原材料易变质和产成品有保质期的生产库存模型研究

考虑需求是时间的线性函数,原材料和产成品的变质率也是时间的线性函数,建立了原材料易变质和产成品有保质期的生产库存模型.用进化规划算法对模型进行求解,确定最佳订购周期,原材料的经济订购批量和产成品的经济生产批量.最后,用具体的数值例子验证了模型与算法的有效性.     

需求不确定情况下的多周期生产批量决策

针对在市场需求不确定的情况下的中小制造型企业的生产批量决策优化问题进行研究,根据多周期生产情况下需求的不确定性,综合考虑缺货成本、库存成本和期初库存等因素,以多生产周期的总利润最大化为目标,建立生产批量决策模型,通过优化分析,得出其利润最大化下的最优生产批量,并通过敏感性分析讨论最优批量与多周期生产条件下的不确定需求等影响因素之间的关系.     

基于数量折扣合同和缺货损失的EOQ模型的改进

经济订购批量模型假定需求率、单位持有成本、订货成本为常数下得到总成本最低的订购批量,这些参数常数化的假设在现实中通常难以满足.假定需求和订货费为不确定的、库存成本包括年固定成本(与订货量无关)和年可变成本(与订货量有关),用三角模糊数表示年需求和订货费,通过引入数量折扣合同来量化单位产品进价,分别在不允许缺货和考虑缺货损失两种情况下得到最佳订货量.最后的算例表明了模型的合理性.     

多供应商多零售商下经济批量问题的多项式时间算法研究

基于多供应商和多零售商构成的经济批量问题,通过构建优化模型,分析了订购费用为全部单位数量折扣和增加数量折扣两种情形模型最优解的相关性质。将这些性质应用到动态规划算法设计中,对订购费用为全部单位数量折扣时的一种特殊情形及增加数量折扣的一般情形分别设计了求解问题最优解的多项式时间算法,并用算例说明了算法的执行过程和有效性。     

基于遗传算法的生产批量优化问题

本文针对生产费用、生产准备费用和库存费用综合指标最小的最优的能力约束生产批量问题,建立基于遗传算法的数学模型,通过模拟试验及实际问题的计算验证了算法的可行性。     

基于改进粒子群算法的备货型生产系统的生产与维修整合模型

生产系统随着设备磨损往往会失控或发生故障,给企业带来巨大损失.本文以备货型生产系统为研究对象,根据其成品先入库后销售的特点,建立基于故障率的非周期的生产、维修、库存整合模型.模型以最小化单位总成本为目标,基于萤火虫算法的邻域结构改进粒子群算法,求解系统的最优生产率和维修策略,并分析比较不合格产品率、失控率对目标函数值和最优策略的影响.     

考虑随机模糊缺陷率且允许缺货的EOQ模型

针对实际库存管理中的产品缺陷问题,研究了含随机模糊缺陷率且允许缺货的经济订购批量(EOQ)模型,并运用随机模糊理论将其转化为确定模型,设计了随机模糊模拟仿真算法进而确定了其最优订购策略.数值算例分析了缺陷率对最优订货量和最优利润的影响.     

带有可变备运期和有限服务率的经济批量模型

本文将备运期（Lead time)作为决定变量，在指数备运时间－费用函数的假定下，建立了服务率为有限的库存系统的最优经济批量模型，提供了寻求最佳备运期、最优订货周期及最优订货批量的简单方法，并给出了参数的灵敏度分析和应用实例。     

考虑事故风险损失的爆炸物品经济订货批量模型研究

爆炸物品在储存过程中存在发生爆炸事故,从而给人类和环境带来伤害的可能,因此在对爆炸物品进行采购决策时必需考虑由此带来的风险损失.在给出爆炸物品事故风险损失度量方法的基础上,建立了爆炸物品的经济订货批量模型,证明了模型存在唯一最优解,并给出了模型的求解步骤,为相关企业合理制定采购决策提供了理论依据.数字算例分析了事故概率、赔偿标准、单位库存费、单次采购费对最优批量的影响,比较了考虑事故风险损失与否时的最优批量,结果表明,当事故概率或赔偿标准较高时,两者对应的最优批量差异明显.这也说明,当事故概率或赔偿标准达到一定程度时,考虑事故风险损失是十分必要的.     

多种变质性物品的经济批量问题

本文考虑了多种变质性物品在同一台设备上生产的最优基本生产周期问题。本文采用了基本周期法,给出了问题的数学模型,分析了模型最优解的存在性,并给出了求解该模型的算法和算例,从算例的结果说明基本周期法比公共周期法解决经济批量问题更优。     

An Optimal Batch Size for a Production System Operating Under a Fixed-Quantity,Periodic Delivery Policy

A manufacturing system which procures raw materials from suppliers and processes them to convert to finished products is considered here. This paper develops an ordering policy for raw materials to meet the requirements of a production facility which, in turn, must deliver finished products demanded by outside buyers at fixed interval points in time. First, a general cost model is developed considering both supplier (of raw material) and buyer (of finished products) sides. This model is used to determine an optimal ordering policy for procurement of raw materials, and the manufacturing batch size to minimize the total cost for meeting equal shipments of the finished products, at fixed intervals, to the buyers. The total cost is found to be a piece-wise convex cost function. An interval that contains the optimal solution is first determined followed by an optimization technique to identify the exact solution from this interval.     

Supply chain models for an assembly system with preprocessing of raw materials

In this paper, we investigate the material procurement and delivery policy in a production system where raw materials enter into the assembly line from two different flow channels. The system encompasses batch production process in which the finished product demand is approximately constant for an infinite planning horizon. Two distinct types of raw materials are passed through the assembly line before to convert them into the finished product. Of the two types of raw materials, one type requires preprocessing inside the facility before the assembly operation and other group is fed straightway in the assembly line. The conversion factors are assigned to raw materials to quantify the raw material batch size required. To analyze such a system, we formulate a nonlinear cost function to aggregate all the costs of the inventories, ordering, shipping and deliveries. An algorithm using the branch and bound concept is provided to find the best integer values of the optimal solutions. The result shows that the optimal procurement and delivery policy minimizes the expected total cost of the model. Using a test problem, the inventory requirements at each stage of production and their corresponding costs are calculated. From the analysis, it is shown that the rate and direction change of total cost is turned to positive when delivery rates per batch reaches close to the optimal value and the minimum cost is achieved at the optimal delivery rate. Also, it is shown that total incremental cost is monotonically increasing, if the finished product batch size is increased, and if, inventory cost rates are increased. We examine a set of numerical examples that reveal the insights into the procurement-delivery policy and the performance of such an assembly type inventory model.     

Modified base-stock policies for semiconductor production system with dependent yield rates

We consider a two-stage production system faced by semiconductor manufacturing which produces a hierarchy of multiple grades of outputs. In the first stage, a single type of input (wafer) is used to produce multiple types of semi-finished parts with dependent yield rates, and in the second stage, each type of semi-finished parts can be transformed into a corresponding type of final products, or downgraded to a type of lower grade final products. Random customer demands are faced on the final products, and demands of different types of final products are not allowed to be substituted. The advantage of this production system is that it can prevent unhealthy ordering from customers who intentionally send out false demand signals for high grade products and revise the orders to lower grade products when the delivery time is close, which was observed in semiconductor manufacturing. The objective of the study is to plan the quantity of the input at the first stage and the respective downgrade quantities at the second stage so as to meet the required service level at the minimum cost. With some common assumptions, we propose a modified base-stock policy for this two-stage production system and show that the occurrence of nil excess inventory above the base-stock level follows a renewal process. We further extend the modified base-stock policy to a better policy that invokes risk pooling over multiple grade products. The performance of these two polices are evaluated via simulation to provide managerial insights.     

A dynamic inventory model with supplier selection in a serial supply chain structure

Considering the inherent connection between supplier selection and inventory management in supply chain networks, this article presents a multi-period inventory lot-sizing model for a single product in a serial supply chain, where raw materials are purchased from multiple suppliers at the first stage and external demand occurs at the last stage. The demand is known and may change from period to period. The stages of this production–distribution serial structure correspond to inventory locations. The first two stages stand for storage areas for raw materials and finished products in a manufacturing facility, and the remaining stages symbolize distribution centers or warehouses that take the product closer to customers. The problem is modeled as a time-expanded transshipment network, which is defined by the nodes and arcs that can be reached by feasible material flows. A mixed integer nonlinear programming model is developed to determine an optimal inventory policy that coordinates the transfer of materials between consecutive stages of the supply chain from period to period while properly placing purchasing orders to selected suppliers and satisfying customer demand on time. The proposed model minimizes the total variable cost, including purchasing, production, inventory, and transportation costs. The model can be linearized for certain types of cost structures. In addition, two continuous and concave approximations of the transportation cost function are provided to simplify the model and reduce its computational time.     

Optimal production control of a dynamic two-product manufacturing system with setup costs and setup times

This paper deals with the optimal control of a one-machine two-product manufacturing system with setup changes, operating in a continuous time dynamic environment. The system is deterministic. When production is switched from one product to the other, a known constant setup time and a setup cost are incurred. Each product has specified constant processing time and constant demand rate, as well as an infinite supply of raw material. The problem is formulated as a feedback control problem. The objective is to minimize the total backlog, inventory and setup costs incurred over a finite horizon. The optimal solution provides the optimal production rate and setup switching epochs as a function of the state of the system (backlog and inventory levels). For the steady state, the optimal cyclic schedule is determined. To solve the transient case, the system's state space is partitioned into mutually exclusive regions such that with each region, the optimal control policy is determined analytically.     

Optimal lot size and inspection policy for products sold with warranty

This paper develops a mathematical model to jointly determine the optimal lot size and product inspection policy for a deteriorating production system, when products are sold with free minimal repair warranty. Due to system deterioration, a last-K product inspection scheme is proposed, under which the last K products in a production lot are inspected and nonconforming products found are reworked. Based on the model, we show that there exist a unique optimal lot size and a corresponding inspection policy such that the expected total cost per unit time is minimized. Since there is no closed-form expression for the optimal lot size, an upper bound and approximate solutions are obtained to facilitate the search process. Furthermore, an algorithm is provided to efficiently search for the optimal policy and the performance of the optimal policy is evaluated through numerical examples.     

Setup cost reduction in (<Emphasis Type="Italic">Q,r</Emphasis>) policy with lot size,setup time and lead-time interactions

It is often assumed in most deterministic and stochastic inventory models that lead-time is a given parameter and the optimal operating policy is determined on the basis of this unrealistic assumption. However, the manufacturing lead-time is made up of several components (moving time, waiting time, setup time, lot size, and rework time) most of which should be treated as controllable variables. In this paper the effect of setup cost reduction is addressed in a stochastic continuous review inventory system with lead-time depending on lot size and setup time. An efficient iterative procedure is developed to determine the near optimal lot size, reorder point and setup time. Furthermore, a sensitivity analysis is carried out to assess the cost savings that can be realised by investing in setup.     

Production and shipment lot sizing in a vendor–buyer supply chain with transportation cost

Previous research on the joint vendor–buyer problem focused on the production shipment schedule in terms of the number and size of batches transferred between the two parties. It is a fact that transportation cost is a major part of the total operational cost. However, in most joint vendor–buyer models, the transportation cost is only considered implicitly as a part of fixed setup or ordering cost and thus is assumed to be independent of the size of the shipment. As such, the effect of the transportation cost is not adequately reflected in final planning decisions. There is a need for models involving transportation cost explicitly for better decision-making. In this study we analyze the vendor–buyer lot-sizing problem under equal-size shipment policy. We introduce the complete solution of the problem in an explicit and extended manner that has not existed in the literature. We incorporate transportation cost explicitly into the model and develop optimal solution procedures for solving the integrated models. All-unit-discount transportation cost structures with and without over declaration have been considered. Numerical examples are presented for illustrative purpose.     

A linear programming embedded genetic algorithm for an integrated cell formation and lot sizing considering product quality

Production lot sizing models are often used to decide the best lot size to minimize operation cost, inventory cost, and setup cost. Cellular manufacturing analyses mainly address how machines should be grouped and parts be produced. In this paper, a mathematical programming model is developed following an integrated approach for cell configuration and lot sizing in a dynamic manufacturing environment. The model development also considers the impact of lot sizes on product quality. Solution of the mathematical model is to minimize both production and quality related costs. The proposed model, with nonlinear terms and integer variables, cannot be solved for real size problems efficiently due to its NP-complexity. To solve the model for practical purposes, a linear programming embedded genetic algorithm was developed. The algorithm searches over the integer variables and for each integer solution visited the corresponding values of the continuous variables are determined by solving a linear programming subproblem using the simplex algorithm. Numerical examples showed that the proposed method is efficient and effective in searching for near optimal solutions.     

Heuristics with guaranteed performance bounds for a manufacturing system with product recovery

We consider a manufacturing system with product recovery. The system manufactures a new product as well as remanufactures the product from old, returned items. The items remanufactured with the returned products are as good as new and satisfy the same demand as the new item. The demand rate for the new item and the return rate for the old item are deterministic and constant. The relevant costs are the holding costs for the new item and the returned item, and the fixed setup costs for both manufacturing and remanufacturing. The objective is to determine the lot sizes and production schedule for manufacturing and remanufacturing so as to minimize the long-run average cost per unit time. We first develop a lower bound among all classes of policies for the problem. We then show that the optimal integer ratio policy for the problem obtains a solution whose cost is at most 1.5% more than the lower bound.