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Optimization of processes in textile industry: models and solution methods

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Author(s):
Victor Claudio Bento de Camargo
Total Authors: 1
Document type: Doctoral Thesis
Press: São Carlos.
Institution: Universidade de São Paulo (USP). Instituto de Ciências Matemáticas e de Computação (ICMC/SB)
Defense date:
Examining board members:
Franklina Maria Bragion de Toledo; Alistair Richard Clark; Bernardo Sobrinho Simões de Almada Lobo; José Fernando da Costa Oliveira; Debora Pretti Ronconi
Advisor: Franklina Maria Bragion de Toledo; Bernardo Sobrinho Simões de Almada Lobo
Abstract

In the practice of a spinning industry, the operational decisions of the production planning are determined by the hierarchical solution of the lot-sizing and scheduling problem and the blending problem of the cotton bales. The tasks are: to define the size, sequence, timing and allocation of each production lot and to select which cotton bales are used for production. Each of these problems represents a large challenge in planning the production. However, in order to better represent the production environment and to reach lower production costs, process industries (as the spinning industry) are integrating more and more of the production sub-problems into the planning. The aim of this thesis is to propose novel mathematical models and solution methods to assist the decision maker to plan the production at the operational level. Three formulations for the synchronized two-stage lot sizing and scheduling are proposed. A new method based on mathematical programming and metaheuristics is also developed to solve this sub-problem. In addition, the integration of the lot sizing and scheduling with decisions related to the raw materials (cotton bales) is analyzed. The novel models represent a more realistic lot sizing and scheduling for the spinning industry and process industries of similar production environment. The solution method finds good solutions to the mentioned problem and outperforms other state-of-the-art methods incorporated in commercial softwares. Moreover, the method is general enough to solve other optimization problems. The integrated lot-sizing, scheduling and blending prove that constraints related to the yarn quality influence the costs and the feasibility of the production planning. The integrated planning of these operations approaches the system considering the constraint relationship and defines more realistic production plans (AU)

FAPESP's process: 08/09953-2 - Optimization of process in textile industry: models and solution methods
Grantee:Victor Claudio Bento de Camargo
Support Opportunities: Scholarships in Brazil - Doctorate