Optimal Volume Planning and Scheduling of Paper Production with Smooth Transitions by Product Grades

The article deals with the problem of calculating the volume calendar plan of a paper mill. The presented mathematical model and methods make it possible to schedule paper production orders between several paper machines (PM) to even their loading, devise cutting plans for each winder and arrange the order of their implementation. When forming cutting plans, orders are grouped in accordance with such parameters as grammage, roll diameter, core diameter, product type and number of layers. Deadlines and volumes in customer orders are taken into account. The cutting plans for each winder account for the allowable roll width limits and the maximum number of knives. To find the optimal schedule, a combination of the following criteria is used: minimal trim loss, minimal changes to the knives’ setup and smooth transitions by product grades. Solution algorithms are presented that use a combination of the simplex method, the column generation, the branch and bound methods, the greedy algorithm and the local search procedure. We tested the solution approach on real production data from a paper mill in European Russia and obtained the production sequence that better matches deadlines in customer orders compared to the plan devised manually by production planners.