Capacitated Lot Sizing with Setup Times

This research focuses on the effect of setup time on lot sizing. The setting is the Capacitated Lot Sizing Problem (the single-machine lot sizing problem) with nonstationary costs, demands, and setup times. A Lagrangian relaxation of the capacity constraints of CLSP allows it to be decomposed into a set of uncapacitated single product lot sizing problems. The Lagrangian dual costs are updated by subgradient optimization, and the single-item problems are solved by dynamic programming. A heuristic smoothing procedure constructs feasible solutions (production plans) which do not require overtime. The algorithm solves problems with setup time or setup cost. Problems with extremely tightly binding capacity constraints were much more difficult to solve than anticipated. Solutions without overtime could not always be found for them. The most significant results are that (1) the tightness of the capacity constraint is a good indicator of problem difficulty for problems with setup time; and (2) the algorithm solves larger problems better than smaller problems, although they are more time consuming to solve. This indicates that larger problems may be easier despite the greater computational effort they require.