The factory schedule example

This tutorial was originally contributed by @Crghilardi.

This tutorial is a Julia translation of Part 5 from Introduction to Linear Programming with Python.

The purpose of this tutorial is to demonstrate how to use DataFrames and delimited files, and to structure your code that is robust to infeasibilities and permits running with different datasets.

Required packages

This tutorial requires the following packages:

using JuMP
import CSV
import DataFrames
import HiGHS
import StatsPlots

Formulation

The Factory Scheduling Problem assumes we are optimizing the production of a good from factories $f \in F$ over the course of 12 months $m \in M$.

If a factory $f$ runs during a month $m$, a fixed cost of $a_f$ is incurred, the factory must produce $x_{m,f}$ units that is within some minimum and maximum production levels $l_f$ and $u_f$ respectively, and each unit of production incurs a variable cost $c_f$. Otherwise, the factory can be shut for the month with zero production and no fixed-cost is incurred. We denote the run/not-run decision by $z_{m,f} \in \{0, 1\}$, where $z_{m,f}$ is $1$ if factory $f$ runs in month $m$. The factory must produce enough units to satisfy demand $d_m$.

With a little effort, we can formulate our problem as the following linear program:

\[\begin{aligned} \min & \sum\limits_{f \in F, m \in M} a_f z_{m,f} + c_f x_{m,f} \\ \text{s.t.} & x_{m,f} \le u_f z_{m,f} && \forall f \in F, m \in M \\ & x_{m,f} \ge l_f z_{m,f} && \forall f \in F, m \in M \\ & \sum\limits_{f\in F} x_{m,f} = d_m && \forall f \in F, m \in M \\ & z_{m,f} \in \{0, 1\} && \forall f \in F, m \in M. \end{aligned}\]

However, this formulation has a problem: if demand is too high, we may be unable to satisfy the demand constraint, and the problem will be infeasible.

We can improve our model by adding a new variable, $\delta_m$, which represents the quantity of unmet demand in each month $m$. We penalize $\delta_m$ by an arbitrarily large value of $10,000/unit in the objective.

\[\begin{aligned} \min & \sum\limits_{f \in F, m \in M} a_f z_{m,f} + c_f x_{m,f} + \sum\limits_{m \in M}10000 \delta_m \\ \text{s.t.} & x_{m,f} \le u_f z_{m,f} && \forall f \in F, m \in M \\ & x_{m,f} \ge l_f z_{m,f} && \forall f \in F, m \in M \\ & \sum\limits_{f\in F} x_{m,f} - \delta_m = d_m && \forall f \in F, m \in M \\ & z_{m,f} \in \{0, 1\} && \forall f \in F, m \in M \\ & \delta_m \ge 0 && \forall m \in M. \end{aligned}\]

Data

The JuMP GitHub repository contains two text files with the data we need for this tutorial.

The first file contains a dataset of our factories, A and B, with their production and cost levels for each month. For the documentation, the file is located at:

factories_filename = joinpath(@__DIR__, "factory_schedule_factories.txt")

"/home/runner/work/JuMP.jl/JuMP.jl/docs/build/tutorials/linear/factory_schedule_factories.txt"

and it has the following contents:

print(read(factories_filename, String))

factory month min_production max_production fixed_cost variable_cost
A       1     20000          100000         500        10
A       2     20000          110000         500        11
A       3     20000          120000         500        12
A       4     20000          145000         500        9
A       5     20000          160000         500        8
A       6     20000          140000         500        8
A       7     20000          155000         500        5
A       8     20000          200000         500        7
A       9     20000          210000         500        9
A       10    20000          197000         500        10
A       11    20000          80000          500        8
A       12    20000          150000         500        8
B       1     20000          50000          600        5
B       2     20000          55000          600        4
B       3     20000          60000          600        3
B       4     20000          100000         600        5
B       5     0              0              0          0
B       6     20000          70000          600        6
B       7     20000          60000          600        4
B       8     20000          100000         600        6
B       9     20000          100000         600        8
B       10    20000          100000         600        11
B       11    20000          120000         600        10
B       12    20000          150000         600        12

You can reproduce this tutorial locally by saving the contents to a new file and updating factories_filename appropriately.

We use the CSV and DataFrames packages to read it into Julia:

factory_df = CSV.read(
    factories_filename,
    DataFrames.DataFrame;
    delim = ' ',
    ignorerepeated = true,
)

The second file contains the demand data by month:

demand_filename = joinpath(@__DIR__, "factory_schedule_demand.txt")

print(read(demand_filename, String))

month demand
1     120000
2     100000
3     130000
4     130000
5     140000
6     130000
7     150000
8     170000
9     200000
10    190000
11    140000
12    100000

demand_df = CSV.read(
    demand_filename,
    DataFrames.DataFrame;
    delim = ' ',
    ignorerepeated = true,
)

Data validation

Before moving on, it's always good practice to validate the data you read from external sources. The more effort you spend here, the fewer issues you will have later. The following function contains a few simple checks, but we could add more. For example, you might want to check that none of the values are too large (or too small), which might indicate a typo or a unit conversion issue (perhaps the variable costs are in $/1000 units instead of $/unit).

function valiate_data(
    demand_df::DataFrames.DataFrame,
    factory_df::DataFrames.DataFrame,
)
    # Minimum production must not exceed maximum production.
    @assert all(factory_df.min_production .<= factory_df.max_production)
    # Demand, minimum production, fixed costs, and variable costs must all be
    # non-negative.
    @assert all(demand_df.demand .>= 0)
    @assert all(factory_df.min_production .>= 0)
    @assert all(factory_df.fixed_cost .>= 0)
    @assert all(factory_df.variable_cost .>= 0)
    return
end

valiate_data(demand_df, factory_df)

JuMP formulation

Next, we need to code our JuMP formulation. As shown in Design patterns for larger models, it's always good practice to code your model in a function that accepts well-defined input and returns well-defined output.

function solve_factory_scheduling(
    demand_df::DataFrames.DataFrame,
    factory_df::DataFrames.DataFrame,
)
    # Even though we validated the data above, it's good practice to do it here
    # too.
    valiate_data(demand_df, factory_df)
    months, factories = unique(factory_df.month), unique(factory_df.factory)
    model = Model(HiGHS.Optimizer)
    set_silent(model)
    @variable(model, status[months, factories], Bin)
    @variable(model, production[months, factories], Int)
    @variable(model, unmet_demand[months] >= 0)
    # We use `eachrow` to loop through the rows of the dataframe and add the
    # relevant constraints.
    for r in eachrow(factory_df)
        m, f = r.month, r.factory
        @constraint(model, production[m, f] <= r.max_production * status[m, f])
        @constraint(model, production[m, f] >= r.min_production * status[m, f])
    end
    @constraint(
        model,
        [r in eachrow(demand_df)],
        sum(production[r.month, :]) + unmet_demand[r.month] == r.demand,
    )
    @objective(
        model,
        Min,
        10_000 * sum(unmet_demand) + sum(
            r.fixed_cost * status[r.month, r.factory] +
            r.variable_cost * production[r.month, r.factory] for
            r in eachrow(factory_df)
        )
    )
    optimize!(model)
    schedules = Dict{Symbol,Vector{Float64}}(
        Symbol(f) => value.(production[:, f]) for f in factories
    )
    schedules[:unmet_demand] = value.(unmet_demand)
    return (
        termination_status = termination_status(model),
        cost = objective_value(model),
        # This `select` statement re-orders the columns in the DataFrame.
        schedules = DataFrames.select(
            DataFrames.DataFrame(schedules),
            [:unmet_demand, :A, :B],
        ),
    )
end

solve_factory_scheduling (generic function with 1 method)

Solution

Now we can call our solve_factory_scheduling function using the data we read in above.

solution = solve_factory_scheduling(demand_df, factory_df);

Let's see what solution contains:

solution.termination_status

OPTIMAL::TerminationStatusCode = 1

solution.cost

1.29064e7

solution.schedules

These schedules will be easier to visualize as a graph:

StatsPlots.groupedbar(
    Matrix(solution.schedules);
    bar_position = :stack,
    labels = ["unmet demand" "A" "B"],
    xlabel = "Month",
    ylabel = "Production",
    legend = :topleft,
    color = ["#20326c" "#4063d8" "#a0b1ec"],
)

Note that we don't have any unmet demand!

What happens if demand increases?

Let's run an experiment by increasing the demand by 50% in all time periods:

demand_df.demand .*= 1.5

12-element Vector{Int64}:
 180000
 150000
 195000
 195000
 210000
 195000
 225000
 255000
 300000
 285000
 210000
 150000

Now we resolve the problem:

high_demand_solution = solve_factory_scheduling(demand_df, factory_df);

and visualize the solution:

StatsPlots.groupedbar(
    Matrix(high_demand_solution.schedules);
    bar_position = :stack,
    labels = ["unmet demand" "A" "B"],
    xlabel = "Month",
    ylabel = "Production",
    legend = :topleft,
    color = ["#20326c" "#4063d8" "#a0b1ec"],
)

Uh oh! We can't satisfy all of the demand.

How sensitive is the solution to changes in variable cost?

Let's run another experiment, this time seeing how the optimal objective value changes as we vary the variable costs of each factory.

First though, let's reset the demand to it's original level:

demand_df.demand ./= 1.5;

For our experiment, we're going to scale the variable costs of both factories by a set of values from 0.0 to 1.5:

scale_factors = 0:0.1:1.5

0.0:0.1:1.5

At a high level, we're going to loop over the scale factors for A, then the scale factors for B, rescale the input data, call our solve_factory_scheduling example, and then store the optimal objective value in the following cost matrix:

cost = zeros(length(scale_factors), length(scale_factors));

Because we're modifying factory_df in-place, we need to store the original variable costs in a new column:

factory_df[!, :old_variable_cost] = copy(factory_df.variable_cost);

Then, we need a function to scale the :variable_cost column for a particular factory by a value scale:

function scale_variable_cost(df, factory, scale)
    rows = df.factory .== factory
    df[rows, :variable_cost] .=
        round.(Int, df[rows, :old_variable_cost] .* scale)
    return
end

scale_variable_cost (generic function with 1 method)

Our experiment is just a nested for-loop, modifying A and B and storing the cost:

for (j, a) in enumerate(scale_factors)
    scale_variable_cost(factory_df, "A", a)
    for (i, b) in enumerate(scale_factors)
        scale_variable_cost(factory_df, "B", b)
        cost[i, j] = solve_factory_scheduling(demand_df, factory_df).cost
    end
end

Let's visualize the cost matrix:

StatsPlots.contour(
    scale_factors,
    scale_factors,
    cost;
    xlabel = "Scale of factory A",
    ylabel = "Scale of factory B",
)

What can you infer from the solution?