Problemas de programação de produção em indústrias de embalagens de papelão ondulado.
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Data
2018-07-31
Autores
Ferreira, Marcelo
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Universidade Estadual Paulista (Unesp)
Resumo
Nessa tese abordamos dois problemas reais identificados no processo produtivo de indústrias de embalagens de papelão ondulado, que denotaremos por Problema de Minimização de Trocas de Gramaturas e Rolos Corrugadores (PMTGRC) e Problema da Alocação de Bobinas no Corrugador (PABC). Ambos os problemas ocorrem no corrugador, máquina multiestágio que produz as chapas de papelão ondulado. O PMTGRC surge da necessidade de minimizar trocas de gramaturas e rolos corrugadores durante o processo de produção dos boletins, uma vez que cada boletim traz as gramaturas específicas das camadas da chapa, além do tipo de onda empregada no(s) miolos(s). O sequenciamento dos boletins impacta na quantidade de mudanças de gramaturas nos porta-bobinas e se haverátrocaderoloscorrugadoresparadoisboletinssubsequentes. Astrocasdegramaturas impactam em custos de transporte de bobinas e as trocas de rolos corrugadores impactam em perda de produtividade. Para o PMTGRC propomos quatro modelos inéditos de programação inteira capazes de integrar essas duas considerações. O PABC integra várias considerações relacionadas à alocação das bobinas no corrugador, como por exemplo, a minimização das sobras não aproveitáveis e das quantidades de consumos parciais, fatores que influenciam diretamente nos custos de produção. Um modelo linear inteiro misto inédito é proposto, determinando quais bobinas serão utilizadas em cada porta-bobinas. Além disso, propomos uma estratégia de sequenciamento das bobinas em cada porta-bobina, evitando paragens no corrugador. Uma série de testes computacionais utilizando instâncias geradas com base em dados reais foram realizados. Os resultados indicam que os modelos foram eficientes em tratar os problemas propostos.
In this thesis we approached two real problems identified over the productive process of corrugated cardboard industries, which we will denote as the Minimization of Converting Weights and Corrugators Problem (MCWCP) and the Corrugators Coil Allocation Problem (CCAP). Both of these problems happen in the corrugators, a multistage machine which produces corrugated cardboard. The MCWCP appears from the necessity to minimize changes of weight and corrugator rolls during the production process of the bulletins, since each one brings the specific layers’s weight of the sheets, besides the kind of wave put in the middle. The sequence of bulletins impact in the number of weight changes in the coil holders and if there will be corrugating rollers’s exchange for two following bulletins. The gramature’s exchanges impact in the costs of transportation and the corrugating rollers exchange causes lost in the productivity. We propose four whole programming models capable of integrating both considerations. The CCAP integrates many considerations related to the coils’s allocation on the corrugators, for example, the minimization of the non-usable leftovers and the amount of partial consumption, factors which influence directly on the production’s costs. A whole new mist linear model is proposed, determined which coil on the corrugators are going to be used in each coil holder. Besides this, we propose a sequel strategy for the coils in each coil holder, avoiding stops on the corrugators. A series of computation tests using instances created based on real data were made. The results indicate that the models were efficient in solving the problems.
In this thesis we approached two real problems identified over the productive process of corrugated cardboard industries, which we will denote as the Minimization of Converting Weights and Corrugators Problem (MCWCP) and the Corrugators Coil Allocation Problem (CCAP). Both of these problems happen in the corrugators, a multistage machine which produces corrugated cardboard. The MCWCP appears from the necessity to minimize changes of weight and corrugator rolls during the production process of the bulletins, since each one brings the specific layers’s weight of the sheets, besides the kind of wave put in the middle. The sequence of bulletins impact in the number of weight changes in the coil holders and if there will be corrugating rollers’s exchange for two following bulletins. The gramature’s exchanges impact in the costs of transportation and the corrugating rollers exchange causes lost in the productivity. We propose four whole programming models capable of integrating both considerations. The CCAP integrates many considerations related to the coils’s allocation on the corrugators, for example, the minimization of the non-usable leftovers and the amount of partial consumption, factors which influence directly on the production’s costs. A whole new mist linear model is proposed, determined which coil on the corrugators are going to be used in each coil holder. Besides this, we propose a sequel strategy for the coils in each coil holder, avoiding stops on the corrugators. A series of computation tests using instances created based on real data were made. The results indicate that the models were efficient in solving the problems.
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Palavras-chave
Programação inteira mista, Modelagem matemática, Indústria de embalagens de papelão, Corrugador, Mixed integer programming, Mathematical modeling, Corrugated cardboard industries, Corrugator