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Publications

Publications by CEGI

2023

Mathematical models for the two-dimensional variable-sized cutting stock problem in the home textile industry

Authors
Salem, KH; Silva, E; Oliveira, JF; Carravilla, MA;

Publication
EUROPEAN JOURNAL OF OPERATIONAL RESEARCH

Abstract
In this paper, we consider the two-dimensional Variable-Sized Cutting Stock Problem (2D-VSCSP) with guillotine constraint, applied to the home textile industry. This is a challenging class of real-world prob-lems where, given a set of predefined widths of fabric rolls and a set of piece types, the goal is to de-cide the widths and lengths of the fabric rolls to be produced, and to generate the cutting patterns to cut all demanded pieces. Each piece type considered has a rectangular shape with a specific width and length and a fixed demand to be respected. The main objective function is to minimize the total amount of the textile materials produced/cut to satisfy the demand. According to Wascher, Hau ss ner, & Schu-mann (2007), the addressed problem is a Cutting Stock Problem (CSP), as the demand for each item is greater than one. However, in the real-world application at stake, the demand for each item type is not very high (below ten for all item types). Therefore, addressing the problem as a Bin-Packing Problem (BPP), in which all items are considered to be different and have a unitary demand, was a possibility. For this reason, two approaches to solve the problems were devised, implemented, and tested: (1) a CSP model, based on the well-known Lodi and Monaci (2003) model (3 variants), and (2) an original BPP-based model. Our research shows that, for this level of demand, the new BPP model is more competitive than CSP models. We analyzed these different models and described their characteristics, namely the size and the quality of the linear programming relaxation bound for solving the basic mono-objective variant of the problem. We also propose an epsilon-constraint approach to deal with a bi-objective extension of the problem, in which the number of cutting patterns used must also be minimized. The quality of the models was evaluated through computational experiments on randomly generated instances, yielding promising results.(c) 2022 Published by Elsevier B.V.

2023

The Floating-Cuts model: a general and flexible mixed-integer programming model for non-guillotine and guillotine rectangular cutting problems

Authors
Silva, E; Oliveira, JF; Silveira, T; Mundim, L; Carravilla, MA;

Publication
OMEGA-INTERNATIONAL JOURNAL OF MANAGEMENT SCIENCE

Abstract
Cutting and packing problems are challenging combinatorial optimization problems that have many rel-evant industrial applications and arise whenever a raw material has to be cut into smaller parts while minimizing waste, or products have to be packed, minimizing the empty space. Thus, the optimal solution to these problems has a positive economic and environmental impact. In many practical applications, both the raw material and the cut parts have a rectangular shape, and cut-ting plans are generated for one raw material rectangle (also known as plate) at a time. This is known in the literature as the (two-dimensional) rectangular cutting problem. Many variants of this problem may arise, led by cutting technology constraints, raw-material characteristics, and different planning goals, the most relevant of which are the guillotine cuts. The absence of the guillotine cuts imposition makes the problem harder to solve to optimality.Based on the Floating-Cuts paradigm, a general and flexible mixed-integer programming model for the general rectangular cutting problem is proposed. To the best of our knowledge, it is the first mixed inte-ger linear programming model in the literature for both non-guillotine and guillotine problems. The basic idea of this model is a tree search where branching occurs by successive first-order non-guillotine-type cuts. The exact position of the cuts is not fixed, but instead remains floating until a concrete small rect-angle (also known as item) is assigned to a child node. This model does not include decision variables either for the position coordinates of the items or for the coordinates of the cuts. Under this framework, it was possible to address various different variants of the problem.Extensive computational experiments were run to evaluate the model's performance considering 16 dif-ferent problem variants, and to compare it with the state-of-the-art formulations of each variant. The results confirm the power of this flexible model, as, for some variants, it outperforms the state-of-the-art approaches and, for the other variants, it presents results fairly close to the best approaches. But, even more importantly, this is a new way of looking at these problems which may trigger even better approaches, with the consequent economic and environmental benefits.

2023

Design of a sales plan in a hybrid contractual and non-contractual context in a setting of limited capacity: A robust approach

Authors
Pereira, DF; Oliveira, JF; Carravilla, MA;

Publication
INTERNATIONAL JOURNAL OF PRODUCTION ECONOMICS

Abstract
Many companies face capacity limitations that impair them to satisfy potential demand. In this context, sales/marketing teams have to decide which demand segments the company should prioritize. In business -to-business contexts, it is common that this selection includes customers with and without a contract. On the operations side, the production teams are interested in finding the most efficient usage for the available capacity. However, decision-making approaches to face such a challenge are scarce. In this paper, we propose a scenario-based robust optimization model to support the sales and marketing teams to define the most profitable sales plan in a setting of limited capacity, to serve multiple customers that can be either non -contractual or operate under quantity-flexibility contracts. The proposed model integrates contract design, portfolio selection, and tactical production planning decisions. By employing our model, we are able to quantify how a product's inclusion in a contract relates not only to its own profitability but also to the profitability of the remaining products that might be offered to the customer using the same resources. Regarding the optimal flexibility level to offer to a customer, it is explained by the expected sales volume, the discount rate depending on the flexibility level, and the demand variability expectation. We expect this approach supports industrial companies in defining the mid-term sales plan and deciding on the conditions to offer to contract customers.

2023

Cutting and packing problems under uncertainty: literature review and classification framework

Authors
Salem, KH; Silva, E; Oliveira, JF;

Publication
INTERNATIONAL TRANSACTIONS IN OPERATIONAL RESEARCH

Abstract
Cutting and packing problems are hard combinatorial optimization problems that arise in several manufacturing and process industries or in their supply chains. The solution of these problems is not only a scientific challenge but also has a large economic impact, as it contributes to the reduction of one of the major cost factors for many production sectors, namely raw materials, together with a positive environmental impact. The explicit consideration of uncertainty when solving cutting and packing problems with optimization techniques is crucial for a wider adoption of research results by companies. However, current research has paid little attention to the role of uncertainty in these problems. In this paper, we review the existing literature on uncertainty in cutting and packing problems, propose a classification framework, and highlight the many research gaps and opportunities for scientific contributions.

2023

The two-dimensional cutting stock problem with usable leftovers and uncertainty in demand

Authors
Nascimento, DN; Cherri, AC; Oliveira, JF; Oliveira, BB;

Publication
COMPUTERS & INDUSTRIAL ENGINEERING

Abstract
When dealing with cutting problems, the generation of usable leftovers proved to be a good strategy for decreasing material waste. Focusing on practical applications, the main challenge in the implementation of this strategy is planning the cutting process to produce leftovers with a high probability of future use without complete information about the demand for any ordered items. We addressed the two-dimensional cutting stock with usable leftovers and uncertainty in demand, a complex and relevant problem recurring in companies due to the unpredictable occurrence of customer orders. To deal with this problem, a two-stage formulation that approximates the uncertain demand by a finite set of possible scenarios was proposed. Also, we proposed a matheuristic to support decision-makers by providing good-quality solutions in reduced time. The results obtained from the computational experiments using instances from the literature allowed us to verify the matheuristic performance, demonstrating that it can be an efficient tool if applied to real-life situations.

2023

A BIOBJECTIVE MATHEURISTIC FOR THE INTEGRATED SOLUTION OF THE IRREGULAR STRIP PACKING AND THE CUTTING PATH DETERMINATION PROBLEMS

Authors
Oliveira, LT; Carravilla, MA; Oliveira, JF; Toledo, FMB;

Publication
Pesquisa Operacional

Abstract
Irregular strip packing problems are present in a wide variety of industrial sectors, such as the garment, footwear, furniture and metal industry. The goal is to find a layout in which an object will be cut into small pieces with minimum raw-material waste. Once a layout is obtained, it is necessary to determine the path that the cutting tool has to follow to cut the pieces from the layout. In the latter, the goal is to minimize the cutting distance (or time). Although industries frequently use this solution sequence, the trade-off between the packing and the cutting path problems can significantly impact the production cost and productivity. A layout with minimum raw-material waste, obtained through the packing problem resolution, can imply a longer cutting path compared to another layout with more material waste but a shorter cutting path, obtained through an integrated strategy. Layouts with shorter cutting path are worthy of consideration because they may improve the cutting process productivity. In this paper, both problems are solved together using a biobjective matheuristic based on the Biased Random-Key Genetic Algorithm. Our approach uses this algorithm to select a subset of the no-fit polygons edges to feed the mathematical model, which will compute the layout waste and cutting path length. Solving both strip packing and cutting path problems simultaneously allows the decision-maker to analyze the compromise between the material waste and the cutting path distance. As expected, the computational results showed the trade-off’s relevance between these problems and presented a set of solutions for each instance solved. © 2023, Sociedade Brasileira de Pesquisa Operacional. All rights reserved.

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