Enhancing industrial efficiency in an integrated lot sizing and scheduling problem

Manufacturing Engineering Laboratory of Tlemcen (MELT), University of Tlemcen, BP 230 Tlemcen, Algeria

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Received: 1 January 2025
Accepted: 6 April 2026

Abstract

This study investigates an integrated production planning and scheduling problem within a complex industrial environment featuring non-identical parallel production lines. It focuses on reducing the impact of downtime, which incurs substantial setup costs. To this end, we introduce advanced transition mechanisms between production periods, motivated by real-world industrial practices, such as setup carryover and setup crossover, in order to enhance inter-period coordination, reduce operational disruptions, and improve overall system efficiency. A mixed-integer mathematical formulation is developed and solved using CPLEX for medium-scale instances, while a Simulated Annealing metaheuristic is designed to handle large-scale cases. The proposed solution framework yields realistic and cost-efficient plans that jointly minimize downtime-related costs, setup costs, production costs, and inventory holding costs.