capacity planning and production scheduling for aircraft ...€¦ · • cost as a function of...
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Department of Industrial and Manufacturing Systems Engineering
Capacity Planning and Production
Scheduling for Aircraft Painting OperationsXiangzhen Li, Minxiang Zhang, Caroline Krejci, Cameron
MacKenzie, John Jackman, Guiping Hu
Iowa State University
Charles Hu, Adam Graunke, Gabriel Burnett
Boeing
Industrial and Manufacturing Systems Engineering
Boeing painting operations
• New aircraft assigned to hangars for
painting based on expert knowledge and
heuristic scheduling
• Painting can occur in house or be
outsourced
2
Industrial and Manufacturing Systems Engineering
Research questions
• Does Boeing have sufficient painting capacity to
meet future demand?
• What is the future demand for airplanes?
• What is the optimal schedule for painting aircraft
to minimize costs given demand?
• How does uncertainty (in painting times, future
demand) impact the optimal schedule and
decision about capacity?
3
Industrial and Manufacturing Systems Engineering
Optimal schedule to minimize cost
• Time frame: 1 month increments (20 years total)
• Minimize cost
• Cost of painting airplanes in house
• Cost of outsourcing airplanes to be painted
• Cost of being late
• Decision variables: assign each plane to a
hangar for painting at each time (assignment
problem)
4
Industrial and Manufacturing Systems Engineering
Constraints
• 5 different models of planes; each model has a
different painting time
• Hangars can only paint certain models of planes
• Setup times can vary with hangar
• Job cannot be assigned until plane is released
for painting
• Per-day tardiness penalty for planes that are
finished late
• All jobs must be assigned to a hangar
• Each hangar can only paint one plane at a time
5
Industrial and Manufacturing Systems Engineering
Input data• Monthly demand data from demand forecasting
model
• 22 hangars: 12 in house and 10 outsource
• Cost as a function of painting time
• $6,000 per day (material and labor)
• $50,000 daily penalty cost for being late
6
Model Setup and painting days
737 3 or 4
747 6
767 5
777 6 or 7
787 5 or 6
Industrial and Manufacturing Systems Engineering
Optimal Solution for Month 1
Hangar 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 737
2 747
3 767
4 777
5 787
6
7
8
9
10
11
12
25
21
14
10
9
11
2
3
7 8 13 12 22
6 16 26 5 27
Time
32 33
31
34
36
37
35
30
29
15
23
4
24
20
19
28
1
18
17
Table 2. Schedule Gantt Chart for month 1
37 total airplanes
7
Industrial and Manufacturing Systems Engineering
Painting assignment
8
0
10
20
30
40
50
60
70
80
90
1001 7
13
19
25
31
37
43
49
55
61
67
73
79
85
91
98
104
110
116
12
2
128
134
140
146
De
ma
nd
Month
Out-Sourcing
On-Site
Dummy
Industrial and Manufacturing Systems Engineering
Cost per month
0
2000
4000
6000
8000
10000
12000
14000
16000
1 7
13
19
25
31
37
43
49
55
61
67
73
79
85
91
97
103
10
9
115
121
127
133
139
145
Co
st
($)
MonthPenaltyCost TotalCost
9
Industrial and Manufacturing Systems Engineering
Overflow
Simulation with random release dates
and painting times
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Industrial and Manufacturing Systems Engineering
Average hangar utilization
0
10
20
30
40
50
60
70
80
90
100
Chr1
Chr2
Em
c1
Evt1
Evt3
Evt4
Rtn
1
Rtn
2
Se
a1
Se
a2
Se
a3
Se
a4
Pd
x1
Pdx2
Sp
o1
Spo2
Sp
o3
Vic
1
Vic
2
Mis
c1
Uti
liza
tio
n %
11
Industrial and Manufacturing Systems Engineering
Key conclusions
• Planes can be painted in house for years 0-2
• Delays start occurring in year 5
• Capacity exceeded in year 6
• Significant delays beginning in year 7
Due to demand uncertainty, capacity could be
exceeded much earlier or later!
12Email: camacken@iastate.edu
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