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alpar@9
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1 # PROD, a multiperiod production model
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2 #
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3 # References:
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4 # Robert Fourer, David M. Gay and Brian W. Kernighan, "A Modeling Language
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5 # for Mathematical Programming." Management Science 36 (1990) 519-554.
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6
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alpar@9
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7 ### PRODUCTION SETS AND PARAMETERS ###
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8
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9 set prd 'products'; # Members of the product group
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10
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11 param pt 'production time' {prd} > 0;
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12
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13 # Crew-hours to produce 1000 units
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14
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15 param pc 'production cost' {prd} > 0;
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16
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17 # Nominal production cost per 1000, used
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18 # to compute inventory and shortage costs
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19
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20 ### TIME PERIOD SETS AND PARAMETERS ###
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21
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22 param first > 0 integer;
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23 # Index of first production period to be modeled
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24
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25 param last > first integer;
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26
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27 # Index of last production period to be modeled
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28
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29 set time 'planning horizon' := first..last;
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30
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31 ### EMPLOYMENT PARAMETERS ###
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32
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33 param cs 'crew size' > 0 integer;
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34
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35 # Workers per crew
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36
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37 param sl 'shift length' > 0;
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38
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39 # Regular-time hours per shift
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40
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41 param rtr 'regular time rate' > 0;
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42
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43 # Wage per hour for regular-time labor
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44
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45 param otr 'overtime rate' > rtr;
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46
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47 # Wage per hour for overtime labor
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48
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49 param iw 'initial workforce' >= 0 integer;
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50
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51 # Crews employed at start of first period
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52
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53 param dpp 'days per period' {time} > 0;
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54
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55 # Regular working days in a production period
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56
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57 param ol 'overtime limit' {time} >= 0;
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58
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59 # Maximum crew-hours of overtime in a period
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60
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61 param cmin 'crew minimum' {time} >= 0;
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62
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63 # Lower limit on average employment in a period
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64
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65 param cmax 'crew maximum' {t in time} >= cmin[t];
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66
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67 # Upper limit on average employment in a period
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68
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69 param hc 'hiring cost' {time} >= 0;
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70
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71 # Penalty cost of hiring a crew
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72
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73 param lc 'layoff cost' {time} >= 0;
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74
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75 # Penalty cost of laying off a crew
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76
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77 ### DEMAND PARAMETERS ###
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78
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79 param dem 'demand' {prd,first..last+1} >= 0;
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80
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81 # Requirements (in 1000s)
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82 # to be met from current production and inventory
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83
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84 param pro 'promoted' {prd,first..last+1} logical;
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85
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86 # true if product will be the subject
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87 # of a special promotion in the period
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88
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89 ### INVENTORY AND SHORTAGE PARAMETERS ###
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90
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91 param rir 'regular inventory ratio' >= 0;
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92
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93 # Proportion of non-promoted demand
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94 # that must be in inventory the previous period
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95
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96 param pir 'promotional inventory ratio' >= 0;
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97
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98 # Proportion of promoted demand
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99 # that must be in inventory the previous period
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100
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101 param life 'inventory lifetime' > 0 integer;
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102
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103 # Upper limit on number of periods that
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104 # any product may sit in inventory
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105
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106 param cri 'inventory cost ratio' {prd} > 0;
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107
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108 # Inventory cost per 1000 units is
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109 # cri times nominal production cost
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110
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111 param crs 'shortage cost ratio' {prd} > 0;
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112
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113 # Shortage cost per 1000 units is
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114 # crs times nominal production cost
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115
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116 param iinv 'initial inventory' {prd} >= 0;
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117
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118 # Inventory at start of first period; age unknown
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119
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120 param iil 'initial inventory left' {p in prd, t in time}
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121 := iinv[p] less sum {v in first..t} dem[p,v];
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122
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123 # Initial inventory still available for allocation
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124 # at end of period t
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125
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126 param minv 'minimum inventory' {p in prd, t in time}
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127 := dem[p,t+1] * (if pro[p,t+1] then pir else rir);
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128
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129 # Lower limit on inventory at end of period t
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130
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131 ### VARIABLES ###
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132
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133 var Crews{first-1..last} >= 0;
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134
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135 # Average number of crews employed in each period
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136
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137 var Hire{time} >= 0; # Crews hired from previous to current period
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138
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139 var Layoff{time} >= 0; # Crews laid off from previous to current period
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140
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141 var Rprd 'regular production' {prd,time} >= 0;
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142
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143 # Production using regular-time labor, in 1000s
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144
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145 var Oprd 'overtime production' {prd,time} >= 0;
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146
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147 # Production using overtime labor, in 1000s
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148
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149 var Inv 'inventory' {prd,time,1..life} >= 0;
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150
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151 # Inv[p,t,a] is the amount of product p that is
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152 # a periods old -- produced in period (t+1)-a --
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153 # and still in storage at the end of period t
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154
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155 var Short 'shortage' {prd,time} >= 0;
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156
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157 # Accumulated unsatisfied demand at the end of period t
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158
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159 ### OBJECTIVE ###
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160
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161 minimize cost:
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162
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163 sum {t in time} rtr * sl * dpp[t] * cs * Crews[t] +
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164 sum {t in time} hc[t] * Hire[t] +
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165 sum {t in time} lc[t] * Layoff[t] +
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166 sum {t in time, p in prd} otr * cs * pt[p] * Oprd[p,t] +
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167 sum {t in time, p in prd, a in 1..life} cri[p] * pc[p] * Inv[p,t,a] +
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168 sum {t in time, p in prd} crs[p] * pc[p] * Short[p,t];
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169
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170 # Full regular wages for all crews employed, plus
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171 # penalties for hiring and layoffs, plus
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172 # wages for any overtime worked, plus
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173 # inventory and shortage costs
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174
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175 # (All other production costs are assumed
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176 # to depend on initial inventory and on demands,
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177 # and so are not included explicitly.)
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178
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179 ### CONSTRAINTS ###
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180
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181 rlim 'regular-time limit' {t in time}:
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182
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183 sum {p in prd} pt[p] * Rprd[p,t] <= sl * dpp[t] * Crews[t];
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184
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185 # Hours needed to accomplish all regular-time
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186 # production in a period must not exceed
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187 # hours available on all shifts
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188
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189 olim 'overtime limit' {t in time}:
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190
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191 sum {p in prd} pt[p] * Oprd[p,t] <= ol[t];
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192
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193 # Hours needed to accomplish all overtime
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194 # production in a period must not exceed
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195 # the specified overtime limit
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196
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197 empl0 'initial crew level': Crews[first-1] = iw;
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198
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199 # Use given initial workforce
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200
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201 empl 'crew levels' {t in time}: Crews[t] = Crews[t-1] + Hire[t] - Layoff[t];
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202
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203 # Workforce changes by hiring or layoffs
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204
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205 emplbnd 'crew limits' {t in time}: cmin[t] <= Crews[t] <= cmax[t];
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206
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207 # Workforce must remain within specified bounds
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208
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209 dreq1 'first demand requirement' {p in prd}:
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210
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211 Rprd[p,first] + Oprd[p,first] + Short[p,first]
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212 - Inv[p,first,1] = dem[p,first] less iinv[p];
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213
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214 dreq 'demand requirements' {p in prd, t in first+1..last}:
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215
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216 Rprd[p,t] + Oprd[p,t] + Short[p,t] - Short[p,t-1]
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217 + sum {a in 1..life} (Inv[p,t-1,a] - Inv[p,t,a])
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218 = dem[p,t] less iil[p,t-1];
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219
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220 # Production plus increase in shortage plus
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221 # decrease in inventory must equal demand
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222
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223 ireq 'inventory requirements' {p in prd, t in time}:
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224
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225 sum {a in 1..life} Inv[p,t,a] + iil[p,t] >= minv[p,t];
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226
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227 # Inventory in storage at end of period t
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228 # must meet specified minimum
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229
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230 izero 'impossible inventories' {p in prd, v in 1..life-1, a in v+1..life}:
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231
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232 Inv[p,first+v-1,a] = 0;
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233
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234 # In the vth period (starting from first)
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235 # no inventory may be more than v periods old
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236 # (initial inventories are handled separately)
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237
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238 ilim1 'new-inventory limits' {p in prd, t in time}:
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239
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240 Inv[p,t,1] <= Rprd[p,t] + Oprd[p,t];
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241
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242 # New inventory cannot exceed
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243 # production in the most recent period
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244
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245 ilim 'inventory limits' {p in prd, t in first+1..last, a in 2..life}:
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246
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247 Inv[p,t,a] <= Inv[p,t-1,a-1];
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248
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249 # Inventory left from period (t+1)-p
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250 # can only decrease as time goes on
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251
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252 ### DATA ###
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253
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254 data;
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255
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256 set prd := 18REG 24REG 24PRO ;
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257
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258 param first := 1 ;
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259 param last := 13 ;
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260 param life := 2 ;
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261
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262 param cs := 18 ;
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263 param sl := 8 ;
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264 param iw := 8 ;
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265
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266 param rtr := 16.00 ;
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267 param otr := 43.85 ;
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268 param rir := 0.75 ;
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269 param pir := 0.80 ;
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270
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271 param : pt pc cri crs iinv :=
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272
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273 18REG 1.194 2304. 0.015 1.100 82.0
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274 24REG 1.509 2920. 0.015 1.100 792.2
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275 24PRO 1.509 2910. 0.015 1.100 0.0 ;
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276
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277 param : dpp ol cmin cmax hc lc :=
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278
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279 1 19.5 96.0 0.0 8.0 7500 7500
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280 2 19.0 96.0 0.0 8.0 7500 7500
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281 3 20.0 96.0 0.0 8.0 7500 7500
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282 4 19.0 96.0 0.0 8.0 7500 7500
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283 5 19.5 96.0 0.0 8.0 15000 15000
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284 6 19.0 96.0 0.0 8.0 15000 15000
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285 7 19.0 96.0 0.0 8.0 15000 15000
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286 8 20.0 96.0 0.0 8.0 15000 15000
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287 9 19.0 96.0 0.0 8.0 15000 15000
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288 10 20.0 96.0 0.0 8.0 15000 15000
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289 11 20.0 96.0 0.0 8.0 7500 7500
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290 12 18.0 96.0 0.0 8.0 7500 7500
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291 13 18.0 96.0 0.0 8.0 7500 7500 ;
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292
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293 param dem (tr) :
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294
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295 18REG 24REG 24PRO :=
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296
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297 1 63.8 1212.0 0.0
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298 2 76.0 306.2 0.0
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299 3 88.4 319.0 0.0
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300 4 913.8 208.4 0.0
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301 5 115.0 298.0 0.0
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302 6 133.8 328.2 0.0
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303 7 79.6 959.6 0.0
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304 8 111.0 257.6 0.0
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305 9 121.6 335.6 0.0
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306 10 470.0 118.0 1102.0
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307 11 78.4 284.8 0.0
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308 12 99.4 970.0 0.0
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309 13 140.4 343.8 0.0
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310 14 63.8 1212.0 0.0 ;
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311
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312 param pro (tr) :
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313
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314 18REG 24REG 24PRO :=
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315
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316 1 0 1 0
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317 2 0 0 0
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318 3 0 0 0
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319 4 1 0 0
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320 5 0 0 0
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321 6 0 0 0
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322 7 0 1 0
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323 8 0 0 0
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324 9 0 0 0
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325 10 1 0 1
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326 11 0 0 0
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327 12 0 0 0
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328 13 0 1 0
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329 14 0 1 0 ;
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330
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331 end;
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