Skip to main content
Log in

Reformulation and a Lagrangian heuristic for lot sizing problem on parallel machines

  • Published:
Annals of Operations Research Aims and scope Submit manuscript

Abstract

We consider the capacitated lot sizing problem with multiple items, setup time and unrelated parallel machines. The aim of the article is to develop a Lagrangian heuristic to obtain good solutions to this problem and good lower bounds to certify the quality of solutions. Based on a strong reformulation of the problem as a shortest path problem, the Lagrangian relaxation is applied to the demand constraints (flow constraint) and the relaxed problem is decomposed per period and per machine. The subgradient optimization method is used to update the Lagrangian multipliers. A primal heuristic, based on transfers of production, is designed to generate feasible solutions (upper bounds). Computational results using data from the literature are presented and show that our method is efficient, produces lower bounds of good quality and competitive upper bounds, when compared with the bounds produced by another method from the literature and by high-performance MIP software.

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

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  • Alfieri, A., Brandimarte, P., & D’Orazio, S. (2002). LP-based heuristics for the capacitated lot-sizing problem: The interaction of model formulation and solution algorithm. International Journal of Production Research, 40, 441–458.

    Article  Google Scholar 

  • Belvaux, G., & Wolsey, L. A. (2000). Bc-prod: A specialized branch-and- cut system for lot-sizing problems. Management Science, 46, 993–1007.

    Article  Google Scholar 

  • Camerini, P. M., Fratta, L., & Maffioli, F. (1975). On improving relaxation methods by modified gradient techniques. Mathematical Programming Study, 3, 26–54.

    Article  Google Scholar 

  • Carreno, J. J. (1990). Economic lot scheduling for multiple products on parallel identical processors. Management Science, 36, 348–358.

    Article  Google Scholar 

  • Chen, W. H., & Thizy, J. M. (1990). Analysis of relaxation for the multi-item capacitated lot-sizing problem. Annals of Operations Research, 26, 29–72.

    Article  Google Scholar 

  • Degraeve, Z., & Jans, R. (2007). A new dantzig-wolfe reformulation and branch-and-price algorithm for the capacited lot-sizing problem with setup times. Operational Research, 55, 909–920.

    Article  Google Scholar 

  • De Matta, R., & Guignard, M. (1994). Dynamic production scheduling for a process industry. Operational Research, 42, 492–503.

    Article  Google Scholar 

  • De Matta, R., & Guignard, M. (1995). The performance of rolling production schedules in a process industry. IIE Transactions, 27, 564–573.

    Article  Google Scholar 

  • Denizel, M., & Süral, H. (2006). On alternative mixed integer programming formulations and LP based heuristics for lot-sizing with setup times. Journal of the Operational Research Society, 57, 389–399.

    Article  Google Scholar 

  • Denizel, M., Altekin, F. T., Süral, H., & Stadtler, H. (2008). Equivalence of the lp relaxation of two strong formulation for the capacitated lot-sizing problem with setup times. OR spectrum, 30, 773–785.

    Article  Google Scholar 

  • Diaby, M., Bahl, H., Karwan, M. H., & Ziont, S. (1992). Capacitated lot-sizing and scheduling by lagrangean relaxation. European Journal of Operational Research, 59, 444–458.

    Article  Google Scholar 

  • Eppen, G. B., & Martin, R. K. (1987). Solving multi-item capacitated lot-sizing problems using variable redefinition. Operations Research, 6, 832–848.

    Article  Google Scholar 

  • Fandel, G., & Stammen-Hegener, C. (2006). Simultaneous lot sizing and scheduling for multi-product multi-level production. International Journal of Production Economics, 104, 308–316.

    Article  Google Scholar 

  • Feyten, P., & Lietaert, F. (1983). Production planning for a packaging departament. Master’s thesis, Division of Industrial Management, Katholiek Universiteit Leuven, Dutch.

  • Helber, S., & Sahling, F. (2010). A fix-and-optimize approach for the multi-level capacitated lot sizing problem. Journal Production Economics, 123, 247–256.

    Article  Google Scholar 

  • Jans, R. (2009). Solving lot-sizing problems on parallel identical machines using symmetry-breaking constraints. INFORMS Journal on Computing, 21, 123–136.

    Article  Google Scholar 

  • Jans, R., & Degraeve, Z. (2004a). Improved lower bounds for capacitated lot sizing problem with setup time. Operation Research Letters, 32, 185–195.

    Article  Google Scholar 

  • Jans, R., & Degraeve, Z. (2004b). An industrial extension of the discrete lot sizing and scheduling problem. IIE Transactions, 36, 47–58.

    Article  Google Scholar 

  • Kang, S., Malik, K., & Thomas, L. J. (1999). Lotsizing and scheduling on parallel machines with sequence-dependent setup costs. Management Science, 45, 273–289.

    Article  Google Scholar 

  • Krarup, J., & Bilde, O. (1977). Plant location, set covering and economic lot size: An O(mn)-algorithm for structured problems. In Numerische Methoden bei Optimierungsaufgaben, Bang 3: Optimierung bei Graphentheoritischen Ganzzahligen Problemen, pp. 155–186.

    Google Scholar 

  • Lasdon, L. S., & Terjung, R. C. (1971). An efficient algorithm for multi-item scheduling. Operations Research, 19, 946–969.

    Article  Google Scholar 

  • Marinelli, F., Nenni, M. E., & Sforza, A. (2007). Capacitated lot sizing and scheduling with parallel machines and shared buffers: A case study in a packaging company. Annals of Operations Research, 150, 177–192.

    Article  Google Scholar 

  • Mergaux, L. P., & van Wassenhove, L. N. (1984). Production planning with capacity constraints, Master thesis, Division of Industrial Management, Katholieke Universiteit Leuven, Dutch.

  • Meyr, H. (2002). Simultaneous lotsizing and scheduling on parallel machines. European Journal of Operational Research, 139, 277–292.

    Article  Google Scholar 

  • Nemhauser, G. L., & Wolsey, L. A. (1988). Integer and combinatorial optmization. New York: Wiley.

  • Ozdamar, L., & Birbil, S. I. (1998). Hybrid heuristics for the capacitated lot sizing and loading problem with setup times and overtime decisions. European Journal of Operational Research, 110, 525–547.

    Article  Google Scholar 

  • Pimentel, C. M. O., Alvelos, F. P., & Carvalho, J. M. V. (2010). Comparing Dantzig-Wolfe decompositions and branch-and-price algorithms for the multi-item capacitated lot sizing problem. Optimization Methods and Software, 25, 229–319.

    Article  Google Scholar 

  • Pochet, Y., & van Vyve, M. (2004). A generic heuristic for production planning problems. INFORMS Journal of Computing. 16, 316–327.

    Article  Google Scholar 

  • Salomon, M., Kroon, L. G., Kuik, R., & van Wassenhove, L. N. (1991). Some extensions of the discrete lot-sizing and scheduling problem. Management Science, 37, 801–812.

    Article  Google Scholar 

  • Stadtler, H. (2003). Multilevel lot sizing with set up times and multiple constrained resources: Internally rolling schedules with lot-sizing windows. Operations Research, 51, 487–502.

    Article  Google Scholar 

  • Sung, C. S. (1986). A single-product parallel-facilities production-planning model. International Journal of Systems Science, 17, 983–989.

    Article  Google Scholar 

  • Süral, H., Denizel, M., & van Wassenhove, L. N. (2009). Lagrangean relaxation based heuristic for lot sizing with setup times. European Journal of Operational Research, 195, 51–63.

    Article  Google Scholar 

  • Tempelmeier, H., & Buschkuhl, L. (2009). A heuristic for the dynamic multi-level capacitated lotsizing problem with linked lotsizes for general product structures. Or Spectrum, 31, 385–404.

    Article  Google Scholar 

  • Thizy, J. M., & Wassenhove, L. N. V. (1985). Lagrangean relaxation for the multi-item capacitated lot-sizing problem: A heuristic implementation. AIIE Transactions, 17, 64–74.

    Google Scholar 

  • Toledo, F. M. B. (1998). Dimensionamento de Lotes em Máquinas Paralelas. Tese (Doutorado), Faculdade de Engenharia Elétrica e Computação, Universidade Estadual de Campinas, Campinas.

  • Toledo, F. M. B., & Armentano, V. A. (2006). A Lagrangian-based heuristic for the capacitated lot-sizing problem in parallel machines. European Journal of Operational Research, 175, 1070–1083.

    Article  Google Scholar 

  • Trigeiro, W. W., Thomas, J., & McClain, J. O. (1989). Capacitated lot sizing with setup times . Management Science, 35, 353–366.

    Article  Google Scholar 

Download references

Acknowledgments

The authors would like to thank the referees for their very helpful feedback, resulting in a better paper, and are also grateful to Franklina M. B. Toledo for making available the code of her heuristic. This research was funded by Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP) (Processes numbers 2010/16727-9 and 2011/22647-0).

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Silvio Alexandre de Araujo.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Fiorotto, D.J., de Araujo, S.A. Reformulation and a Lagrangian heuristic for lot sizing problem on parallel machines. Ann Oper Res 217, 213–231 (2014). https://doi.org/10.1007/s10479-014-1570-1

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10479-014-1570-1

Keywords

Navigation