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IE 312 1 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model tractable? Solution techniques

IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

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Page 1: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 1

Solution Techniques Models

Thousands (or millions) of variables Thousands (or millions) of constraints

Complex models tend to be valid Is the model tractable?

Solution techniques

Page 2: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 2

Definitions Solution: a set of values for all variables n decision variables: solution n-vector Scalar is a single real number Vector is an array of scalar components

Page 3: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 3

Some Vector Operations Length (norm) of a vector x

Sum of vectors

Dot product of vectors

n

jjx

1

2x

nn yx

yx

11

yx

n

jjj yx

1

yx

Page 4: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 4

Neighborhood/Local Search

Find an initial solution

Loop: Look at “neighbors” of current solution

Select one of those neighbors

Decide if to move to selected solution

Check stopping criterion

Page 5: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 5

Example: DClub Location Location of a discount department

store Three population centers

Center 1 has 60,000 people Center 2 has 20,000 people Center 3 has 30,000 people

Maximize business Decision variables: coordinates of

location

Page 6: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 6

Constraints

222

21

222

21

222

21

)2/1())4(()0(

)2/1()3()1(

)2/1()3()1(

xx

xx

xx

Must avoid congested centers (within 1/2 mile):

Page 7: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 7

Objective Function

22

21

22

21

22

21

21

)3()(1

30

)3()1(1

20

)3()1(1

60),(max

xx

xx

xxxxp

Page 8: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 8

Objective Function

Page 9: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 9

-5 -4 -3 -2 -1 0 1 2 3 4 5-5

-4

-3

-2

-1

0

1

2

3

4

5

Searching

Page 10: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 10

Improving Search Begin at feasible solution Advance along a search path Ever-improving objective function

value

Neighborhood: points within small positive distance of current solution

Stopping criterion: no improvement

Page 11: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 11

Local Optima Improving search finds a local optimum

May not be a global optimum(heuristic solution)

Tractability: for some models there is only one local optimum (which hence is global)

Page 12: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 12

Selecting Next Solution Direction-step approach

Improving direction: objective function better for than for all value of that are sufficiently small

Feasible direction: not violate constraints

xxx )()1( tt

Search directionStep size

xx )(t )(tx

Page 13: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 13

Step Size How far do we move along the

selected direction? Usually:

Maintain feasibility Improve objective function value

Sometimes: Search for optimal value

Page 14: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 14

Detailed Algorithm

0 Initialize: choose initial solution x(0); t=01 If no improving direction x, stop.2 Find improving feasible direction x (t+1)

3 Choose largest step size t+1 that remains feasible and improves performance

4 Update

Let t=t+1 and return to Step 1

)1(1

)()1(

tt

tt xxx

Page 15: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 15

Stopping Search terminates at local optimum

If improving direction exists cannot be a local optimum

If no improving direction then local optimum

Potential problem with unboundedness Can improve performance forever Search does not terminate

Page 16: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 16

-5 -4 -3 -2 -1 0 1 2 3 4 5-5

-4

-3

-2

-1

0

1

2

3

4

5

Local Optimum

Page 17: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 17

Improving Search Still a bit abstract ‘Find improving feasible direction’

How?

Page 18: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 18

Smooth Functions Assume objective function is

smooth What does this mean? You can find the derivative

Smooth Not Smooth

Page 19: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 19

Gradients Function

The gradient is found from the partial derivatives

Note that the gradient is a vector

),...,,()( 21 nxxxff x

)/,...,/,/()( 21 nxfxfxff x

Page 20: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 20

Example

22

21

22

21

22

21

21

)3()(1

30

)3()1(1

20

)3()1(1

60),(max

xx

xx

xxxxp

Page 21: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 21

Partial Derivatives

...)3()1(1

)1(120

...)3()1(1

)3()1(160),(

222

21

1

222

21

22

21

1

1

21

xx

x

xx

xxx

x

xxp

Page 22: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 22

-5 -4 -3 -2 -1 0 1 2 3 4 5-5

-4

-3

-2

-1

0

1

2

3

4

5

Plotting Gradients

Page 23: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 23

Direction of Gradients Gradients are

perpendicular to contours of objective function

direction most rapid objective value increase

Using gradients as direction gives us the steepest descent/ascent (greedy)

Page 24: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 24

Effect of Moving When moving in direction x: The objective function is increased if

(Improving direction for maximization)

The objective function is decreased if

0)( xxf

0)( xxf

Page 25: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 25

1x

62 x

1 9x

Feasible Direction Make sure the direction is feasible Only have to worry about active

constraints (tight/binding constraints)

No active constrains

One active constraint

Active if equalitysign holds!

Page 26: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 26

Linear Constraints Direction x is feasible if and only

if (iff)

n

jjj

n

jjj

n

jjj

bxa

bxa

bxa

1

1

1

if,0

if,0

if,0

xa

xa

xa

Page 27: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 27

Comments The gradient gives us

A greedy improving direction Building block for other improving

directions (later) Conditions

Check if direction is improving (gradient)

Check if direction is feasible (linear)

Page 28: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 28

Validity versus Tractability Which models are tractable for

improving search? Stops when it encounters a local

optimum

This is guaranteed to be a global optimum only if it is unique

Page 29: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 29

Unimodal Functions Unimodal functions:

Straight line from a point to a better point is always an improving direction

Page 30: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 30

Typical Unimodal Function

Page 31: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 31

Linear Objective Linear objective functions

Unimodal for both maximization and minimization

xcx

n

jjj xcf

1

)(

Page 32: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 32

Check

)()(

)(

)()(

)1()2()1(

)1()2(

1

)1()2(

1

)1(

1

)2()2()1(

xxx

xxc

xx

f

xxc

xcxcff

n

jj

n

jj

n

jj

jj

jj

First calculate

Then apply our test to)1()2( xxx

Page 33: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 33

Optimality Assume our objective function is

unimodal

Then every unconstrained local optimum is an unconstrained global optimum

Note that none of the constraints can be active (tight)

Page 34: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 34

Convexity Now lets turn to the feasible region A feasible region is convex if any

line segment between two points in the region is contained in the region

Page 35: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 35

Line Segments Representing a line

To prove convexity, we have to show that for any points in the region, all points that can be represented as above are also in the region

]1,0[,)1()2()1( xxx

Page 36: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 36

Linear Constraints

If all constraints are linear then the feasible region is convex Suppose we have two feasible points:

How about a point on the line between:

bxabxan

jjj

n

jjj

1

)2(

1

)1( and

?)1( )2()1()1()2()1( xxxxxx

Page 37: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 37

Verify Constraints Hold

bbb

xaxa

xaxa

xaxaxxa

n

jjj

n

jjj

n

jjj

n

jjj

n

jjjjj

n

jjjj

)1(

)1(

)1(

)1()1(

1

)2(

1

)1(

1

)2(

1

)1(

1

)2()1(

1

)2()1(

Page 38: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 38

Example

1x

62 x

1 9x

2x

Page 39: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 39

Tractability

(This is the reason we are defining all these term!)

The most tractable models for improving search are models with unimodal objective function convex feasible region

Here every local optimum is global

Page 40: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 40

Improving Search Algorithm

0 Initialize: choose initial solution x(0); t=01 If no improving direction x, stop.2 Find improving feasible direction x (t+1)

3 Choose largest step size t+1 that remains feasible and improves performance

4 Update

Let t=t+1 and return to Step 1

)1(1

)()1(

tt

tt xxx

Page 41: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 41

Initial Feasible Solutions Not always trivial to find an initial

solution Thousands of constraints and variables

Initial analysis: Does a feasible solution exist? If yes, find a feasible solution

Two methods Two-phase method Big-M method

Page 42: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 42

Two-Phase Method Choose a solution to model and construct

a new model by adding artificial variables for each violated constraint

Assign values to artificial variables. Perform improving search to minimize

sum of artificial variables If terminate at zero then feasible model

and continue, otherwise stop Delete artificial components to get

feasible solution Start an improving search

Phase I

Phase II

Page 43: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 43

Crude Oil Refinery

0,

6

9

s)(lubricant 5.03.02.0

fuel)(jet 5.12.04.0

(gasoline) 0.24.03.0s.t.

21

2

1

21

21

21

xx

x

x

xx

xx

xx

21 1520min xx

Page 44: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 44

Artificial Variables Select a convenient solution

Add artificial variables for violated constraints

0,0 21 xx

0,,,,

6

9

5.03.02.0

5.12.04.0

0.24.03.0

54321

2

1

521

421

321

xxxxx

x

x

xxx

xxx

xxx

Page 45: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 45

Phase I Model

0,,,,

6

9

5.03.02.0

5.12.04.0

0.24.03.0

54321

2

1

521

421

321

xxxxx

x

x

xxx

xxx

xxxs.t.

321321 ),,(min xxxxxxf

Page 46: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 46

Phase I Initial Solutions As before

To assure feasibility

Thus, the initial solution is

0,0 )0(2

)0(1 xx

5.0,5.1,2 )0(4

)0(3

)0(3 xxx

)5.0,5.1,2,0,0()0( x

Page 47: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 47

Phase I Outcomes We cannot get negative numbers and

problem cannot be unbounded Three possibilities

Terminate with f =0 Start Phase II with final solution as initial

solution Terminate at global optimum with f > 0

Problem is infeasible Terminate at local optimum with f > 0

Cannot say anything

Page 48: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 48

Big-M Method Artificial variables as before Objective function

Combines Phase I and Phase II search

sconstraint ingfor violatpenalty

523

objective original

21 )(1520min xxxMxx

Page 49: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 49

Terminating Big-M If terminates at local optimum with all

artificial variables = 0, then also local optimum for original problem

If M is ‘big enough’ at terminates at global optimum with some artificial variables >0, then original problem infeasible

Cannot say anything in between

Page 50: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 50

Linear Programming We know what leads to high

tractability: Unimodal objective function Convex feasible region

We know how to guarantee this Linear objective function Linear constraints

When are linear programs valid?

Much stronger!

Page 51: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 51

Allocation Models Scarce resource

Land, capital, time, fuel, etc. Allocate resources to competing ‘jobs’ Decision variables:

How much to allocate to each job Constraints:

Limitation on resources Other dynamics

Page 52: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 52

Forest Service Allocation Manage 191 acres of national forest Jobs (Prescriptions):

Logging Grazing Wilderness preservation

7 analysis areas

This is a simplified version of an actual application (fewer variables/constraints)

Page 53: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 53

Analysis Goals

Maximize the net present value (NPV) of

the land, such that we produce at least 40 million board feet of

timber,

we have at least 5 thousand animal unit

months of grazing, and

we keep wilderness index at least 70.

Page 54: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 54

DataArea Acres Use NPV Timber Grazing Wild

s i j p i,j t i,j g i,j w i,j

1 75 1 503 310 0.01 402 140 50 0.04 803 203 0 0 95

2 90 1 675 198 0.03 552 100 46 0.06 603 45 0 0 65

3 140 1 630 210 0.04 452 105 57 0.07 553 40 0 0 60

4 60 1 330 112 0.01 302 40 30 0.02 353 295 0 0 90

5 212 1 105 40 0.05 602 460 32 0.08 603 120 0 0 70

6 98 1 490 105 0.02 352 55 25 0.03 503 180 0 0 75

7 113 1 705 213 0.02 402 60 40 0.04 453 400 0 0 95

Page 55: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 55

Objective: Maximize NPV

jix ji on prescriptiby managed areain acres of thousands,

3,72,71,7

3,1

7

1

3

12,11,1,,

40060705...

...203140503max

xxx

xxxxpi j

jiji

Page 56: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 56

Constraints All acres in an area are allocated

Performance requirements are met

isx jj

ji

,3

1,

s)(wildernes 70788

1

(grazing) 5

(timber) 000,40

7

1

3

1,,

7

1

3

1,,

7

1

3

1,,

i jjiji

i jjiji

i jjiji

xw

xg

xt

Page 57: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 57

Blending Models Best mix of ingredients Applications

chemicals animal feed metals diets

Example: Fagersta AB - Swedish Steel Mill

Page 58: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 58

Steel Mill Charging a furnish

1000 kilogram charge Combine

Scrap in inventory Pure blend

Blend with right % of chemical elements Iron Other: Carbon, Nickel, Chromium,

Molybdenum

Page 59: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 59

Formulation Decision variables

How much of each available ingredient to use

j=1,2,…,7

Four supplies of scrap (1,2,3,4) Three pure materials (5,6,7)

chargein included ingredient of kilograms jx j

Page 60: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 60

Formulation (cont.) Constraints

Correct amount

Composition constraints Properties of the resulting blend

10007654321 xxxxxxx

total

blend

blend in the

fraction allowedor

used ingredient

th ofamount

ingredientth

infraction j

jj

Page 61: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 61

Example Constraints

7

172

7

172

7

1621

7

1621

7

1521

7

1521

7

14321

7

14321

013.00.1001.0

011.00.1001.0

012.00.1011.0120.0

010.00.1011.0120.0

0035.00.1032.0180.0

0030.00.1032.0180.0

0075.00040.00085.00070.0008.0

0065.00040.00085.00070.0008.0

jj

jj

jj

jj

jj

jj

jj

jj

xxx

xxx

xxxx

xxxx

xxxx

xxxx

xxxxx

xxxxx

Page 62: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 62

Other Constraints Availability

Positive Amounts

250

75

2

1

x

x

7,...,2,1,0 jx j

Page 63: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 63

Objective Function Minimize Cost

Note that the pure additives are very expensive!

7654321 536048981016min xxxxxxx

Page 64: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 64

Ration Constraints Bound quotients of linear functions

by a constant

Not linear! Can often be converted to linear

constraints

0065.00040.00085.00070.0008.0

0065.00040.00085.00070.0008.0

7654321

4321

7

14321

xxxxxxx

xxxx

xxxxxj

j

Page 65: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 65

Linear Programming Models

Allocation

Blending

Operations Planning

Shift Scheduling

Page 66: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 66

Operations Planning

What to do and when to do it?

Tubular Products Division of Babcock and Wilcox

New mill

Three existing mills

Optimal distribution of work?

Page 67: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 67

Problem DataWeekly

Cost Hours Cost Hours Cost Hours Cost Hours Demand

1 .5" thick 90 0.8 75 0.7 70 0.5 63 0.6 1002 .5" thin 80 0.8 70 0.7 65 0.5 60 0.6 6303 1" thick 104 0.8 85 0.7 83 0.5 77 0.6 5004 1" thin 98 0.8 79 0.7 80 0.5 74 0.6 9805 2" thick 123 0.8 101 0.7 110 0.5 99 0.6 7206 2" thin 113 0.8 94 0.7 100 0.5 84 0.6 2407 8" thick - - 160 0.9 156 0.5 140 0.6 758 8" thin - - 142 0.9 150 0.5 130 0.6 22

1 .5" thick 140 1.5 110 0.9 - - 122 1.2 502 .5" thin 124 1.5 96 0.9 - - 101 1.2 223 1" thick 160 1.5 133 0.9 - - 138 1.2 3534 1" thin 143 1.5 127 0.9 - - 133 1.2 555 2" thick 202 1.5 150 0.9 - - 160 1.2 1256 2" thin 190 1.5 141 0.9 - - 140 1.2 357 8" thick - - 190 1.0 - - 220 1.5 1008 8" thin - - 175 1.0 - - 200 1.5 10

Mill 2 Mill 3 Mill 4

Pressure

StandardProduct

Mill 1

Page 68: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 68

Formulation Decision Variables

Objective

ek)(pounds/we

millat produced product ofamount , mpx mp

16

1

product ofcost

4

1,,min

p

p

mmpmp xc

Page 69: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 69

Constraints Demand is met

Capacity is ok

Non-negativity

16,...,2,1,4

1,

pdx pm

mp

4,3,2,1,16

1,

mbx mp

mp

mpx mp ,,0,

Page 70: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 70

Canadian Forest Products

purchaselogs

peellogs

purchaseveneer

dry andprocess

presssheets

sand andtrim

Page 71: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 71

Study Objectives Stages of Production - More Complex Objective of OR analysis

How to operate production facilities Maximize contributed margin

Sales - Wood cost

Fixed costs: labor, maintenance, etc. Constraints: availability of wood, market for

products, capacity of plants

Page 72: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 72

Production Yield Data

Good Fair Good Fair

Available per month 200 300 100 1000Cost per log ($ Canadian) 340 190 490 140

A 1/16" green veneer (ft2) 400 200 400 200

B 1/16" green veneer (ft2) 700 500 700 500

C 1/16" green veneer (ft2) 900 1300 900 1300

A 1/8" green veneer (ft2) 200 100 200 100

B 1/8" green veneer (ft2) 350 250 350 250

C 1/8" green veneer (ft2) 450 650 450 650

Vendor 1 Vendor 2Veneer Yield (ft2)

Page 73: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 73

Availability and Costs

A B C A B C

Available (ft2/month) 5000 25000 40000 10000 40000 50000

Cost ($/ft2) 1.00 0.30 0.10 2.20 0.60 0.20

1/8" Green Veneer1/16" Green Veneer

Page 74: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 74

Composition of Products

AB AC BC AB AC BC

Front veneer 1/16 A 1/16 B 1/16 B 1/16 A 1/16 B 1/16 B

1/8 C 1/8 C 1/8 C1/8 C 1/8 C 1/8 C 1/8 B 1/8 B 1/8 B

1/8 C 1/8 C 1/8 C

Back veneer 1/16 B 1/16 C 1/16 C 1/16 B 1/16 C 1/16 C

Market/month 1000 4000 8000 1000 5000 8000

Price 45.00$ 40.00$ 33.00$ 75.00$ 65.00$ 50.00$

Pressing time 0.25 0.25 0.25 0.40 0.40 0.40

1/4" Plywood Sheets 1/2" Plywood Sheets

Core veneer

Page 75: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 75

Decision Variables

sold and pressed , gradeback , gradefront , thicknessof sheets

grade from processingafter grade as used thicknessof sheets

directly purchased veneer grade , thicknessof ft

thicknessinto peeled and vendor frombought quality of logs

',,

',,

2,

,,

g'gtz

gg'ty

gtx

tvqw

ggt

ggt

gt

twq

Page 76: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 76

Continuous Variables Treat all variables as continuous Continuous models more tractable Is it equally valid?

Does one unit back or forth really matter?

If no, then ok to use continuous approximation

Example: Does $0.01 ever matter?

Page 77: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 77

Objective

income) (sales cost) veneer (purchased - cost) (log- max

Page 78: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 78

Constraints Log availability

Purchased veneer availability

Pressing capacity

,...2008/1,1,16/1,1, GG ww

,...5000,16/1 Ax

,...1000,,4/1 BAz

Page 79: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 79

Balance Constraints Must link log and veneer

purchasing Balance constraint

assures in-flows equal or exceed out-flows for each stage of production

BAAA

AFGFG

yy

xwwww

,,16/1,,16/1

,16/116/1,2,16/1,2,16/1,1,16/1,1,

3535

200400200400

Etc.

Page 80: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 80

Assembly for Two Products

Assembly2

Part3

Part3

Part4

Assembly1

Part3

Part3

Part4

Assembly2

Page 81: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 81

Balance Equations

produced ofnumber jx j Decision Variable

Assembly 2 must be at least assembly 1

Must have enough parts

12 xx

214

213

21

12

xxx

xxx

Page 82: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 82

Shift Scheduling

Work fixed

Plan resources to do work

Shift scheduling/staff planning

models

How many types of workers/shifts

Page 83: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 83

Ohio National Bank

Hour Arrivals Hour Arrivals11:00 AM 10 5:00 PM 3212:00 PM 11 6:00 PM 501:00 PM 15 7:00 PM 302:00 PM 20 8:00 PM 203:00 PM 25 9:00 PM 84:00 PM 28 - -

Check processing center All checks must clear by 10 PM Check arrivals:

Page 84: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 84

Workers Two types:

Full time (8 hour shift, 1 hour lunch) $11 hour + $1 night 150% overtime 1000 checks/hour

Part time (4 hour shift) $7 hour 800 check/hour

Page 85: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 85

All Possible Shifts

11 12 13 11 12 13 14 15 16 17 18

11:00 AM R - - R - - - - - - -

12:00 PM R R - R R - - - - - -

1:00 PM R R R R R R - - - - -

2:00 PM R R R R R R R - - - -

3:00 PM - R R - R R R R - - -4:00 PM R - R - - R R R R - -5:00 PM R R - - - - R R R R -6:00 PM RN RN RN - - - - - RN RN RN7:00 PM RN RN RN - - - - RN RN RN8:00 PM OT RN RN - - - - - - RN RN9:00 PM - OT RN - - - - - - - RN

Start Part Time ShiftsFull Time Shifts

Page 86: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 86

Decision Variables

18...11at starting workerspart time

1211at starting e w/overtim workers timefull

131211at starting workers timefull

,,hz

,hy

,,hx

h

h

h

Page 87: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 87

Objective Function

181716151413

12111211131211

323130292828

28281818929190min

zzzzzz

zzyyxxx

Page 88: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 88

Constraints No more than 35 operators on duty

Overtime limits

machines) AM (11 351111 zx

202

12

1

1211

1212

1111

yy

xy

xy

Page 89: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 89

Covering Constraints Shift provides enough workers

131212111211

121111

shifts

118.08.011

108.01

trequiremenduty)on er rker)(numb(output/wo

wwzzxx

wzx

Page 90: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 90

Example Government agency Clerical workers can work 4x 10-hour

days/week

Need: Monday - 10 workers Friday 9 workers, and Tuesday - Thursday 7 workers

j = 1 Monday-Wednesday-Thursday-Fridayj = 2 Monday-Tuesday-Thursday-Fridayj = 3 Monday-Tuesday-Wednesday-Friday

Page 91: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 91

Formulation Decision variables

LP Model

jx j pattern workingemployees ofnumber

0,,

9

7

7

7

10s.t.min

321

321

21

31

32

321

321

xxx

xxx

xx

xx

xx

xxxxxx

Friday) (cover

Thursday) (cover

Wednesday) (cover

Tuesday) (cover

Monday) (cover

Page 92: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 92

Time-Phased Models

Static Models One point in time

Planning or design stage decisions

Dynamic Models Account for decision over time

Operational decisions

Page 93: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 93

Institutional Food Services (IFS) Cash Flow Supplies food to restaurants,

schools, etc. Cash flow decisions

Item 1 2 3 4 5 6 7 8

Cash sales s t 600$ 750$ 1,200$ 2,100$ 2,250$ 180$ 330$ 540$

Accounts receivable r t 770$ 1,260$ 1,400$ 1,750$ 2,800$ 4,900$ 5,250$ 420$

Accounts payable p t 3,200$ 5,600$ 6,000$ 480$ 880$ 1,440$ 1,600$ 2,000$

Expenses e t 350$ 400$ 550$ 940$ 990$ 350$ 350$ 410$

Projected Weekly Amount/Week

Page 94: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 94

System Dynamics Cash sales and accounts receivable result in

immediate income to checking account Accounts payable are due in 3 weeks but

get 2% discount if paid immediately Bank

$4 million line of credit 0.2% interest/week Must have 20% of borrowed amount in checking

Short-term money market with 0.1%/week $20,000 safety balance in checking

Page 95: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 95

Decision Variables

tz

ty

tx

tw

th

tg

t

t

t

t

t

t

week during handon cash

in week debt credit of line cumulative

in week market money in investedamount

3 week until delayed payable accounts

in week paiddebt ofamount

in week borrowedamount

Decision Variables

Define for convenience

Page 96: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 96

Balance Constraints

1 period

incash

period

ingain net

period

incash

1 period

in level

starting

decisions

period

ofimpact

period

in level

starting

ttt

t

t

t

General time-phased models

Cash flow models

Page 97: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 97

Net Gain in Each Period Note that we carry both cash and debt

Cost Increments Cash DecrementsFunds borrowed in week t Borrowing paid off in week tInvestment principal from week t-1 Investment in week tInterest on investment in week t-1 Interest on debt in week t-1Cash sales from week t Expenses paid in week tAccounts receivable for week t Accounts payable paid with discount for week t

Accounts payable paid without discount for week t-3

Page 98: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 98

Balance Constraints Cash balance

Debt balance

3

1111

)(98.0

002.0001.0

tttttt

tttttttt

wwpres

yxxxhgzz

tttt hgyy 1

Page 99: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 99

Linear Programming Model

tttttt

t

tt

tt

t

ttt

tttttt

tttttttt

tt

tt

tt

zyxwhg

z

pw

yz

y

gyy

wwpres

yxxxhgzz

x.w.y.

,,,,,0

20

20.0

4000

)(98.0

002.0001.0s.t.

00100200020min

1

3

1111

8

1

8

1

8

1

Page 100: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 100

Optimal Solution

Decision Variable 1 2 3 4 5 6 7 8Borrowing 100.0$ 505.7$ 3,394.3$ -$ 442.6$ -$ -$ -$ Debt payment -$ -$ -$ 442.5$ -$ 2,715.3$ 1,284.7$ -$ Payables delayed 2,077.6$ 3,544.5$ 1,138.5$ -$ -$ -$ -$ -$ Short-term investments -$ -$ -$ -$ -$ -$ 2,611.7$ 1,204.3$ Cumulative debt 100.0$ 605.7$ 4,000.0$ 3,557.4$ 4,000.0$ 1,284.7$ -$ -$ Cumulative cash 20.0$ 121.1$ 800.0$ 711.5$ 800.0$ 256.9$ 20.0$ 20.0$

Optimal Weekly Amount for Weeks

Page 101: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 101

Time Horizons Fixed time horizon

usual case problems with boundaries start with ‘typical’ numbers condition to assure ends ‘reasonably’

Infinite time horizon wrap around (output of last stage input to the first

stage)

Page 102: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 102

Example: Balance Constraints

Decision variables

Demand: 11000, 48000, 64000, 15000

inventoryin held shovels snow of thousands

quarter in produced shovels snow of thousands

q

q

i

qx

443

332

221

11

15

64

48

110

inventory

endingdemandproduction

inventory

beginning

ixi

ixi

ixi

ix

Page 103: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 103

“Typical” Initial Inventory

443

332

221

11

15

64

48

119

inventory

endingdemandproduction

inventory

beginning

ixi

ixi

ixi

ix

Page 104: IE 3121 Solution Techniques Models Thousands (or millions) of variables Thousands (or millions) of constraints Complex models tend to be valid Is the model

IE 312 104

Wrapper (Infinite Horizon)

443

332

221

114

15

64

48

11

inventory

endingdemandproduction

inventory

beginning

ixi

ixi

ixi

ixi