Decision Support and Optimization in Shutdown and Turnaround Scheduling

Large-scale maintenance in industrial plants requires the entire shutdown of production units for disassembly, comprehensive inspection, and renewal. We derive models and algorithms for this so-called turnaround scheduling that include different features such as time-cost trade-off, precedence constraints, external resource units, resource leveling, different working shifts, and risk analysis. We propose a framework for decision support that consists of two phases. The first phase supports the manager in finding a good makespan for the turnaround. It computes an approximate project time-cost trade-off curve together with a stochastic evaluation. Our risk measures are the expected tardiness at time t and the probability of completing the turnaround within time t. In the second phase, we solve the actual scheduling optimization problem for the makespan chosen in the first phase heuristically and compute a detailed schedule that respects all side constraints. Again, we complement this by computing upper bounds for the same two risk measures. Our experimental results show that our methods solve large real-world instances from chemical manufacturing plants quickly and yield an excellent resource utilization. A comparison with solutions of a mixed-integer program on smaller instances proves the high quality of the schedules that our algorithms produce within a few minutes.