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- Creators: Fowler, John W
Description
A good production schedule in a semiconductor back-end facility is critical for the on time delivery of customer orders. Compared to the front-end process that is dominated by re-entrant product flows, the back-end process is linear and therefore more suitable for scheduling. However, the production scheduling of the back-end process is still very difficult due to the wide product mix, large number of parallel machines, product family related setups, machine-product qualification, and weekly demand consisting of thousands of lots. In this research, a novel mixed-integer-linear-programming (MILP) model is proposed for the batch production scheduling of a semiconductor back-end facility. In the MILP formulation, the manufacturing process is modeled as a flexible flow line with bottleneck stages, unrelated parallel machines, product family related sequence-independent setups, and product-machine qualification considerations. However, this MILP formulation is difficult to solve for real size problem instances. In a semiconductor back-end facility, production scheduling usually needs to be done every day while considering updated demand forecast for a medium term planning horizon. Due to the limitation on the solvable size of the MILP model, a deterministic scheduling system (DSS), consisting of an optimizer and a scheduler, is proposed to provide sub-optimal solutions in a short time for real size problem instances. The optimizer generates a tentative production plan. Then the scheduler sequences each lot on each individual machine according to the tentative production plan and scheduling rules. Customized factory rules and additional resource constraints are included in the DSS, such as preventive maintenance schedule, setup crew availability, and carrier limitations. Small problem instances are randomly generated to compare the performances of the MILP model and the deterministic scheduling system. Then experimental design is applied to understand the behavior of the DSS and identify the best configuration of the DSS under different demand scenarios. Product-machine qualification decisions have long-term and significant impact on production scheduling. A robust product-machine qualification matrix is critical for meeting demand when demand quantity or mix varies. In the second part of this research, a stochastic mixed integer programming model is proposed to balance the tradeoff between current machine qualification costs and future backorder costs with uncertain demand. The L-shaped method and acceleration techniques are proposed to solve the stochastic model. Computational results are provided to compare the performance of different solution methods.
ContributorsFu, Mengying (Author) / Askin, Ronald G. (Thesis advisor) / Zhang, Muhong (Thesis advisor) / Fowler, John W (Committee member) / Pan, Rong (Committee member) / Sen, Arunabha (Committee member) / Arizona State University (Publisher)
Created2011
Description
This research develops heuristics to manage both mandatory and optional network capacity reductions to better serve the network flows. The main application discussed relates to transportation networks, and flow cost relates to travel cost of users of the network. Temporary mandatory capacity reductions are required by maintenance activities. The objective of managing maintenance activities and the attendant temporary network capacity reductions is to schedule the required segment closures so that all maintenance work can be completed on time, and the total flow cost over the maintenance period is minimized for different types of flows. The goal of optional network capacity reduction is to selectively reduce the capacity of some links to improve the overall efficiency of user-optimized flows, where each traveler takes the route that minimizes the traveler’s trip cost. In this dissertation, both managing mandatory and optional network capacity reductions are addressed with the consideration of network-wide flow diversions due to changed link capacities.
This research first investigates the maintenance scheduling in transportation networks with service vehicles (e.g., truck fleets and passenger transport fleets), where these vehicles are assumed to take the system-optimized routes that minimize the total travel cost of the fleet. This problem is solved with the randomized fixed-and-optimize heuristic developed. This research also investigates the maintenance scheduling in networks with multi-modal traffic that consists of (1) regular human-driven cars with user-optimized routing and (2) self-driving vehicles with system-optimized routing. An iterative mixed flow assignment algorithm is developed to obtain the multi-modal traffic assignment resulting from a maintenance schedule. The genetic algorithm with multi-point crossover is applied to obtain a good schedule.
Based on the Braess’ paradox that removing some links may alleviate the congestion of user-optimized flows, this research generalizes the Braess’ paradox to reduce the capacity of selected links to improve the efficiency of the resultant user-optimized flows. A heuristic is developed to identify links to reduce capacity, and the corresponding capacity reduction amounts, to get more efficient total flows. Experiments on real networks demonstrate the generalized Braess’ paradox exists in reality, and the heuristic developed solves real-world test cases even when commercial solvers fail.
This research first investigates the maintenance scheduling in transportation networks with service vehicles (e.g., truck fleets and passenger transport fleets), where these vehicles are assumed to take the system-optimized routes that minimize the total travel cost of the fleet. This problem is solved with the randomized fixed-and-optimize heuristic developed. This research also investigates the maintenance scheduling in networks with multi-modal traffic that consists of (1) regular human-driven cars with user-optimized routing and (2) self-driving vehicles with system-optimized routing. An iterative mixed flow assignment algorithm is developed to obtain the multi-modal traffic assignment resulting from a maintenance schedule. The genetic algorithm with multi-point crossover is applied to obtain a good schedule.
Based on the Braess’ paradox that removing some links may alleviate the congestion of user-optimized flows, this research generalizes the Braess’ paradox to reduce the capacity of selected links to improve the efficiency of the resultant user-optimized flows. A heuristic is developed to identify links to reduce capacity, and the corresponding capacity reduction amounts, to get more efficient total flows. Experiments on real networks demonstrate the generalized Braess’ paradox exists in reality, and the heuristic developed solves real-world test cases even when commercial solvers fail.
ContributorsPeng, Dening (Author) / Mirchandani, Pitu B. (Thesis advisor) / Sefair, Jorge (Committee member) / Wu, Teresa (Committee member) / Zhou, Xuesong (Committee member) / Arizona State University (Publisher)
Created2017