Abstract
We address a scheduling problem in an actual environment of the tortilla industry. Since the problem is NP hard, we focus on suboptimal scheduling solutions. We concentrate on a complex multistage, multiproduct, multimachine, and batch production environment considering completion time and energy consumption optimization criteria. The production of wheat-based and corn-based tortillas of different styles is considered. The proposed bi-objective algorithm is based on the known Nondominated Sorting Genetic Algorithm II (NSGA-II). To tune it up, we apply statistical analysis of multifactorial variance. A branch and bound algorithm is used to assert obtained performance. We show that the proposed algorithms can be efficiently used in a real production environment. The mono-objective and bi-objective analyses provide a good compromise between saving energy and efficiency. To demonstrate the practical relevance of the results, we examine our solution on real data. We find that it can save 48% of production time and 47% of electricity consumption over the actual production.
Highlights
Tortillas are a very popular food as a favorite snack and meal option in various cultures and countries
We formulated the complex problem of the real-life industry environment of tortilla production considering two optimization criteria: total completion time and energy consumption; (2)
We proposed a bi-objective solution to solve a hybrid flow shop with unrelated machines, setup time, and work in progress buffers
Summary
Tortillas are a very popular food as a favorite snack and meal option in various cultures and countries. There are two types of tortillas: wheat-based and corn-based. Their overall consumption is growing all over the world. Tortillas were made by hand: grinding corn into flour, mixing the dough, and pressing to flatten it. Many small firms today still use processes that are more labor-intensive, requiring people to perform a majority of the tasks such as packaging, loading, baking, and distributing. This trend is expected to change over the years. Due to its considerable practical significance, optimization of tortilla production is important. To improve the production timing parameters (setup, changeover, waiting), operational cost (energy consumption, repairing, service), throughput, etc., careful analysis of the process and of advance scheduling approaches is needed
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