The production planning problem of orders in small foundries

Abstract

The production planning problem in market-driven foundries consists of determining the alloys to be melted and the items to be produced. A production plan is defined based on the foundry book order that compiles customer requests. Each customer order can be composed of items of different types and made from different alloys. In the literature, production planning does not usually consider the customers’ orders, i.e., items are independently handled. However, in practical situations, several orders cannot be partially delivered. An order can be delivered only when all of its items have been produced, which often results in delays in meeting the customer demands. Conversely, some orders may be split, which would incur delivering costs. This paper addresses the production planning problem of orders in market-driven foundries, which is considered a gap in the literature. A mathematical model and a relax-and-fix heuristic are proposed to address the problem. An experimental evaluation using synthetic datasets and a real dataset compares the proposed methods with the practical policy planning and a state-of-the-art method that solve the production planning problem of items. The results demonstrate the relevance of the production planning of orders.

Mathematical modeling to optimize production planning and scheduling in a small foundry with multiple alternating furnaces

“…This result was already expected, as Duda and Stawowy (2018) pointed out when they noted that the use of heuristic or meta-heuristic algorithms is more appropriate for solving large instances. Tonaki and Toledo (2010), Camargo et al (2012), andFurtado et al (2019) suggest the importance of reducing furnace waste for market foundries. The waste is caused by allocating alloys to be melted in smaller quantities than the furnace capacity.…”

“…As solution methods, the authors use commercial solvers such as CPLEX, and different heuristics and meta-heuristics are proposed. Furtado et al (2019) also address the lot-sizing and scheduling problem in market foundries with a single furnace, considering the orders to which the items belong. In addition to the traditional aspects addressed in other studies, the models proposed by the authors aim to minimize the cost delay in the delivery of orders with the possibility of partial deliveries.…”

Problemas de dimensionamento de lotes e planejamento de pedidos aplicados a uma indústria moveleira

“…Entretanto, neste trabalho, foram incorporadas decisões de planejamento de pedidos juntoàs decisões dos tamanhos dos lotes e, para este caso, encontramos apenas um trabalho na literatura. Furtado et al (2019) abordaram o planejamento da produção de pedidos em fundições de pequeno porte. Neste setor, a carteirá e composta por pedidos de clientes que podem conter diferentes itens.…”