A two-stage solution approach for plastic injection machines scheduling problem

Abstract

One of the most common plastic manufacturing methods is injection molding. In injection molding process, scheduling of plastic injection machines is very difficult because of the complex nature of the problem. For example, similar plastic parts should be produced sequentially to prevent long setup times. On the other hand, to produce a plastic part, its mold should be fixed on an injection machine. Machine eligibility restrictions should be considered because a mold can be usually fixed on a subset of the injection machines. Some plastic parts which have same shapes but different colors are used same mold so these parts can only be scheduled simultaneously if their mold has copies, otherwise resource constraints should be considered. In this study, a multi-objective mathematical model is proposed for parallel machine scheduling problem to minimize makespan, total tardiness, and total waiting time. Since NP-hard nature of problem, this paper presents a two-stage mathematical model and a two-stage solution approach. In the first stage of mathematical model, jobs are assigned to the machines and each machine is scheduled separately in the second stage. The integrated model and two-stage mathematical model are scalarized by using goal programming, compromise programming and Lexicographic Weighted Tchebycheff programming methods. To solve large-scale problems in a short time, a two-stage solution approach is also proposed. In the first stage of this approach, jobs are assigned to machines and scheduled by using proposed simulated annealing algorithm. In the second stage of the approach, starting time, completion time and waiting time of the jobs are calculated by using a mathematical model. The performance of the methods is demonstrated on randomly generated test problems.