1 Project title: DISTRIBUTED AND CAPE-OPEN COMPLIANT PLATFORM FOR PLANNING AND SCHEDULING MULTI-SITE...

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Project title:

DISTRIBUTED AND CAPE-OPEN COMPLIANT PLATFORM FOR PLANNING AND SCHEDULING MULTI-SITE

MANUFACTURING SYSTEMS

Universitat Politecnica de CatalunyaChemical Engineering Department

BULGARIAN ACADEMY OF SCIENCESINSTITUTE OF CHEMICAL ENGEENERING

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Outline

MPMB optimal control strategy

Mathematical formulation of the problem

Software realization integrated software “SC-MOPP”

Example Supply Chain and Scheduling problem solve in “SC-MOPP”

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General structure of “Supply chain” using of SC-MOPP

COSTOMERSSUPPLIERS MULTIPURPOSE PLANTS

STOAGES DISTRIBUTORS

PROBLEM STATEMENT FOR PROFIT MAXIMIZATION

The FIRST STAGE includes an obligatory preliminary study of the MARKET DEMANDS

During this stage, the requirements put forward by each potential costumer in the planning horizon have to be determined

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COSTOMERSSUPPLIERS MULTIPURPOSE PLANTS


PROBLEM STATEMENT FOR PROFIT MAXIMIZATION

The SECOND STAGE includes DETERMINATION: 1.Optimal product portfolio, 2.Optimal supply plants, 3. Optimal distribution

Optimal product portfolio for each

plants

Optimal raw materials supply to each plants

1.Optimal scheme of loading of storages with products

2.Optimal scheme of serving the distributors

3.Optimal scheme of serving the costumers

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SUPPLIERS MULTIPURPOSE PLANTS


The THIRD STAGE concerns the production schedules on plant scale corresponding to the product portfolio, obtained in the second stage

Optimal scheduling in campaign mode (SC) :

Optimal scheduling in Job – shop mode (MOPP)

COSTOMERSCOSTOMERS

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G1 - Planed minimal quantity , which have to be manufactured for product 1

G2 - Planed minimal quantity , which have to be manufactured for product 2

The task of Optimal synthesis of manufacture scheduling is arrived to identify the campaigns, which are participate and working time,

so that the optimal criteria to be satisfied. The criteria are:1. Minimum time duration programm. 2. Maximum profit for planning horizon.

MIN(ts1+tc1+ts2+tc2+...+ ts14+tc14) MAX(P1r + P2r)

(ts1 + tc1 + ts2 + tc2 + . . . + ts14 + tc14) < H

In case of performed the constraints :

G1r > G1) G2r > G2)

Service time

S1

ts1

Service time

S2

ts1

Service time

S14

ts14

Campaign 1

tc1

5 Batch size=250kg Cycle time=15h


Campaign 2

tc2



Campaign 14

tc14



H - Planning period /horizon/

Production scheduling model in campaign mode

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Optimal scheduling in Job – shop mode (MOPP)

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Set of Variables

njq - Amount of n-th product, produced in the j-th plants

njix - Ratios of raw material supply relevant to production of n-th product

njky - Indicates the ratios of products qnj supplied to the SC warehouses

nklz - Indicates the ratios of stored products supply from the SC warehouses to the distributors

nlmg - Indicates the ratios of product supplied from the SC distributors to the markets


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Objective function:

CofitMAX _Pr

M

m

N

n

L

l

K

k

J

jnjnjknklnlmnlmnlnm qyzgcgDiceccCofit

1 1 1 1 1

...)_(Pr_Pr


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Interaction between “Supply Chain” and “MOPP”

“SC” Software “MOPP” Software

Replica of MOPP graphical interface

Supply Chain elements :

Data Base - SUPPLIERS

Data Base - PLANTS

Data Base - STORAGES

Data Base - DISTRIBUTORS

Data Base - COSTUMERS

Supply Chain superstructure

Problem for optimization

Numerical method selection

Problem solution

XML Input files generation for MOPP

Transfer of XML files to MOPP

Transfer of XML files to SC

Plants elements :

Data Base - MATERIALS

Data Base - UNITS

Data Base - PROFILES

Data Base – STORAGES (Plants)

Data Base - RECIPES

SCEDULING PROBLEM

Problem solution

SCHEDULE visualition

XML Input files generation for SC

Numerical method selection

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Dairy Supply Chain

Productsdrinking milk-P1

curds-P2butter-P3

Capacity[ton/month]

Milk cost[BGN / ton]

S1 600 310

S2 1800 280

Capacities of milk suppliers and milk costs Markets demands and products selling costs.

Market demands[ton /month]

Selling costs [BGN/ton]

P1 P2 P3 P1 P2 P3

M1 1400 55 53 790 1430 4530

M2 400 20 28 900 2800 6320

Distances between dairies and markets, and dairies and milk centers and their respective transportation costs

Distance [km] Transportation cost [BGN/ton.km]

M1 M2 S1 S2 M1 M2 S1 S2

Dairy 1 226 92 41 36 1 2 1 1

Dairy 2 238 89 31 61 1 2 1 1

i

QRM

Separation for milk processing

Separation for curd processing

Separation for butter rocessing

Cream

Curd processing

Butter processing

Milk processing

QP1; FP1QP1; FP1

QMP2; FP2 QP2;

QP3; FP3QCR; FCR

QCR1; FCR

QCR2; FCR

QCR3; FCR

FBMFSM

QRM1; FRM

QRM2; FRM

QRM3; FRM

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Supplier 1

Supplier 2

Dairy 1

Dairy 2

Market 1

Fictios Storages Fictios Distributors

1

2

1

2

1 2 3 4 5

Set of Suppliers Set of Plants Set of Storages Set of Distributors Set of Costumers

“SUPPLY CHAIN” Model

Market 2

Dairy Supply Chain

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RESOLUTION set up

Interface “SC–MOPP”

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Main “CONTROL PANEL”


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Get DATA for “SUPPLAY CHAIN” Model

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List of PRODUCTS in “SUPPLAY CHAIN”

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List of SUPPLIERS in “SUPPLAY CHAIN”


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List of PLANTS in “SUPPLAY CHAIN”


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List of STORAGES in “SUPPLAY CHAIN”

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List of DISTRIBUTORS in “SUPPLAY CHAIN”


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List of COSTUMERS in “SUPPLAY CHAIN”


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Enter in DATA BASES for SUPPLAY CHAIN elements

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Detailed DATA for “SUPPLIERS”


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Detailed DATA for “SUPPLIERS”

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Detailed DATA for “PLANTS”

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Detailed DATA for elements of “PLANTS”


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Summarized DATA for Materials, Units, Profiles, Storages


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Replica of MOPP Graphical interface for “MATERIALS”


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Replica of MOPP Graphical interface for “UNITS”


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Replica of MOPP Graphical interface for “PROFILES”


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Replica of MOPP Graphical interface for “STORAGES”


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Replica of MOPP Graphical interface for Recipes (1)

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Detailed DATA for “STORAGES”

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Detailed DATA for “DISTRIBUTORS”

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Detailed DATA for “COSTUMERS”

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Definition of SUPPLAY CHAIN superstructure- Choice of “SUPPLIERS”

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Definition of SUPPLAY CHAIN superstructure- Choice of “PLANTS”

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Definition of SUPPLAY CHAIN superstructure- Choice of “STORAGES”

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Definition of SUPPLAY CHAIN superstructure- Choice of “DISTRIBUTORS”

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Definition of SUPPLAY CHAIN superstructure- Choice of “COSTUMERS”

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Problem for optimization

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Choice of numerical METHOD

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Optimal Distribution : “SUPPLIERS” - “PLANTS”

Results obtained intersections:


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Optimal Product Portfolio for “PLANTS”



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Costs Distributions on the “SUPPLAY CHAIN” elements



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Results Saving

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Scheduling problems solution for “PLANTS”

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Data Loading for Optimal scheduling

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Optimal Scheduling for a chosen “PLANT”

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Choice of Plant’s elements

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XML Input File generation for MOPP

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Visualition of generated XML file

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Data for Optimal product portfolio

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Data for “RECIPES”

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Thank you for attention

1 Project title: DISTRIBUTED AND CAPE-OPEN COMPLIANT PLATFORM FOR PLANNING AND SCHEDULING MULTI-SITE...

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