Proactive Scheduling and Routing of MRP-Based Production with Constrained Resources

Abstract

This research addresses the challenges of proactive scheduling and routing in manufacturing systems governed by the Material Requirement Planning (MRP) method. Such systems often face capacity constraints, difficulties in resource balancing, and limited traceability of component requirements. The lack of seamless integration between customer orders and production tasks, combined with the manual and time-consuming nature of schedule adjustments, highlights the need for an automated and optimized scheduling method. We propose a novel optimization-based approach that leverages mixed-integer linear programming (MILP) combined with a proprietary procedure for reducing the size of the modeled problem to generate feasible and/or optimal production schedules. The model incorporates dynamic routing, partial resource utilization, limited additional resources (e.g., tools, workers), technological breaks, and time quantization. Key results include determining order feasibility, identifying unfulfilled order components, minimizing costs, shortening deadlines, and assessing feasibility in the absence of available resources. By automating the generation of data from MRP/ERP systems, constructing an optimization model, and exporting the results back to the MRP/ERP structure, this method improves decision-making and competes with expensive Advanced Planning and Scheduling (APS) systems. The proposed innovation solution—the integration of MILP-based optimization with the proprietary PT (data transformation) and PR (model-size reduction) procedures—not only increases operational efficiency but also enables demand source tracking and offers a scalable and economical alternative for modern production environments. Experimental results demonstrate significant reductions in production costs (up to 25%) and lead times (more than 50%).