process operations in various multi-product manufacturing systems. Often spanning a number of operations, time constraints tend to follow each other in close succession and overlap, forming thus time constraint tunnels (TCTs). The regulation problem of releasing lots in these time constraint tunnels is particularly challenging in semiconductor manufacturing systems, because of re-entrant flows, machine heterogeneity and high mix low volume (HM-LV) production configurations, which are typical in many wafer fabrication facilities. In such an evolving and time-varying context, this paper proposes a sequential sampling-based approach to estimate the probability that, prior to its release, a lot leaves a given time constraint tunnel on time. The proposed approach proves to be competitive in various respects by (i) taking into account industry specific features, (ii) being industrially tractable, and (iii) being sensitive and responsive to the current manufacturing system. Based on real-life instances, numerical experiments highlight the computational effectiveness and the industrial soundness of the proposed problem modelling together with the solution approach. [ABSTRACT FROM AUTHOR]

This research combines deep neural network (DNN) and Markov decision processes (MDP) for the dynamic dispatching of re-entrant production systems. In re-entrant production systems, jobs enter the same workstation multiple times and dynamic dispatching oftentimes aims to dynamically assign different priorities to various job groups to minimise weighted cycle time or maximise throughput. MDP is an effective tool for dynamic production control, but it suffers from two major challenges in dynamic control problems. First, the curse of dimensionality limits the computational performance of solving large MDP problems. Second, a different model should be built and solved after system configuration is changed. DNN is used to overcome both challenges by learning directly from optimal dispatching policies generated by MDP. Results suggest that a properly trained DNN model can instantly generate near-optimal dynamic control policies for large problems. The quality of the DNN solution is compared with the optimal dynamic control policies through the standard K-fold cross-validation test and discrete event simulation. On average, the performance of the DNN policy is within 2% of optimal in both tests. The proposed artificial intelligence algorithm illustrates the potential of machine learning methods in manufacturing applications. [ABSTRACT FROM AUTHOR]

Motivated by the high investment and operational metrology cost, and subsequently the limited metrology capacity, in modern semiconductor manufacturing facilities, we model and solve the problem of optimally assigning the capacity of several imperfect metrology tools to minimise the risk in terms of expected product loss on heterogeneous production machines. In this paper, metrology tools can differ in terms of reliability and speed. The resulting problem can be reduced to a variant of the Generalized Assignment Problem (GAP), the Multiple Choice, Multiple Knapsack Problem (MCMKP). A Lagrangian heuristic, including multiple feasibility heuristics, is proposed to solve the problem that are tested on randomly generated instances. [ABSTRACT FROM AUTHOR]