Integrated Planning and Machine-Level Scheduling for High-Mix Discrete Manufacturing: A Profit-Driven Heuristic Framework

Abstract: Modern manufacturing enterprises struggle to create efficient and reliable production schedules under multi-variety, small-batch, and rush-order conditions. High-mix discrete manufacturing systems require jointly optimizing mid-term production planning and machine-level scheduling under heterogeneous resources and stringent delivery commitments. We address this problem with a profit-driven integrated framework that couples a mixed-integer planning model with a machine-level scheduling heuristic. The planning layer allocates production, accessory co-production, and outsourcing under aggregate economic and capacity constraints, while the scheduling layer refines these allocations using a structure-aware procedure that enforces execution feasibility and stabilizes daily machine behavior. This hierarchical design preserves the tractability of aggregated optimization while capturing detailed operational restrictions. Evaluations are conducted on a real industrial scenario. A flexible machine-level execution scheme yields 73.3% on-time completion and significant outsourcing demand, revealing bottleneck congestion. In contrast, a stability-enforcing execution policy achieves 100% on-time completion, eliminates all outsourcing, and maintains balanced machine utilization with only 1.9 to 4.6% capacity loss from changeovers. These results show that aligning planning decisions with stability-oriented execution rules enables practical and interpretable profit-maximizing decisions in complex manufacturing environments.