Mathematical modeling to optimize production planning and scheduling in a small foundry with multiple alternating furnaces

Abstract

Purpose - This study presents an extension to a model in the literature for lot-sizing and scheduling in a small foundry with multiple alternate furnaces. The purpose of the model is to minimize delays and inventory costs. In addition, it determines the best use of the load capacity in the furnaces.Theoretical framework – Lot-sizing in foundries in the marketplace is a subject of academic interest due to its applicability and mathematical and computational complexity. Many papers address the production problem in foundries with a single furnace, however, few papers address the possibility of multiple furnaces.Design/methodology/approach - Mathematical modeling was used to represent the lot-sizing and scheduling problem in a small foundry. Data from the company's order books were collected and model validation questionnaires were applied.Findings - The extended model was able to generate good production plans at different planning horizons, with better performance than the current methods obtained by the company.Originality/value - the extension of the model contributes to the literature by addressing the existence of multiple non-simultaneous furnaces, a feature that has not been greatly explored. A comparison with other models is performed to indicate the most suitable model for actual application.Keywords: Alloys scheduling. Foundry. Lot size. Mixed integer programming.