1 Project title: DISTRIBUTED AND CAPE-OPEN COMPLIANT PLATFORM FOR PLANNING AND SCHEDULING MULTI-SITE MANUFACTURING SYSTEMS Universitat Politecnica de Catalunya Chemical Engineering Department BULGARIAN ACADEMY OF SCIENCES INSTITUTE OF CHEMICAL ENGEENERING

2 Outline MPMB optimal control strategy Mathematical formulation of the problem Software realization integrated software “SC-MOPP” Example Supply Chain and Scheduling problem solve in “SC-MOPP”

3 General structure of “Supply chain” using of SC-MOPP COSTOMERS SUPPLIERS MULTIPURPOSE PLANTS STOAGES DISTRIBUTORS PROBLEM STATEMENT FOR PROFIT MAXIMIZATION The FIRST STAGE includes an obligatory preliminary study of the MARKET DEMANDS During this stage, the requirements put forward by each potential costumer in the planning horizon have to be determined

4 General structure of “Supply chain” using of SC-MOPP COSTOMERS SUPPLIERS MULTIPURPOSE PLANTS STOAGES DISTRIBUTORS PROBLEM STATEMENT FOR PROFIT MAXIMIZATION The SECOND STAGE includes DETERMINATION: 1.Optimal product portfolio, 2.Optimal supply plants, 3. Optimal distribution Optimal product portfolio for each plants Optimal raw materials supply to each plants 1.Optimal scheme of loading of storages with products 2.Optimal scheme of serving the distributors 3.Optimal scheme of serving the costumers

5 General structure of “Supply chain” using of SC-MOPP SUPPLIERS MULTIPURPOSE PLANTS STOAGES DISTRIBUTORS The THIRD STAGE concerns the production schedules on plant scale corresponding to the product portfolio, obtained in the second stage Optimal scheduling in campaign mode (SC) : Optimal scheduling in Job – shop mode (MOPP) COSTOMERS

6 4 G 1 - Planed minimal quantity, which have to be manufactured for product 1 G 2 - Planed minimal quantity, which have to be manufactured for product 2 The task of Optimal synthesis of manufacture scheduling is arrived to identify the campaigns, which are participate and working time, so that the optimal criteria to be satisfied. The criteria are: 1. Minimum time duration programm.2. Maximum profit for planning horizon. MIN(t s1 +t c1 +t s2 +t c t s14 +t c14 )MAX(P 1r + P 2r ) (t s1 + t c1 + t s2 + t c t s14 + t c14 ) < H In case of performed the constraints : G 1r > G 1 )G 2r > G 2 ) Service time S1 t s1 Service time S2 t s1 Service time S14 t s14 Campaign 1 t c1 5 Batch size=250kg Cycle time=15h 1 Batch size=250kg Cycle time=15h Campaign 2 t c2 4 Batch size=100kg Cycle time=15h 1 Batch size=250kg Cycle time=15h Campaign 14 t c14 1 Batch size=80kg Cycle time=10h 5 Batch size=250kg Cycle time=15h H - Planning period /horizon/ Production scheduling model in campaign mode

7 Optimal scheduling in Job – shop mode (MOPP)

8 Set of Variables - Amount of n-th product, produced in the j-th plants - Ratios of raw material supply relevant to production of n-th product - Indicates the ratios of products q nj supplied to the SC warehouses - Indicates the ratios of stored products supply from the SC warehouses to the distributors - Indicates the ratios of product supplied from the SC distributors to the markets Mathematical formulation of the problem

9 Objective function: Mathematical formulation of the problem

10 Interaction between “Supply Chain” and “MOPP” “SC” SoftwareSoftware“MOPP” Software Replica of MOPP graphical interfaceMOPP Supply Chain elements : Data Base - SUPPLIERSSUPPLIERS Data Base - PLANTS PLANTS Data Base - STORAGESSTORAGES Data Base - DISTRIBUTORSDISTRIBUTORS Data Base - COSTUMERSCOSTUMERS Supply ChainSupply Chain superstructure Problem for optimizationoptimization Numerical method selectionselection Problem solutionsolution XML Input files generation for MOPPgeneration Transfer of XML files to MOPP Transfer of XML files to SC Plants elements : Data Base - MATERIALSMATERIALS Data Base - UNITSUNITS Data Base - PROFILESPROFILES Data Base – STORAGES (Plants)STORAGES (Plants) Data Base - RECIPES RECIPES SCEDULING PROBLEM Problem solution SCHEDULE visualition XML Input files generation for SCgeneration Numerical method selection

11 Dairy Supply Chain Products drinking milk-P1 curds-P2 butter-P3 Capacity [ton/month] Milk cost [BGN / ton] S1S S2S Capacities of milk suppliers and milk costs Markets demands and products selling costs. Market demands [ton /month] Selling costs [BGN/ton] P1P1 P2P2 P3P3 P1P1 P2P2 P3P3 M1M M2M Distances between dairies and markets, and dairies and milk centers and their respective transportation costs Distance [km]Transportation cost [BGN/ton.km] M1M1 M2M2 S1S1 S2S2 M1M1 M2M2 S1S1 S2S2 Dairy Dairy QRM Separation for milk processing Separation for curd processing Separation for butter rocessing Cream Curd processing Butter processing Milk processing QP 1 ; FP 1 QM P2 ; FP 2 QP 2 ; QP 3 ; FP 3 QCR; F CR Q CR 1 ; F CR Q CR 2 ; F CR Q CR 3 ; F CR F BM F SM Q RM 1 ; F RM Q RM 2 ; F RM Q RM 3 ; F RM

12 Supplier 1 Supplier 2 Dairy 1 Dairy 2 Market 1 Fictios StoragesFictios Distributors Set of SuppliersSet of Plants Set of StoragesSet of DistributorsSet of Costumers “SUPPLY CHAIN” Model Market 2 Dairy Supply Chain

13 RESOLUTION set up Interface “SC–MOPP”

14 Main “CONTROL PANEL” Interface “SC–MOPP”

15 Interface “SC–MOPP” Get DATA for “SUPPLAY CHAIN” Model

16 Interface “SC–MOPP” List of PRODUCTS in “SUPPLAY CHAIN”

17 List of SUPPLIERS in “SUPPLAY CHAIN” Interface “SC–MOPP”

18 List of PLANTS in “SUPPLAY CHAIN” Interface “SC–MOPP”

19 Interface “SC–MOPP” List of STORAGES in “SUPPLAY CHAIN”

20 List of DISTRIBUTORS in “SUPPLAY CHAIN” Interface “SC–MOPP”

21 List of COSTUMERS in “SUPPLAY CHAIN” Interface “SC–MOPP”

22 Interface “SC–MOPP” Enter in DATA BASES for SUPPLAY CHAIN elements

23 Detailed DATA for “SUPPLIERS” Interface “SC–MOPP”

24 Interface “SC–MOPP” Detailed DATA for “SUPPLIERS”

25 Interface “SC–MOPP” Detailed DATA for “PLANTS”

26 Detailed DATA for elements of “PLANTS” Interface “SC–MOPP”

27 Summarized DATA for Materials, Units, Profiles, Storages Interface “SC–MOPP”

28 Replica of MOPP Graphical interface for “MATERIALS”MATERIALS Interface “SC–MOPP”

29 Summarized DATA for Materials, Units, Profiles, Storages Interface “SC–MOPP”

30 Replica of MOPP Graphical interface for “UNITS”UNITS Interface “SC–MOPP”

31 Summarized DATA for Materials, Units, Profiles, Storages Interface “SC–MOPP”

32 Replica of MOPP Graphical interface for “PROFILES”PROFILES Interface “SC–MOPP”

33 Summarized DATA for Materials, Units, Profiles, Storages Interface “SC–MOPP”

34 Replica of MOPP Graphical interface for “STORAGES”STORAGES Interface “SC–MOPP”

35 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (1)Recipes

36 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (2)Recipes

37 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (3)Recipes

38 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (4)

39 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (5)

40 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (6)Recipes

41 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (7)

42 Interface “SC–MOPP” Replica of MOPP Graphical interface for Recipes (8)Recipes

43 Interface “SC–MOPP” Detailed DATA for “STORAGES”

44 Interface “SC–MOPP” Detailed DATA for “DISTRIBUTORS”

45 Interface “SC–MOPP” Detailed DATA for “COSTUMERS”

46 Interface “SC–MOPP” Definition of SUPPLAY CHAIN superstructure- Choice of “SUPPLIERS”

47 Interface “SC–MOPP” Definition of SUPPLAY CHAIN superstructure- Choice of “PLANTS”

48 Interface “SC–MOPP” Definition of SUPPLAY CHAIN superstructure- Choice of “STORAGES”

49 Interface “SC–MOPP” Definition of SUPPLAY CHAIN superstructure- Choice of “DISTRIBUTORS”

50 Interface “SC–MOPP” Definition of SUPPLAY CHAIN superstructure- Choice of “COSTUMERS”

51 Interface “SC–MOPP” Problem for optimization

52 Interface “SC–MOPP” Choice of numerical METHOD

53 Optimal Distribution : “SUPPLIERS” - “PLANTS” Results obtained intersections: Interface “SC–MOPP”

54 Optimal Product Portfolio for “PLANTS” Results obtained intersections: Interface “SC–MOPP”

55 Costs Distributions on the “SUPPLAY CHAIN” elements Results obtained intersections: Interface “SC–MOPP”

56 Interface “SC–MOPP” Results Saving

57 Interface “SC–MOPP” Scheduling problems solution for “PLANTS”

58 Interface “SC–MOPP” Data Loading for Optimal scheduling

59 Interface “SC–MOPP” Optimal Scheduling for a chosen “PLANT”

60 Interface “SC–MOPP” Choice of Plant’s elements

61 Interface “SC–MOPP” XML Input File generation for MOPP

62 Interface “SC–MOPP” Visualition of generated XML file

63 Interface “SC–MOPP” Data for Optimal product portfolio

64 Interface “SC–MOPP” Data for “RECIPES”

65 Interface “SC–MOPP” Data for “RECIPES”

66 Interface “SC–MOPP” Data for “RECIPES”

67 Thank you for attention

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69 Optimal scheduling in campaign mode Choice campaign mode

70 Optimal scheduling in campaign mode

71 Optimal scheduling in campaign mode

72 Optimal scheduling in campaign mode

73 Optimal scheduling in campaign mode

74 Optimal scheduling in campaign mode

75 Optimal scheduling in campaign mode

76 Optimal scheduling in campaign mode

77 Optimal scheduling in campaign mode

78 Optimal scheduling in campaign mode

79 Optimal scheduling in campaign mode

80 Optimal scheduling in campaign mode

81

82 General structure of “Supply chain” using of SC-MOPP COSTOMERS SUPPLIERS MULTIPURPOSE PLANTS STORAGES DISTRIBUTORS Supply Chain Elements Market Demands for each costumers Determination of Optimal row materials supply to each plants Determination optimal product portfolio of each plants Determination optimal distribution between element of Supply Chain PROBLEM STATEMENT FOR PROFIT MAXIMIZATION

83 Mathematical formulation of the problem 1.Set of suppliers: 2.Set of plants: 3.Set of storagies: 4.Set of distributors: 5.Set of customers: 6.Set of products: 7.Matrix of available products in given plant: 8.Matrix of available capacity in given plant: I. Sets of data describing relationships “suppliers –customers”

84 9.Matrix of available preservation in given storage: 10.Matrix of available capacity in given storage: 11.Matrix of available operation of products in given distributors: 12.Matrix of available capacity in given distributors: 13.Matrix with customer requirements: Mathematical formulation of the problem

85 14.Matrix with customer requirements /max. quantity/: 15.Matrix with customer requirements /min. quantity/: 16.Matrix with suppliers availability to supply require row materials: 17.Matrix with quantity availability of suppliers to supply require row materials: 18.Matrix with available connect between suppliers and plants: 19.Matrix with available connect between plants and storagies : Mathematical formulation of the problem

86 20.Matrix with available connect between storages and distributors : 21.Matrix with available connect between distributors and customers : 22.Matrix with transport prices between distributors and customers : 23.Matrix with service prices in distributors centers : 24.Matrix with transport prices between storages and distributors centers /per 1product/: Mathematical formulation of the problem

87 25.Matrix with service prices in storages: 26.Matrix with transport prices between plants and storages : 27.Matrix with transport prices between suppliers and plants : /per unit product/ 28.Matrix with prices of raw material of suppliers without transport costs : 29.Matrix with data base about production expenses in plants : 30.Matrix with data base about final prices : 31.Vektor with scale coefficients about material quantities /per unit product/: Mathematical formulation of the problem

88 Set of Variables - Amount of n-th product, produced in the j-th plants - Ratios of raw material supply relevant to production of n-th product - Indicates the ratios of products q nj supplied to the SC warehouses - Indicates the ratios of stored products supply from the SC warehouses to the distributors - Indicates the ratios of product supplied from the SC distributors to the markets Mathematical formulation of the problem

89 III. Basic equations: 1.Require raw materials quantities on given product in all plants: 2. Quantities on given product in given storage which will be delivered from all plants: 3.Quantities on given product which will be delivered to given distributor center: 4.Quantities on given product which will be delivered to given customer: Mathematical formulation of the problem

90 IV. Price characteristics : 1.Subjection which described the prices on the exit of plants /production price/ : 2.Subjection which described the average prices on the exit of storages: 3.Subjection which described the average prices on the exit of distributors centers: 4.Subjection which described the final profit: Mathematical formulation of the problem

91 V. Constraints : District constraints : 1.Capacity constraints of suppliers : 2.Capacity constraints of storages: 3.Capacity constraints of distributors: 4.Capacity constraints of customers: 5.Constraints describing the balance between manufactured production and customer requirements: Mathematical formulation of the problem

92 6.Capacity constraints of plants : /only one supplier can deliver the raw materials/ Functional constraints: 1.Distribution proportion constraints between storages : 2.Distribution proportion constraints between distributors : 3.Distribution proportion constraints between customers : Factor constraints: Mathematical formulation of the problem

93 Objective function: Mathematical formulation of the problem

94 General structure of “Supply chain” using of SC-MOPP COSTOMERS SUPPLIERS MULTIPURPOSE PLANTS STORAGES DISTRIBUTORS Supply Chain Elements Market Demands for each costumers Determination of Optimal row materials supply to each plants Determination optimal product portfolio of each plants Determination optimal distribution between element of Supply Chain PROBLEM STATEMENT FOR PROFIT MAXIMIZATION