A Production Planning Model for Make-to-Order Foundry Flow Shop with Capacity Constraint

Abstract

The mode of production in the modern manufacturing enterprise mainly prefers to MTO (Make-to-Order); how to reasonably arrange the production plan has become a very common and urgent problem for enterprises’ managers to improve inner production reformation in the competitive market environment. In this paper, a mathematical model of production planning is proposed to maximize the profit with capacity constraint. Four kinds of cost factors (material cost, process cost, delay cost, and facility occupy cost) are considered in the proposed model. Different factors not only result in different profit but also result in different satisfaction degrees of customers. Particularly, the delay cost and facility occupy cost cannot reach the minimum at the same time; the two objectives are interactional. This paper presents a mathematical model based on the actual production process of a foundry flow shop. An improved genetic algorithm (IGA) is proposed to solve the biobjective problem of the model. Also, the gene encoding and decoding, the definition of fitness function, and genetic operators have been illustrated. In addition, the proposed algorithm is used to solve the production planning problem of a foundry flow shop in a casting enterprise. And comparisons with other recently published algorithms show the efficiency and effectiveness of the proposed algorithm.