A constraint programming approach for resource-constrained flexible assembly flow shop scheduling problem with batch direct delivery

Abstract

Production and distribution are both crucial components of supply chains. Integrated production and distribution scheduling (IPDS) in the context of flexible assembly flow shop scheduling and batch delivery problems is often overlooked. A realistic problem inspired by the production and distribution processes of a dishwasher factory can be modeled as a resource-constrained flexible assembly flow shop scheduling problem with batch direct delivery (RCFAFSP-BDD). In this problem, order requirements are decomposed into several production tasks processed at different stages of the workshop, and are then delivered in batches via a third-party logistics provider to regional distributors at various locations. Auxiliary resource restrictions, hierarchical coupling constraints, machine eligibility restrictions and sequence-dependent setup times, are incorporated into the problem as operational constraints. To the best of our knowledge, this is the first attempt to solve this problem. This work formulates a mixed-integer linear programming (MIP) model to minimise total costs, including tardiness, inventory, and delivery costs. Given the problem’s strong NP-hard nature, the focus is on developing an efficient solution approach using constraint programming (CP). A CP model is proposed and enhanced with multiple redundant constraints. To reduce runtime, two branching strategies are designed for the CP model. Numerical experiments with varying instance scales reveal that the proposed CP model outperforms the MIP model in accuracy and efficiency within the given time limit. The redundant constraints and search strategy can reduce CP model runtime by up to 263.83%. Compared to manual scheduling at the studied factory, the CP model can cut costs by up to 26.59% for real data, offering viable alternatives for factory planners.