A Hybrid Approach For Cross-Docking Scheduling: 1. Introduction
A Hybrid Approach For Cross-Docking Scheduling: 1. Introduction
A Hybrid Approach For Cross-Docking Scheduling: 1. Introduction
Indian Journal of Science and Technology, Vol 8(12), IPL010, June 2015 ISSN (Online) : 0974-5645
[email protected]
2
Department of Industrial Engineering, Iran University of Science and Technology, Tehran, Iran; [email protected]
Abstract
Background/Objectives: Cross-docking is an innovative logistical strategy, which means discharging the cargos from
in-bound trucks into the warehouse directly and saved automatically. This article investigates the scheduling of a distribution
system consisting of suppliers, cross-docks and the ultimate destinations. The aim of analyzing this problem is presenting a
scheduling model so that lateness, earliness and holding costs will be minimized. Methods/Statistical Analysis: Restrictions
are applied on the number of arrival and exit doors, departure time, release time, earliness, lateness, and the required space
for discharging. Since the offered model is NP-Hard and highly complicated, the hybrid form of firefly and genetic algorithms
is applied to solve the model. Results: Tuning the parameters performed and several numerical examples shows the appli-
ance of this model. Comparisons via ANOVA and interval plot show that hybrid form can act better than GA and FF in large
sizes. Conclusion/Application: The innovation of this article is thanks to its model type and solution method.
Keywords: Crossdocking, Hybrid Firefly and Genetic Algorithms, Logistics, Metaheuristic, Scheduling
Comprehensive explanations of solution methodology the trucks were available in the beginning of scheduling
based on hybridization of genetic algorithm and firefly horizon. The authors of this article proved that the prob-
algorithm is discussed in section 4. Section 5 is dedicated lem in question is NP Hard; hence, a heuristic approached
to tuning the parameters and numerical examples. Finally based on Johnsons law was suggested for solving it.
in section 6 conclusions is presented and some directions Vahdani and Zandieh6 considered the previous prob-
for future work are discussed. lem and used 5 meta-heuristic approaches for solving the
model. The answer of Problem3 was used as the initial
answer. It was proved that these meta-heuristic methods
2. Literature Review improve the results, with slightly longer run time.
There are not many researches about cross-docking. For Boysen & Fliedner1 were presented an optimizing
example up until 2005, no article has been published model. This model assigns fixed schedule for out-bound
about short-term scheduling for the trucks1. The current trucks, with the aim to minimize the number of delayed
part of this study has a brief shot about several researches transportations. This model considered the travel time
on cross-docking. McWilliams et al.2 were considered in- between arrival and exit doors as well. They also proved
bound truck scheduling for cross-docks of postal parcels that this model is NP Hard.
in postal industries. In this system, the parcels were con- In order to reduce the number of goods passing standby
veyed to out-bound trucks using fixed conveyor belt. The area, a sequence was presented for in-bound and out-bound
objective of this scheduling model was minimizing the trucks by Forouharfard and Zandieh7. Also Imperialist
time between discharging the first parcel till loading the Competitive Algorithm was used for solving the problem.
last postal parcel. Also, in order to detect the amount of Vahdani et al.8 were considered a similar problem, and for-
delays, a solution based on genetic algorithm was presented. mulated it as a mixed-integer programming model. They
In the end, numerical calculations showed that their sug- used genetic algorithm and electro-magnetism algorithm
gested method has lead to significant reduction of delays. for solving the problem. Two meta-heuristic algorithms,
Yu and Egbelu3 studied a cross-docking system with one including simulated annealing, and variable neighbor-
arrival and one exit door. The objective was minimizing hood algorithm were used for solving the similar problem
the total operation time. The cargos were considered to be by Soltani and Sajadi9. Arabani et al.10 assumed that all out-
interchangeable. Assigning the cargos to trucks and the bound trucks have due date. The target function aimed
travel-time between doors were supposed to be already to minimize the earliness and lateness for trucks. Three
determined. The only differences were the truck inter- meta-heuristic approaches were demonstrated for solv-
change time, and optional sequence for discharging the ing the problem. These approaches included genetic
in-bound trucks. In the end, the problem was formulated algorithm, evolutionary algorithm, and particle swarm
with a mixed-integer model, and solved using a heuristic algorithm. A similar problem was considered by Arabani
algorithm. In Wang and Regan4 a scheduling model was et al11. The time span was sectioned into several parts. This
contrived for in-bound trucks. Several dispatching rules, problem was formulated as an NP Hard model. It used
required for real dynamic environments, were presented break down approach, including two segments: 1. Finding
as follows: Among the few in-bound trucks that are wait- a fixed sequence for in-bound trucks; 2. Determining the
ing for discharging their cargos, only the first truck was sequence of out-bound trucks. Those subsets could find
considered. The next trucks were selected with First- a near-optimum answer with heuristic algorithms, and
com first-served policy. This method pays attention the accurate answer with Dynamic Planning Approach.
only to the standby time of in-bound trucks, which does Alpan et al.12 were considered a cross-dock with several
not influence the whole system significantly. In the end, arrival and exit doors. The aim of analyzing this problem
2 algorithms were introduced for solving the problems. was finding an optimum or near-optimum answer for the
Chen and Lee5 investigated the problem of cross-docking scheduling model, so to minimize the total costs of con-
flow shop scheduling aimed to find the optimum sequence veyance operations. Agustina et al.13 developed a model for
of in-bound and out-bound trucks that could minimize scheduling a cross-dock with delivery time window and
makespan. The discharge and loading times were con- temporary storage. Their target function aims to minimize
sidered to be different for each truck. In some cases, this distribution cost and holding cost. The resulted model was
included travel time as well. Also, it was assumed that all Mixed-Integer. They used Lingo for solving the model.
2 Vol 8 (12) | June 2015 | www.indjst.org Indian Journal of Science and Technology
Tokhmehchi Nafiseh and Makui Ahmad
Li et al. (2012) introduced 3 different aspects of reloaded to outgoing trucks, or stay in the warehouse for
ptimum planning, including trucks-grouping, clustering,
o a period, usually less than 24 hours. Other conditions and
and in the end determining the sequence of trucks and assumptions in this problem are as follows:
assigning the trucks to the docks in cross-docking system. Unlike the time of exiting from warehouse that is
McWilliams and McBride13 used beam search algorithm variable, the arrival time to the warehouse is already
for solving the problem of scheduling postal parcel distri- determined.
bution centers, with the aim to minimize the time span of The warehouse space for discharging the incoming
the transfer operation in the terminal. They finally com- trucks is limited, but it is unlimited for outgoing trucks.
pared their suggested algorithm with other approaches. The number of incoming and outgoing trucks is limited.
Bellanger et al.14 were used a compound 3-step flow shop
model with aim to minimize completion time. They also 3.1 Notations, Parameters and Variables
used branch and bound algorithm. This article inves-
The following notations, parameters, and variables are
tigates the problem of truck scheduling in uncertainty
used for mathematical model of the problem:
conditions of truck arrival for in-bound trucks. Buijs et
al.15 focused on the problem of correlation among dif- i Index of items i = 1, 2, , I
ferent aspects of cross-docking problem, with the aim to n Index of inbound doors n = 1, 2, , N
support and develop the future practical decisions. They m Index of outbound doors m = 1, 2, , M
also presented an overall classification of decision trends zi Earliest delivery time for item i (hours)
in this area. Miao et al.16 used adaptive tabusearch to solve di Latest delivery time for item i (hours)
the problem of contriving a cross-docking management vi Arrival time for item i (hours)
system. Some numerical tests proved that the suggested a Earliness cost rate
solution, both with regards to effectiveness and efficiency, b Lateness cost rate
overcomes CPLEX solution.
d Inventory holding cost rate
In previous models of cross-dock scheduling, the
H Planning horizon h = 1, 2, , H (hours)
discharge area of in-bound trucks was considered to be
fi Required space for item i (m2)
unlimited, but in the real industrial world such condition
F Total space in in-bound yard (m2)
is completely impossible. In order to address this research
gap, a mathematical model was presented. The mathemati- Decision Variables:
cal model of this article is a development to13 model. Since ri Release timetime for item i (hours)
the previous model was NP Hard, the new one is obviously ai Departure time for item i (hours)
NP Hard as well. We can use metaheuristic algorithms for ei Earliness for item i (hours)
solving this problem. The difference of the mathematical ti Lateness for item i (hours)
model presented in this article, with the one suggested xinh If item i loaded at inbound dock door n at time h = 1;
by 13 was considering the assumption of having limited xinh = 0, otherwise
discharge space. This model minimized the earliness and ximh If item i unloaded at outbound dock door m at time
lateness costs, as well as holding costs. Additionally, it h =1; ximh = 0, otherwise
considers the condition of limited discharge space.
In the next part we will introduce the mathematical
3.2 Formation of the Model
model and its conditions.
The mathematical model of the problem becomes:
3.The Suggested Mathematical Minimize
Model I I I
TC = a ei + b ti + d (ai - ri ) (1)
In the beginning of this plans time-scope, the retailers i =1 i =1 i =1
Vol 8 (12) | June 2015 | www.indjst.org Indian Journal of Science and Technology 3
A Hybrid Approach for Cross-Docking Scheduling
H M
For larger scales, other solutions must be contrived.
x
h =1 m=1
imh = 1 i = 1, 2, , I (3)
This article uses Hybrid form of Firefly Algorithm and
Genetic Algorithm as a solution method; therefore, in
N I
this section a brief description of each innovative solu-
x
n =1 i =1
inh N h = 1, 2, , H (4)
tion will be raised. In each section, the solution structure
will be reviewed. In the end the hybrid solution will be
M I
suggested.
x
m =1 i =1
imh M , h = 1, 2, , H (5)
N I
4.1 Genetic Algorithm
f x
n =1 i =1
i inh F h = 1, 2, , H (6) Genetic Algorithm (GA) is a Search_algorithm heuris-
tic belong to the larger class of evolutionary algorithms
ai H, i = 1, 2, , I (7) (Gen, 1997). In this approach, a random solution will be
selected initially. Afterwards, the fitness function value
vi ri ai, i = 1, 2, , I (8) will be calculated for each chromosome of the initial pop-
ulation. A suitable number of chromosome pairs shall be
ai - di ti - ei, i = 1, 2, , I (9) selected in this phase according to their fitness levels, so
to be used in later steps.
zi - ai ti - ei, i = 1, 2, , I (10)
In the next phase, crossover operator with probability
xinh, ximh = 0, 1 (11) of Pc will act upon the parent chromosomes, and com-
bines them to create new chromosomes (offspring). Then
ri, ai, ei, ti 0 (12) mutation with probability of Pm will happen on the chro-
mosomes created from crossover operation. Actually, by
The objective function of this problem is regarded changing the bits of these chromosomes, a new way for
as cost, and consists of 3 elements: Earliness penalty entering new data will be achieved. Then, in order to eval-
cost, lateness penalty cost, and cargo warehousing cost. uate the offspring, the fitness level of new chromosomes
Equation 2 indicates that every cargo uses only one arrival shall be calculated.
door for discharging. In the next level, a new population will be selected for
Constraint 3 guarantees that each cargo will use only the input of next phase. If the end conditions of algorithm
one exit door for reloading. Constraint 4 shows that the happen, the algorithm will end up; otherwise, the avail-
numbers of discharging procedures are fewer than the able population will be used as the input population of
total number of arrival doors. Constraint 5 makes sure the next phase.
that the number of reloading procedures will not exceed
the number of exit doors.
4.1.1 Initial Population
Next restrictions guarantee that the space required
for discharging in-bound cargos is limited. Constraint 7 In this paper, just like many genetic problems, the initial
demonstrates departure time is within the time scope of population is created randomly. The reason is creating a
the plan. Constraint 8 displays that release time is a num- large range of solutions. Of course the information from
ber between arrival time and departure time. Constraints systems users can be used as well. Their suggestions and
9 and 10 are respectively used for determining earliness comments might be applied to the initial population. An
and lateness. Equations 11 and 12 display the range of accurate solution shall also help.
decision variables.
4.1.2 Chromosome Structure
According to the decision variables of this model, the
4. Solution Method
following chromosome structure is suggested. Each row
Like mentioned before, the mathematical model of this indicates the variable values for one type of product. For
problem is NP Hard (Garey & Johnson, 1979). It has example the elements of second row are respectively:
complicated search space. In other words, accurate solu- Release time, departure, earliness, and lateness of product 2.
tion can be available only for small scales of this problem. The last 2 indexes show having or not having discharged
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Tokhmehchi Nafiseh and Makui Ahmad
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A Hybrid Approach for Cross-Docking Scheduling
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