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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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General structure of “Supply chain” using of SC-MOPP
COSTOMERSSUPPLIERS MULTIPURPOSE PLANTS
STOAGES DISTRIBUTORS
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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General structure of “Supply chain” using of SC-MOPP
SUPPLIERS MULTIPURPOSE PLANTS
STOAGES DISTRIBUTORS
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
1 Batch size=250kg Cycle time=15h
Campaign 2
tc2
4 Batch size=100kg Cycle time=15h
1 Batch size=250kg Cycle time=15h
Campaign 14
tc14
1 Batch size=80kg Cycle time=10h
5 Batch size=250kg Cycle time=15h
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
Mathematical formulation of the problem
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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
Mathematical formulation of the problem
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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”
Interface “SC–MOPP”
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Interface “SC–MOPP”
Get DATA for “SUPPLAY CHAIN” Model
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Interface “SC–MOPP”
List of PRODUCTS in “SUPPLAY CHAIN”
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List of SUPPLIERS in “SUPPLAY CHAIN”
Interface “SC–MOPP”
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List of PLANTS in “SUPPLAY CHAIN”
Interface “SC–MOPP”
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Interface “SC–MOPP”
List of STORAGES in “SUPPLAY CHAIN”
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List of DISTRIBUTORS in “SUPPLAY CHAIN”
Interface “SC–MOPP”
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List of COSTUMERS in “SUPPLAY CHAIN”
Interface “SC–MOPP”
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Interface “SC–MOPP”
Enter in DATA BASES for SUPPLAY CHAIN elements
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Detailed DATA for “SUPPLIERS”
Interface “SC–MOPP”
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Interface “SC–MOPP”
Detailed DATA for “SUPPLIERS”
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Interface “SC–MOPP”
Detailed DATA for “PLANTS”
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Detailed DATA for elements of “PLANTS”
Interface “SC–MOPP”
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Summarized DATA for Materials, Units, Profiles, Storages
Interface “SC–MOPP”
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Replica of MOPP Graphical interface for “MATERIALS”
Interface “SC–MOPP”
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Summarized DATA for Materials, Units, Profiles, Storages
Interface “SC–MOPP”
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Replica of MOPP Graphical interface for “UNITS”
Interface “SC–MOPP”
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Summarized DATA for Materials, Units, Profiles, Storages
Interface “SC–MOPP”
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Replica of MOPP Graphical interface for “PROFILES”
Interface “SC–MOPP”
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Summarized DATA for Materials, Units, Profiles, Storages
Interface “SC–MOPP”
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Replica of MOPP Graphical interface for “STORAGES”
Interface “SC–MOPP”
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (1)
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (2)
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (3)
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (4)
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (5)
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (6)
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (7)
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Interface “SC–MOPP”
Replica of MOPP Graphical interface for Recipes (8)
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Interface “SC–MOPP”
Detailed DATA for “STORAGES”
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Interface “SC–MOPP”
Detailed DATA for “DISTRIBUTORS”
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Interface “SC–MOPP”
Detailed DATA for “COSTUMERS”
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Interface “SC–MOPP”
Definition of SUPPLAY CHAIN superstructure- Choice of “SUPPLIERS”
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Interface “SC–MOPP”
Definition of SUPPLAY CHAIN superstructure- Choice of “PLANTS”
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Interface “SC–MOPP”
Definition of SUPPLAY CHAIN superstructure- Choice of “STORAGES”
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Interface “SC–MOPP”
Definition of SUPPLAY CHAIN superstructure- Choice of “DISTRIBUTORS”
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Interface “SC–MOPP”
Definition of SUPPLAY CHAIN superstructure- Choice of “COSTUMERS”
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Interface “SC–MOPP”
Problem for optimization
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Interface “SC–MOPP”
Choice of numerical METHOD
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Optimal Distribution : “SUPPLIERS” - “PLANTS”
Results obtained intersections:
Interface “SC–MOPP”
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Optimal Product Portfolio for “PLANTS”
Results obtained intersections:
Interface “SC–MOPP”
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Costs Distributions on the “SUPPLAY CHAIN” elements
Results obtained intersections:
Interface “SC–MOPP”
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Interface “SC–MOPP”
Results Saving
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Interface “SC–MOPP”
Scheduling problems solution for “PLANTS”
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Interface “SC–MOPP”
Data Loading for Optimal scheduling
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Interface “SC–MOPP”
Optimal Scheduling for a chosen “PLANT”
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Interface “SC–MOPP”
Choice of Plant’s elements
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Interface “SC–MOPP”
XML Input File generation for MOPP
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Interface “SC–MOPP”
Visualition of generated XML file
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Interface “SC–MOPP”
Data for Optimal product portfolio
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Interface “SC–MOPP”
Data for “RECIPES”
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Interface “SC–MOPP”
Data for “RECIPES”
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Interface “SC–MOPP”
Data for “RECIPES”
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Thank you for attention
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