European Journal of Operational Research 125 (2000) 440±449
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Theory and Methodology
On three-machine ¯ow shops with random job processing times Jerzy Kamburowski
*
Department of Information Systems and Operations Management, The University of Toledo, Toledo, OH 43606-3390, USA Received 1 May 1998; accepted 1 February 1999
Abstract The paper deals with scheduling n jobs on three machines in JohnsonÕs ¯ow shops. The job processing times are assumed to be independent random variables, and the problem is to minimize stochastically the makespan. Using a convenient makespan representation, we present sucient conditions on the job processing time distributions which imply that the makespan becomes stochastically smaller when two adjacent jobs in a given job sequence are interchanged. They lead, in particular, to an extension of TalwarÕs rule known for two-machine stochastic ¯ow shops with exponential job processing times. Extensions of other results are also included. Ó 2000 Elsevier Science B.V. All rights reserved. Keywords: Stochastic scheduling; Flow shop; Makespan; Stochastic order relation
1. Introduction Consider a shop which has m 3 machines and must process n jobs, f1; 2; . . . ; ng, available at time zero. Each job has to be processed ®rst on machine A, next on B, and last on C. Moreover, no machine can process more than one job at a time, no preemption is allowed, all setup times are included into the job processing times, and there is unlimited intermediate storage in between the machines. The problem, F3|prmu|Cmax , is to determine a job sequence (permutation) that minimizes the com-
*
Tel.: +1-419-530-4361; fax: +1-419-530-7744. E-mail address:
[email protected] (J. Kamburowski).
pletion of the last job, the so-called makespan. Recall that for m 2 and m 3 permutation schedules have been proven to be optimal among all schedules, but the shortest schedule may have dierent job orderings on dierent machines for m > 3 [1,2]. Recall also that the problem of minimizing the makespan in permutation ¯ow shops is strongly NP-hard for m P 3 [3]. Assume that Ak , Bk and Ck are independent random variables representing the processing times of job k on machines A, B and C, respectively. The stochastic counterpart of F3|prmu|Cmax is to determine a job sequence which minimizes the makespan in a certain stochastic sense, for example, in the sense of the expected value or the stochastic order. (A random variable X is smaller than another random variable Y in the sense of the
0377-2217/00/$ - see front matter Ó 2000 Elsevier Science B.V. All rights reserved. PII: S 0 3 7 7 - 2 2 1 7 ( 9 9 ) 0 0 2 2 2 - 2
J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
441
stochastic order, written X 6 st Y , if P
X > t 6 P
Y > t for every t.) To follow pairwise job interchange arguments for two adjacent jobs i and j, let p1
q; i; j; x and p2
q; j; i; x be two job sequences, where q and x are subsequences of jobs excluding i and j, and assume that M1 and M2 denote the makespans of p1 and p2 , respectively. Ku and Niu [4] presented the following condition in the case of F2|prmu|Cmax :
can be regarded as a generalization of (1), and its proof clearly indicates how to determine an analogical condition for Fm|prmu|Cmax . We show, in particular, that if TalwarÕs rule applied to A and B, and B and C yields the same job sequence, then this sequence stochastically minimizes the makespan. Simple proofs and extensions of the results of [10,11] are also included.
if; for all a and b in the supports of Ai Aj and
2. The makespan representations
Bi Bj ; min
Aj ; Bi jAi Aj a; Bi Bj b P st min
Ai ; Bj jAi Aj a; Bi Bj b; then M1 6 st M2 :
1
A simple and complete proof of this condition was given in [5]. Using (1), Ku and Niu proved the optimality of TalwarÕs [6±8] scheduling rule for exponentially distributed job processing times, which, similarly as JohnsonÕs rule, states that job i precedes job j if E
min
Aj ; Bi > E
min
Ai ; Bj :
2
As noted in [4,6±8], if ak and bk are the shape parameters of Ak and Bk , that means E
Ak 1=ak and E
Bk 1=bk ; then the rule (2) is equivalent to job i precedes job j if ai ÿ bi > aj ÿ bj :
3
Some special cases of the stochastic F2|prmu|Cmax problem were studied in [5,7±10]. Frostig and Adiri [11] showed a stochastic counterpart of SzwarcÕs [12] eciently solvable special case for F3|prmu|Cmax . Some results pertaining to m-machine stochastic ¯ow shops with identical machines were obtained in [10]. Excellent overviews of rather limited research on stochastic ¯ow shops can be found in [13], and in Chapter 13 of [14] written by Righter. In this paper we derive convenient representations and graphical illustrations of the makespans M1 and M2 in the case of F3|prmu|Cmax . They lead to a sucient condition for M1 6 st M2 which lays a theoretical foundation to follow pairwise job interchange arguments in the stochastic F3|prmu|Cmax problem. The proposed condition
Recall that when the jobs of a given sequence go through a ¯ow shop in the reverse order and in the opposite direction (®rst on C, next on B, and last on A), then the makespans of both sequences are the same [13, p. 96]. By the reverse sequence we mean the sequence de®ned above. For given job sequences p1
q; i; j; x and p2
q; i; j; x, denote their reverse sequences by p1 and p2 . Thus, M1 and M2 stand for the makespans of p1 and p1 , and p2 and p2 , respectively. We assume that all jobs are processed as soon as possible (without unecessary idle-times) under p1 , p1 , p2 and p2 . The following theorem shows convenient representations of M1 and M2 . Theorem 1. The makespans M1 and M2 can be represented as follows: M1 Aq Cx Aij Bij Cij ÿ V1
and
M2 Aq Cx Aij Bij Cij ÿ V2 ; where V1 and V2 are the shortest path lengths in the networks of Fig. 1, and Aq
X
Ak ;
k2q
Bij Bi Bj ;
Cx
X
Ck ;
Aij Ai Aj ;
k2x
Cij Ci Cj ;
and QAB (QAC ) is the additional time after Aq necessary to complete the processing of the jobs of q on B (C) under p1 and p2 , and QCB (QCA ) the additional time after Cx necessary to complete the processing of the jobs of x on B (A) under p1 and p2 :
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J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
Fig. 1. Shortest path networks for computing V1 and V2 :
Proof. Consider the makespan M1 of p1 and p1 . It is well-known that the makespan of a given job sequence can be represented by the longest path length in an acyclic network, see e.g., [13, p. 95]. For the de®ned times Aq ,Cx , QAB , QAC , QCB and QCA , the makespan M1 is Aq R1 Cx ; where R1 is the longest path length in the network of Fig. 2a. Since the networks of Figs. 2a
and b have the same path lengths, R1 is also the longest path length in the network of Fig. 2b. It suces now to extract the term Aij Bij Cij from R1 and observe that R1 Aij Bij Cij ÿ V1 , which veri®es the representation of M1 . When we switch i and j and notice that Aji Aij ; Bji Bij and Cji Cij , one obtains the representation of M2 .
J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
443
Fig. 2. Longest path networks for computing R1 :
Below we present some interpretations for the case of p1 and p1 ; analogous interpretations are valid for the case of p2 and p2 . Let S1 min
Aj Bj ; Bi Ci ; Aj Ci , that is, S1 is the shortest path length in the subnetwork restricted to heavy arcs in the network representing V1 . Then Aij Bij Cij ÿ S1 is the makespan of
i; j. S1 can be interpreted as the time savings from allowing jobs i and j to overlap on A, B and C under
i; j. Clearly, if i and j are the only jobs in the system, and they are not allowed to overlap, then their processing time would be
Aij Bij Cij . It is interesting to observe that either S1 min
Aj ; Bi min
Bj ; Ci or S1 min
Aj Bj ; Bi Ci ; and min
Aj ; Bi min
Bj ; Ci 6 min
Aj Bj ; Bi Ci :
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J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
The terms min
Aj ; Bi and min
Bj ; Ci can be interpreted as the time savings from allowing jobs i and j to overlap on A and B, and B and C under
i; j. On the other hand, min
Aj Bj ; Bi Ci is the corresponding time saving when B can be regarded as a non-bottleneck machine, or equivalently, the jobs are processed on two machines A and C, while Bk denotes the time lag between the completion of job k on A and its start on C. Moreover, R1 Aij Bij Cij ÿ V1 is the maximum of the times needed to process jobs i and j under p1 and p1 . Therefore, V1 can be interpreted as the time savings from allowing jobs i and j to overlap on A, B and C under p1 and p1 . Observe that V1 6 S1 , that is, the release times Aq QAB ; Aq QAC ; Cx QCB and Cx QCA may reduce the time savings S1 which are possible when i and j are the only jobs in the system. We also have: Aq Aij Bij ÿ min
Aij ÿ QAB ; min
Aj ; Bi the completion time of job j on B under p1 , Cx Cij Bij ÿ min
Cij ÿ QCB ; min
Bj ; Ci the completion time of job i on B under p1 , Aq Aij Bij Cij ÿmin
S1 ; Aij ÿQAB min
Bj ;Ci ; Aij Bij ÿQAC the completion time of job j on C under p1 , and Cx Aij Bij Cij ÿmin
S1 ;Cij ÿQCB min
Aj ;Bi ; Cij Bij ÿQCA the completion time of job i on A under p1 : From Theorem 1 one can easily derive the following result. Corollary 1. Sufficient conditions for M1 6 M2 are (i) V1 P V2 : (ii) min
Aj ; Bi P min
Ai ; Bj ; min
Bj ; Ci P min
Bi ; Cj ; and S1 P S2 [15].
Bj ; Ci P (iii) min
Aj ; Bi P min
Ai ; Bj , min
Bi ; Cj , and min
Aj ; Ci P min
Ai ; Cj [15]. Moreover, ((ii) () (iii)) ) (i).
3. Sucient conditions for job interchange in the stochastic case Assume that the job processing times Ak , Bk and Ck are independent random variables. For
convenience, the conditional random variable X jY y is often denoted by X jy. Theorem 2. Sufficient conditions for M1 6 st M2 are (i) V1 jh P st V2 jh for all h in the support of H
QAB ; QAC ; QCB ; QCA ; Aij ; Bij ; Cij : (ii) min
Aj ; Bi ja; b P st min
Ai ; Bj ja; b, and min
Bj ; Ci jb; c P st min
Bi ; Cj jb; c, min
Aj ; Ci ja; c P st min
Ai ; Cj ja; c for all a, b and c in the supports of Aij , Bij and Cij . Moreover, Condition (ii) implies Condition (i). Proof. To prove that Condition (i) implies M1 6st M2 , note ®rst that Aq and Cx are stochastically independent, Aq and V1 , and Aq and V2 , are dependent on QAB and QAC , while Cx and V1 , and Cx and V2 , are dependent on QCB and QCA . Moreover, X Pst Y if, and only if, ÿX 6st ÿ Y , and the stochastic order is closed under convolution. Therefore, the use of Theorem 1 leads to M1 jh Aq jqAB ; qAC Cx jqCB ; qCA a b c ÿ V1 jh 6 st Aq jqAB ; qAC Cx jqCB ; qCA a b c ÿ V2 jh M2 jh; and unconditioning gives the desired result (the order `` 6 st '' is closed under mixtures). To show that Condition (ii) implies (i), observe ®rst that min
Aj ; Bi jh min
Aj ; Bi ja; b; min
Ai ; Bj jh min
Ai ; Bj ja; b; min
Bj ; Ci jh min
Bj ; Ci jb; c; min
Bi ; Cj jh min
Bi ; Cj jb; c; min
Aj ; Ci jh min
Aj ; Ci ja; c; min
Ai ; Cj jh min
Ai ; Cj ja; c: Furthermore, under condition H h, V1 and V2 can be represented as V1 jh min
S1 ; b c ÿ qCA ; a b ÿ qAC jh; V2 jh min
S2 ; b c ÿ q ; a b ÿ qAC jh; CA
J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
where S1 jh and S2 jh are the shortest path lengths in the networks shown in Fig. 3a and b, respectively, with d a ÿ qAB and e c ÿ qCB . Therefore, to prove that Condition (ii) implies Condition (i), it suces to show that S1 jh Pst S2 jh for all h in the support of H. This will be accomplished by verifying S1 jh Pst S 0 jh P st S 00 jh Pst S2 jh, where S 0 jh and S 00 jh are the shortest path lengths in the networks depicted in Fig. 3b and c, respectively. We have S1 jh min
min
Aj ; Bi ; d min
Ci ; e; min
Aj ; d Bj jh
min
min
Aj ; Bi ; d min
Ci ; e; min
a ÿ Ai ; d Bj jh P st min
min
Ai ; Bj ; d min
Ci ; e; min
a ÿ Ai ; d Bj jh min
min
Ai ; Bj ; d min
Ci ; e; min
Aj ; d Bj jh S 0 jh min
min
Ci ; Aj ; d; e Bj ; min
Ai ; d min
Ci ; ejh min
min
Ci ; Aj ; d; e Bj ; min
Ai ; d min
c ÿ Cj ; ejh
Fig. 3. Shortest path networks for computing S1 jh, S 0 jh; S 00 jh and S2 jh.
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J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
E
min
X2 ; Y1 P E
min
X1 ; Y2
P st min
min
Cj ; Ai ; d; e Bj ; min
Ai ; d min
c ÿ Cj ; ejh
implies
min
min
Cj ; Ai ; d; e Bj ;
min
X2 ; Y1 jx; y P st min
X1 ; Y2 jx; y
min
Ai ; d min
Ci ; ejh;
for all x and y in the supports of X and Y.
00
S jh min
min
Bj ; Ci ; e min
Ai ; d; Bj min
Cj ; ejh min
min
Bj ; Ci ; e min
Ai ; d; bij ÿ Bi min
Cj ; ejh P st min
min
Bi ; Cj ; e min
Ai ; d;
Proposition 1. Let the job processing times Ak , Bk and Ck be independently and exponentially distributed random variables with the shape parameters ak , bk and ck , respectively. Then a sufficient condition for M1 6st M2 is a i ÿ b i P a j ÿ bj
and
bi ÿ ci P bj ÿ cj :
4
bij ÿ Bi min
Cj ; ejh min
min
Bi ; Cj ; e min
Ai ; d; Bj min
Cj ; ejh S2 jh:
Remark 1. Theorem 2(ii) can be regarded as a stochastic counterpart of Corollary 1(iii). The stochastic order Pst assumed in Conditions (i) and (ii) of Theorem 2 can be weakened by the increasing concave order Picv , which leads then to M1 6icx M2 , where 6icx stands for the increasing convex order; see e.g. [14] for de®nitions. Such replacement seems to be desirable when one only seeks to minimize the expected makespan, because of M1 6st M2 ) M1 6icx M2 ) E
M1 6 E
M2 . The proposed proof shows rather clearly how Theorem 2 can be generalized in the case of Fm|prmu|Cmax . Namely, to secure M1 6st M2 , the conditions analogous to (1) must hold then between any pair of machines. This is not any surprise because similar conditions are necessary in the deterministic case [16].
Proof. For independently and exponentially distributed random variables X and Y, min(X,Y) is exponentially distributed with the expected value
Eÿ1
X Eÿ1
Y ÿ1 . Therefore, (4) can be rewritten as E
min
Aj ; Bi P E
min
Ai ; Bj and E
min
Bj ; Ci P E
min
Bi ; Cj . Moreover, (4) that is, to leads to a i ÿ c i P aj ÿ c j , E
min
Aj ; Ci P E
min
Ai ; Cj . Therefore, the use Lemma 1 makes Theorem 2(ii) applicable, which completes the proof. Corollary 2. Assume that the job processing times are independently and exponentially distributed random variables. If Talwar's rule applied to machines A and B, and B and C yields the same job sequence, then this sequence stochastically minimizes the makespan. Remark 2. Rather surprisingly, Corollary 2 includes a stronger result than could be stated in the deterministic case; compare with Corollary 1(iii). Clearly, for the exponential case, E
min
Aj ; Bi E
min
Ai ; Bj
4. Special cases The lemma below is needed to extend TalwarÕs rule (3) to the case of three machines. Lemma 1 [4]. If X1 , X2 , Y1 , and Y2 are independently and exponentially distributed random variables, X X1 + X2 and Y Y1 +Y2 , then
and E
min
Bj ; Ci E
min
Bi ; Cj imply E
min
Aj ; Ci E
min
Ai ; Cj : In the deterministic case, however,
J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
min
Aj ; Bi min
Ai ; Bj
bility distribution. Then from Theorem 2 and Proposition 2, one obtains the following result.
and
Corollary 3 [10]. If the processing times of all jobs are either deterministic or independent and exponential random variables, and Aj st Bj st Cj for all j, then the makespans of all job sequences are stochastically equal, that is, the jobs can be processed in any order.
min
Bj ; Ci min
Bi ; Cj do not imply min
Aj ; Ci min
Ai ; Cj [15]. Let p be a TalwarÕs (A,B)-sequence, that is a sequence satisifying TalwarÕs rule on machines A and B. A subsequence of p is said to be a segment if ai ÿ bi aj ÿ bj for all jobs i and j
i 6 j belonging to g. To check whether of the optimal sequence of Corollary 2 exists, it suces to ®nd ®rst a TalwarÕs (A; B)-sequence, and next reorder all segments according to TalwarÕs rule applied to B and C. If the resulting sequence is a TalwarÕs (B; C)-sequence, then it is optimal. If none of the sequences is both TalwarÕs (A; B)and (B; C)-sequence, we propose to schedule jobs according to the following heuristic rule:
The following result is valid under weaker assumptions than those imposed above. Proposition 2. Let the processing times of all jobs be either deterministic or independent and exponential random variables, and let either Aj st Bj or Bj st Cj for all j. If the jobs are renumbered to satisfy E
min
Aj ; Ci P E
min
Ai ; Cj for all i < j, then sequence
1; 2; . . . ; n stochastically minimizes the makespan. Proof. Let Aj st Bj for all j. Then for both the deterministic and exponential cases, min
Aj ; Bi ja; b st min
Ai ; Bj ja; b; and
job i precedes job j if
E
min
Aj ; Ci P E
min
Ai ; Cj
ai bi =
ai bi ÿ bi ci =
bi ci P aj bj =
aj bj ÿ bj cj =
bj cj :
447
5
The rule (5) is motivated by the well-known and widely applied JohnsonÕs heuristic rule for the deterministic case: job i precedes job j if min
Aj Bj ; Bi Ci P min
Ai Bi ; Bj Cj :
6 However, (5) cannot be completely regarded as a stochastic counterpart of (6), because in deriving (5) the distributions of Ak Bk and Bk Ck have been approximated by the exponential distributions with the means E
Ak E
Bk and E
Bk E
Ck . As in [10], assume that the machines are identical in the sense that for each job its processing times on dierent machines have the same proba-
implies min
Aj ; Ci ja; c P st min
Ai ; Cj ja; c; which is equivalent to min
Bj ; Ci jb; c P st min
Bi ; Cj jj; c: Therefore, Theorem 2(ii) is applicable. The case Bj st Cj for all j is symmetric. It should be pointed out here that in the general case, Ai st Bi and Aj st Bj only imply min
Aj ; Bi st min
Ai ; Bj ; but not min
Aj ; Bi ja; b st min
Ai ; Bj ja; b: Szwarc [12] presented an eciently solvable special case for the deterministic three-machine problem. He showed that sequence
1; 2; . . . ; n is
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J. Kamburowski / European Journal of Operational Research 125 (2000) 440±449
optimal if Ai 6 Aj ; Bi Bj ; Ci P Cj for all i < j. A stochastic version of this case was proposed by Frostig and Adiri [11] who veri®ed Proposition 3 using rather lengthy arguments. Recall that a continuous random variable X with density f is said to be smaller than another continuous random variable Y with density g in the sense of the likelihood ratio order, written X 6lr Y , if f(t)/g(t) is non-increasing in t over the union of supports of X and Y. Recall also that X 6lr Y ) X 6st Y ) E
X
Y : Proposition 3 [11]. If the jobs can be renumbered to satisfy Ai 6 lr Aj ; Bi st Bj ; Ci P lr Cj for all i < j, then sequence
1; 2; . . . ; n stochastically minimizes the makespan. Proof. The proof is obvious in light of Theorem 2(ii) and the following result. Lemma 2 [4]. If X and Y are independent random variables such that X 6lr Y , then X jX Y z 6lr Y jX Y z for all z: The next lemma is needed to extend the result of [11]. Lemma 3 [14, p. 384]. Let X and Y be independent random variables, and U a bivariate function U : R2 ! R such that U
x; y ÿ U
y; x is nondecreasing in x. Then X Pst Y implies E
U
X ; Y P E
U
Y ; X : When we are only interested in minimizing the expected makespan, one can employ the following result. Proposition 4. If the jobs can be renumbered to satisfy Ai 6st Aj ; Bi st Bj ; Ci Pst Cj for all i < j, then sequence
1; 2; . . . ; n has the minimum expected makespan.
Proof. Suppose Aj Pst Ai ; Bi st Bj , and Ci Pst Cj , and i and j are adjacent. It suces to show that E
V1 P E
V2 . Note here that X 6st Y does not imply X jX Y z 6st Y jX Y z even if X and Y are independent. Therefore, Theorem 2 is not applicable and there is a need for a dierent argument which demonstrates another usefulness of Theorem 1; compare with [9] and [14, p. 395]. Let us switch Aj and Ai in the network of Fig. 1 representing V1 , and denote the resulting shortest path length by V 0 . If V1 is regarded as a function U
Aj ; Ai , then V 0 U
Ai ; Aj . Since U
Aj ; Ai ÿ U
Ai ; Aj is non-decreasing in Aj , Lemma 3 is applicable and E
V1 P E
V 0 : Let us switch Bi and Bj in V 0 , and denote the resulting shortest path length by V 00 . Since Bi st Bj , we have V 0 st V 00 , so E
V 0 E
V 00 . Moreover, we observe that V 00 and V2 dier only in the lengths of heavy arc (3,4) which are Ci and Cj , respectively. If V 00 is regarded as a function V 00 U
Ci ; Cj , then V2 U
Cj ; Ci , and Lemma 3 is again applicable. This gives E
V 00 P
V2 , and the proof is complete. References [1] S.M. Johnson, Optimal two- and three-stage production schedules with setup times included, Naval Research Logistics Quarterly 1 (1954) 61±68. [2] S.S. Panwalkar, M.L. Smith, C.R. Woolam, Counterexamples to optimal permutation schedules for certain ¯owshop problems, Naval Research Logistics Quarterly 28 (1981) 339±340. [3] M.R.D. Garey, D.S. Johnson, R. Sethi, The complexity of ¯owshop and job shop scheduling, Mathematics of Operations Research 1 (1976) 117±129. [4] P.S. Ku, S.C. Niu, On JohnsonÕs two machine ¯ow shop with random processing times, Operations Research 34 (1986) 130±136. [5] J. Kamburowski, Stochastically minimizing the makespan in two-machine ¯ow shops without blocking, European Journal of Operational Research 112 (1999) 304±309. [6] P.P. Talwar, A note on sequencing problems with uncertain job times, Journal of Operations Research Society of Japan 9 (1967) 93±97. [7] A.A. Cunningham, S.K. Dutta, Scheduling jobs with exponentially distributed processing times on two machines of a ¯ow shop, Naval Research Logistics Quarterly 16 (1973) 69±81. [8] V.R. Prasad, N 2 ¯owshop sequencing problem with random processing times, Opsearch 18 (1981) 1±14.
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[13] M. Pinedo, Scheduling: Theory Algorithms and Systems, Prentice-Hall, Englewood Clis, NJ, 1995. [14] M. Shaked, J.G. Shanthikumar, Stochastic Orders and Their Applications, Academic Press, Boston, MA, 1994. [15] F. Burns, J. Rooker, JohnsonÕs three-machine ¯ow-shop conjecture, Operations Research 24 (1976) 578±580. [16] C.L. Monma, A.H.G. Rinnooy Kan, A concise survey of eciently solvable special cases of the permutation ¯owshop problem, RAIRO Recherche Operationelle 17 (1983) 105±119.