混合式啟發式解法求解多產品裝瓶產線批量與排序問題 – 以巴拿馬啤酒公司為例

Abstract

本研究旨在協助巴拿馬啤酒公司之生產計畫者，於多產品裝瓶生產線之批量與排程。本研究建立一個混合整數規劃模型其符合個案公司決策分析之情境，問題旨在決定各生產計畫期間內，各產品批量與三條裝瓶生產線上之生產順序，以最小化生產計畫期間內之總成本(包含生產，存貨，整備之成本)，且能滿足各產品的需求。本研究考量該公司裝瓶生產線特性之相關因素如：生產速率限制、產能、整備時間與存貨策略。本研究提倡運用混合式啟發式演算法（又稱為GA-LP法）其 結合基因演算法(Genetic algorithm)及線性規劃(Linear programming)，基因演算法是著眼於解決排序問題，而線性規劃則是處理批量決策。本研究運用該公司二十週的實際數據，比較GA-LP法與該公司原先的生產規劃進行效益評比， 結果顯示不僅可以在更短的時間完成生產規劃，且可降低總成本達21%；故本研究提出之GA-LP法，可以作為多產品裝瓶生產系統之生產規劃者在批量與排程有效的決策輔助工具。

This study was motivated to support the production planners in the lot sizing and sequencing of multiple products on the packaging lines of the Panama Beer Company. We formulate a mixed integer programming model that matches with the decision-making scenarios in the company. The problem aims at the determination of the lot size of each product, and the sequence of production in the three packaging lines for each period, so as to minimize the total costs (including the production, inventory and setup costs) in the planning horizon, while meeting the demand of each product. We took into account the limitations on the production rate, capacity, setup times, and inventory policies to fit the characteristics of the packaging lines in the Panama Beer Company. In order to solve the problem, we propose a hybrid-heuristic (called GA-LP) that combines Genetic Algorithm (GA) and Linear Programming (LP) in which GA is used to solve the sequencing problem, and LP aims to solve the lot sizing problem. We evaluated the effectiveness of the proposed hybrid-heuristic by comparing the obtained solutions with the historical production plans. We conduct our experiments with the real-world data for a planning period of twenty weeks, and our results showed that the proposed GA-LP approach not only solved the production plan efficiently in a much shorter run time, but also led to an improvement of 21% in the total cost. Therefore, the proposed GA-LP approach may serve as an effective tool that supports the production planner in the lot sizing and sequencing of bottling production systems.