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DOI 10.1007/s00170-007-1048-2
ORIGINAL ARTICLE
Received: 27 November 2006 / Accepted: 11 April 2007 / Published online: 24 May 2007
# Springer-Verlag London Limited 2007
Abstract In recent years, most researchers have focused on the end of this study, there will be a comparison of the
methods which mimic natural processes in problem solving. performance of the proposed method presented in this paper
These methods are most commonly termed “nature- and the branch and bound (B&B) method presented by
inspired” methods. Ant colony optimization (ACO) is a Neron et al. (Omega 29(6):501–511, 2001). The results
new and encouraging group of these algorithms. The ant show that the improved ACO method is an effective and
system (AS) is the first algorithm of ACO. In this study, an efficient method for solving HFS problems.
improved ACO method is used to solve hybrid flow shop
(HFS) problems. The n-job and k-stage HFS problem is one Keywords Ant colony optimization . Improved ant system .
of the general production scheduling problems. HFS Hybrid flow shop scheduling
problems are NP-hard when the objective is to minimize
the makespan [1]. This research deals with the criterion of
makespan minimization for HFS scheduling problems. The 1 Introduction
operating parameters of AS have an important role on the
quality of the solution. In order to achieve better results, a In a hybrid flow shop (HFS), machines are arranged into s
parameter optimization study is conducted in this paper. stages in series. In each stage k (k=1,..., s), there are mk
The improved ACO method is tested with benchmark identical machines in parallel. Job j (j=1,..., n) has to be
problems. The test problems are the same as those used by processed on any one machine at each stage. Job j has finite
Carlier and Neron (RAIRO-RO 34(1):1–25, 2000), Neron processing times at each stage (p1j, p2j,..., psj). Preemption
et al. (Omega 29(6):501–511, 2001), and Engin and Döyen is not allowed and each machine can process at most one
(Future Gener Comput Syst 20(6):1083–1095, 2004). At operation at a time. The objective is to minimize the
makespan. The hybrid flow shop problems have been
proved to be NP-hard [5] when the objective is to minimize
the makespan in the case of max(M(1), M(2))>1, where M(l)
K. Alaykýran is the number of machines at stage l.
Department of Industrial Engineering, Gazi University,
Ankara, Turkey
The branch and bound (B&B) method and heuristics are
e-mail: kalaykiran@yahoo.com the most often used methods to solve HFS problems
because of the NP-hard nature of the problem.
O. Engin (*) A previous study [6] which uses B&B as a solving
Department of Industrial Engineering, Faculty of Engineering,
Selçuk University (Alladdin Keykubat Kampüsü Selçuklu),
method shows that the minimum makespan is attained at
Konya 42079, Turkey least for one member of the set of schedules, called
e-mail: orhanengin@yahoo.com preferred schedules. Preferred schedules ensure less search-
ing effort. Later, a three-part B&B algorithm [7], which
A. Döyen
Department of Industrial Engineering, Boğaziçi University,
consists of lower bound (LB) calculation, branching, and
Istanbul, Turkey node elimination parts, has been presented. The LB values
e-mail: alper.doyen@boun.edu.tr found in the study have been improved by a genetic
542 Int J Adv Manuf Technol (2007) 35:541–550
algorithm (GA) [8]. Here, several heuristics have been study [11] has reduced the initial gap between upper and
introduced to compute an initial upper bound (UB), and lower bounds to half in a few minutes of running time.
then GA is used to improve that UB. Global LBs for Two polynomial bounded heuristic algorithms were
makespan (Cmax) minimization when it is not the case to developed by Gupta and Tunç [12] to find an acceptable
find optimal values have been proposed by Santos et al. [9]. solution for makespan minimization. It could solve prob-
In an effort to restrict the size of the search tree for a B&B lems with only two stages, where the first stage had only
method, a branching rule has been adopted, and 13 heuristic one machine and the second stage allowed multiple
methods have been used to generate an initial lower bound identical machines. Additionally, four heuristic algorithms
[10]. To increase the efficiency of B&B procedures, tests and have been presented to minimize makespan for the problem
time-bound adjustments based on energetic reasoning and with separable setup and removal times [12]. As a
global operations have been implemented [3]. A previous comparative study, three heuristic algorithms have been
Int J Adv Manuf Technol (2007) 35:541–550 543
presented and their results have been compared. The first Ant colony optimization (ACO) algorithms are multi-agent
two heuristic algorithms have applied the rules used by systems in which the behavior of each single agent, called
Campbell et al. [13] and the third algorithm was an an artificial ant, is inspired by the behavior of real ants
extension of a discussion presented by Gupta [14]. Another [27]. ACO algorithms are one of the most successful
comparative study [15] tests five different heuristics for examples of swarm intelligent systems [28], and have been
their performances of makespan and mean flow time applied to many classes of problems, ranging from the
criteria. The effects of problem characteristics and the classical traveling salesman problem to scheduling prob-
performance of heuristics have been examined by regres- lems. Ants are able to find good solutions to shortest path
sion analysis. The results have shown that structural problems between a food source and their home colony.
characteristics of the problems have a greater effect than ACO algorithms are inspired by the study of Charon and
the type of the employed heuristics on performance. Some Hudry [29] on a colony of Argentine ants to understand
of the researchers have studied a real-world problem that how ants can find the shortest path from their nest to the
has a particular structure (one machine in the first and third food source. The emergence of this shortest path selection
stages and two dedicated machines in stage two) [16]. Two behavior can be explained in terms of autocatalysis
α 0 1 2 3 4 5 6 7 8 9 10
β 0 1 2 3 4 5 6 7 8 9 10
ρ 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
544 Int J Adv Manuf Technol (2007) 35:541–550
Table 3 The best parameter set for the hybrid flow shop (HFS) (positive feedback) and differential path length, and it is
problem
made possible by an indirect form of communication,
α β ρ known as stigmergy [27]. It was found that the media used
to communicate among individuals’ information regarding
4 6 0.5 paths and used to decide where to go consists of pheromone
Problem LB Best Cmax with improved AS % difference of improved AS Best Cmax with B&B % difference of B&B
j10c5a2 88 88 0 88 0
j10c5a3 117 117 0 117 0
j10c5a4 121 121 0 121 0
j10c5a5 122 124 1.6 122 0
j10c5a6 110 110 0 110 0
j10c5b1 130 131 0.7 130 0
j10c5b2 107 107 0 107 0
j10c5b3 109 109 0 109 0
j10c5b4 122 124 1.6 122 0
j10c5b5 153 153 0 153 0
j10c5b6 115 115 0 115 0
j10c5c1 68 68 0 68 0
j10c5c2 74 76 2 74 0
j10c5c3 71 72 1 71 0
j10c5c4 66 66 0 66 0
j10c5c5 78 78 0 78 0
j10c5c6 69 69 0 69 0
j10c10b1 163 163 0 163 0
j10c10b2 157 157 0 157 0
j10c10b3 169 169 0 169 0
j10c10b4 159 159 0 159 0
j10c10b5 165 165 0 165 0
j10c10b6 165 165 0 165 0
j10c10c1 113 118 4 127 12.4
j10c10c2 116 117 0.8 116 0
j10c10c3 98 108 10 133 35.7
j10c10c4 103 112 8 135 31.1
j10c10c5 121 126 4 145 19.8
j10c10c6 97 102 5 112 15.5
j15c5a1 178 178 0 178 0
j15c5a2 165 165 0 165 0
j15c5a3 130 132 1 130 0
j15c5a4 156 156 0 156 0
j15c5a5 164 166 1 164 0
j15c5a6 178 178 0 178 0
j15c5b1 170 170 0 170 0
j15c5b2 152 152 0 152 0
j15c5b3 157 157 0 157 0
j15c5b4 147 149 1 147 0
j15c5b5 166 166 0 166 0
j15c5b6 175 176 0.5 175 0
j15c5c1 85 85 0 85 0
j15c5c2 90 90 0 90 0
j15c5c3 87 87 0 87 0
j15c5c4 89 89 0 90 1.1
j15c5c5 73 73 0 84 15.1
j15c5c6 91 91 0 91 0
j15c5d1 167 167 0 167 0
Int J Adv Manuf Technol (2007) 35:541–550 545
Table 4 (continued)
Problem LB Best Cmax with improved AS % difference of improved AS Best Cmax with B&B % difference of B&B
j15c5d2 82 86 4 85 3.7
j15c5d3 77 83 7 96 24.7
j15c5d4 61 84 37 101 65.6
j15c5d5 67 80 19 97 44.8
j15c5d6 79 79 0 87 10.1
j15c10a1 236 236 0 236 0
j15c10a2 200 200 0 200 0
j15c10a3 198 198 0 198 0
j15c10a4 225 228 1 225 0
j15c10a5 182 182 0 183 0.5
j15c10a6 200 200 0 200 0
j15c10b1 222 222 0 222 0
j15c10b2 187 188 0.5 187 0
j15c10b3 222 224 0.9 222 0
j15c10b4 221 221 0 221 0
trails [30]. This system works as follows: a moving ant The first and most common algorithm of ACO is the ant
drops some pheromone on the ground in varying quantities, system (AS) algorithm, which was proposed by Dorigo et
related to the quality and quantity of the food source; in this al. [36]. The formula of AS is as follows:
way, the track becomes marked. The following ants can a b
detect this substance and they make their choice due to the t ij ðt Þ hij
Pijk ðt Þ ¼ P ð1Þ
intensity of the pheromone trail. In ACO algorithms, this ½t il ðt Þa ½hil b
natural process is used to solve combinatorial optimization l2Nik
problems. In recent years, so many papers have been
published about ACO algorithms and so many new and where:
robust algorithms have been developed. In the literature, there
t ij(t) The intensity of the pheromone trail on the path
is a number of studies on scheduling problems by ACO. Some
between i and j at time t
of these studies which may be considered as the milestones of
ηij The heuristic value 1/dij (known as visibility), where
ACO literature on scheduling problems include: Stützle and
dij is the physical distance between i and j
Hoos [31] dealing with permutation flow shop scheduling
α The relative importance of the pheromone trail
problems with the objective of minimizing the makespan;
β The relative importance of visibility
Merkle and Middendorf [32] considering the permutation
k
scheduling problem; Chandrasekharan and Ziegler [33] Q L ðt Þ
considering the problem of scheduling in permutation flow Δt ij ðt Þ ¼
k
ð2Þ
0
shops by using ACO algorithms with the objective of
minimizing the sum of the total flow time of jobs; Shyu where:
et al. [34] considering the no-wait flow shop scheduling Lk(t) The length of the tour found by ant k
problem to minimize the total completion time with ACO; Q A constant
and Ying and Liao [35] considering the permutation flow
The pheromone updating rule [34] is as follows:
shop sequencing problem to minimize the makespan with
ACO. X
n
t ij ¼ ð1 pÞt ij þ Δt kij ð3Þ
k¼1
Table 6 Percentage differences (from lower bounds, LBs) due to the which is used to solve the HFS problems. The improved AS
problem sizes
algorithm is presented in the next section.
Problem type 10×5 10×10 15×5 15×10
3 The improved AS algorithm
Percentage difference 0.406 2.65 2.9375 2.4
3.00
to the problem sizes
2.50
2.00
Problem type
1.50
1.00
0.50
0.00
10x5 10x10 15x5 15x10
Problem type
Int J Adv Manuf Technol (2007) 35:541–550 547
Table 7 Percentage differences (from LBs) due to the machine layout the pheromone trail (α), the relative importance of visibility
type
(β), and the evaporation parameter (ρ). In order to achieve
Layout type a b c d better results, a parameter optimization study is conducted in
this investigation for the α, β, and ρ parameters. The number
Percentage difference 0.27 0.24 1.93 11.17 of ants and the number of tours are assumed to be 50 and
100, respectively, as in the literature.
The α and β parameters are selected in the interval [1,
10]. Eleven different values are determined from 0 to 10 by
Step 2 Solving the problem: increasing by one at each level. Parameter ρ is selected in
the interval [0, 1] by increasing by 0.1 at each of the levels.
Determine the tour number
The implementation of parameter optimization is full
Determine the ant number
factorial, thus, not all but four of Carlier and Neron’s [2]
Determine the α parameter
HFS problems are considered. These are the j15c5b1,
Determine the β parameter
j15c5d1, j15c5a2, and j15c5c5 problems. The parameter
Determine the ρ parameter
levels are shown in Table 2.
For each ant, determine a random beginning job: For each parameter set, 25 trials were handled, therefore,
For each tour: for each of the problems, a total of 11*11*11*25=33,275
runs were made. The average tours and the shortest tour
For each ant: values were evaluated.
Determine the next node by using Eq. 1 after The best parameter set found after parameter optimiza-
calculating the ηij value from Step 1 tion is shown in Table 3. These parameters were used in the
Determine the probability value solving of all of the test problems.
Carry out the pheromone updating by using Eqs. 2
and 3
5 Solutions to the HFS problems
Stop
The summarized flow chart for the improved ACO In order to evaluate the success of the algorithm on HFS
method is given in Fig. 1. problems, it was been run on 63 different benchmark
problems taken from Carlier and Neron [2]. The problem
sizes vary from 10 jobs×5 stages to 15 jobs×10 stages. The
processing times of the jobs have a uniform distribution in
4 Parameter test on HFS problems the range (3, 20). Three characteristics that define a problem
are the number of jobs, the number of stages, and the number
The operating parameters of AS play an important role in the of identical machines at each stage. For example, the notation
quality of the solution. The parameters of ACO include the of j15c10b1 means a 15-job, 10-stage problem. The letters j
number of ants, number of tours, the relative importance of and c are abbreviations for job and stage, respectively. The
8.00
4.00
2.00
0.00
a b c d
Machine Layouts
548 Int J Adv Manuf Technol (2007) 35:541–550
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