Models for two- and three-stage two-dimensional cutting stock problems with a limited number of open stacks

Abstract

We address three variants of the two-dimensional cutting stock problem in which the guillotine cutting of large objects produces a set of demanded items. The characteristics of the variants are the rectangular shape of the objects and items; the number of two or three orthogonal guillotine stages; and a sequencing constraint that limits the number of open stacks to a scalar associated with the number of automatic compartments or available space near the cutting machine. These problems arise in manufacturing environments that seek minimum waste solutions with limited levels of work-in-process. Despite their practical relevance, we are not aware of mathematical models for them. In this paper, we propose an integer linear programming (ILP) formulation for each of these variants based on modelling strategies for the two-dimensional guillotine cutting stock problem and the minimisation of the open stacks problem. The first two variants deal with exact and non-exact 2-stage patterns, and the third with a specific type of 3-stage patterns. Using a general-purpose ILP solver, we performed computational experiments to evaluate these approaches with benchmark instances. The results show that several equivalent solutions of the cutting problem allow obtaining satisfactory solutions with a reduced number of open stacks.