A two-level hedging point policy for controlling a manufacturing system with time-delay,demand uncertainty and extra capacity

This paper focuses on the production control of a manufacturing system with time-delay, demand uncertainty and extra capacity. Time-delay is a typical feature of networked manufacturing systems (NMS), because an NMS is composed of many manufacturing systems with transportation channels among them and the transportation of materials needs time. Besides this, for a manufacturing system in an NMS, the uncertainty of the demand from its downstream manufacturing system is considered; and it is assumed that there exist two-levels of demand rates, i.e., the normal one and the higher one, and that the time between the switching of demand rates are exponentially distributed. To avoid the backlog of demands, it is also assumed that extra production capacity can be used when the work-in-process (WIP) cannot buffer the high-level demands rate. For such a manufacturing system with time-delay, demand uncertainty and extra capacity, the mathematical model for its production control problem is established, with the objective of minimizing the mean costs for WIP inventory and occupation of extra production capacity. To solve the problem, a two-level hedging point policy is proposed. By analyzing the probability distribution of system states, optimal values of the two hedging levels are obtained. Finally, numerical experiments are done to verify the effectiveness of the control policy and the optimality of the hedging levels.     

Base stock policies for production/inventory problems with uncertain capacity levels

In this paper we consider a single item, stochastic demand production/inventory problem where the maximum amount that can be produced (or ordered) in any given period is assumed to be uncertain. Inventory levels are reviewed periodically. The system operates under a stationary modified base stock policy. The intent of our paper is to present a procedure for computing the optimal base stocl level of this policy under expected average cost per period criterion. This procedure would provide guidance as to the appropriate amount of capacity to store in the form of inventory in the face of stochastic demand and uncertain capacity. In achieving this goal, our main contribution is to establish the analogy between the class of base stock production/inventory policies that operate under demand/capacity uncertainty, and the G/G/1 queues and their associated random walks. We also present example derivations for some important capacity distributions.     

Transient and steady-state analysis of a manufacturing system with setup changes

This paper deals with the optimal scheduling of a one-machine two-product manufacturing system with setup, operating in a continuous time dynamic environment. The machine is reliable. A known constant setup time is incurred when switching over from a part to the other. Each part has specified constant processing time and constant demand rate, as well as an infinite supply of raw material. The problem is formulated as a production flow control problem. The objective is to minimize the sum of the backlog and inventory costs incurred over a finite planning horizon. The global optimal solution, expressed as an optimal feedback control law, 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 (Limit Cycle) is determined. This is equivalent to solving a one-machine two-product Lot Scheduling Problem. To solve the transient case, the system's state space is partitioned into mutually exclusive regions such that with each region is associated an optimal control policy. A novel algorithm (Direction Sweeping Algorithm) is developed to obtain the optimal state trajectory (optimal policy that minimizes the sum of inventory and backlog costs) for this last case.     

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.     

Inventory Control for Supply Chains with Service Level Constraints: A Synergy between Large Deviations and Perturbation Analysis

We consider a model of a supply chain consisting of n production facilities in tandem and producing a single product class. External demand is met from the finished goods inventory maintained in front of the most downstream facility (stage 1); unsatisfied demand is backlogged. We adopt a base-stock production policy at each stage of the supply chain, according to which the facility at stage i produces if inventory falls below a certain level w _i and idles otherwise. We seek to optimize the hedging vector w=(w ₁,...,w _n ) to minimize expected inventory costs at all stages subject to maintaining the stockout probability at stage 1 below a prescribed level (service level constraint). We make rather general modeling assumptions on demand and production processes that include autocorrelated stochastic processes. We solve this stochastic optimization problem by combining analytical (large deviations) and sample path-based (perturbation analysis) techniques. We demonstrate that there is a natural synergy between these two approaches.     

Production control of an unreliable manufacturing system under the assumption of no backlog

This paper deals with an unreliable manufacturing system in which no backlog is allowed. The hedging point policy is used to control production. This paper's objective is to find the optimum hedging point so as to minimize the average inventory cost. Firstly, for a tentative hedging point, we derive the limiting distribution of the inventory level. This derivation is accomplished by comparison between this system and a finite storage-production system. Based on it we calculate the average inventory cost and find the optimum hedging point.This research was supported in part by the National Natural Science Foundation of China. Bin Liu was partially supported by ITDC, contract No. 105-82150.     

On the value of customer information for an independent supplier in a continuous review inventory system

We consider the inventory control problem of an independent supplier in a continuous review system. The supplier faces demand from a single customer who in turn faces Poisson demand and follows a continuous review (R, Q) policy. If no information about the inventory levels at the customer is available, reviews and ordering are usually carried out by the supplier only at points in time when a customer demand occurs. It is common to apply an installation stock reorder point policy. However, as the demand faced by the supplier is not Markovian, this policy can be improved by allowing placement of orders at any point in time. We develop a time delay policy for the supplier, wherein the supplier waits until time t after occurrence of the customer demand to place his next order. If the next customer demand occurs before this time delay, then the supplier places an order immediately. We develop an algorithm to determine the optimal time delay policy. We then evaluate the value of information about the customer’s inventory level. Our numerical study shows that if the supplier were to use the optimal time delay policy instead of the installation stock policy then the value of the customer’s inventory information is not very significant.     

Stockpiling under price uncertainty and storage capacity constraints

A model is presented for the operation of an agent whose responsibility is to purchase and perhaps stockpile sufficient quantities of a certain commodity in order to satisfy an exogenous constant demand per time period. This is the situation faced by a state agency which is responsible for the purchasing of oil products to satisfy the demand of a country in which demand for energy has stabilized at a certain level.An important feature of the model is that the price of the commodity is described by a stochastic process. This reflects the volatility of prices of oil products. Furthermore, the model takes storage capacity constraints explicitly into account, and thus can help to assess the optimal level of storage capacity expansion.The relevant stochastic dynamic programming equations are derived and solved for the least cost function, which turns out to be piecewise linear in the inventory level. The storage capacity enters only in the computation of the constant term of the value function. The solution of the dynamic programming equation leads also to the optimal purchasing strategy of agencies with different levels of flexibility in their policy: in the model, an agency can be allowed or not to resell from the stock and it can have finite or infinite storage capacity.     

A two-echelon base-stock inventory model with Poisson demand and the sequential processing of orders at the upper echelon

We consider a two-echelon inventory system with a number of non-identical, independent ‘retailers’ at the lower echelon and a single ‘supplier’ at the upper echelon. Each retailer experiences Poisson demand and operates a base stock policy with backorders. The supplier manufactures to order and holds no stock. Orders are produced, in first-come first-served sequence, with a fixed production time. The supplier therefore functions as an M/D/1 queue. We are interested in the performance characteristics (average inventory, average backorder level) at each retailer. By finding the distribution of order lead time and hence the distribution of demand during order lead time, we find the steady state inventory and backorder levels based on the assumption that order lead times are independent of demand during order lead time at a retailer. We also propose two alternative approximation procedures based on assumed forms for the order lead time distribution. Finally we provide a derivation of the steady state inventory and backorder levels which will be exact as long as there is no transportation time on orders between the supplier and retailers. A numerical comparison is made between the exact and approximate measures. We conclude by recommending an approach which is intuitive and computationally straightforward.     

Optimal control of an inventory-production system with state-dependent random yield

In this paper we study a single stage, periodic-review inventory problem for a single item with stochastic demand. The inventory manager determines order sizes according to an order-up-to logic and observes a random yield due to quality problems in the production. We distinguish between two different states of the production process combined with different probabilities to produce a defective unit. In order to improve the production process, periodic inspections are conducted and in case of a failure the machine is repaired. Approximations are developed to evaluate the average cost for a given order-up-to level and a given inspection interval and we illustrate the existence of optimal policy parameters. The approximations are tested in a simulation study and reveal an excellent performance as they lead to near optimal policy parameters. Moreover, we decompose the problem and test different methods to compute the policy parameters either sequentially or separately. Our results show that a joint optimization of the inventory and maintenance policy leads to a better system performance and reduced costs.     

Optimal Production and Setup Scheduling: A One-Machine, Two-Product System

This paper studies the scheduling problem for two products on a single production facility. The objective is to specify a production and setup policy that minimizes the average inventory, backlog, and setup costs. Assuming that the production rate can be adjusted during the production runs, we provide a close form for an optimal production and setup schedule. Dynamic programming and Hamilton–Jacobi–Bellman equation is used to verify the optimality of the obtained policy.     

大庆油田物资采购及库存优化机制设计与模型研究

本文结合大庆油田物资采购中的实际问题, 考虑物资市场、需求、库存三方之间的不确定性和复杂性,分别讨论了物资采购价格时变、物资需求时变、以及不同仓储容量限制下的库存优化模型的研究进展。进一步,设计了针对大庆油田物资的采购及库存优化机制,并选取大庆油田实际采购中的4种A类物资,基于时间序列方法和0-1混合整数规划,分别对机制中的价格预测部分和策略优化部分进行了数值试算,结果表明,基于准确度较高的预测价格,运用混合0-1整数规划模型制定的多品种物资的最优联合采购策略,可以实现采购成本的节省,相比于4种物资2009年的实际采购成本,节约比率高达7.66%,同时价格预测的精度也得到了用户的认可。该机制为油田物资采购和库存优化管理项目中的辅助决策支持系统原型设计提供了参照。但考虑到大庆油田实际采购中的各种复杂因素的影响,还需进一步完善该优化机制,并对相关模型进行改进。     

Age-dependent production planning and maintenance strategies in unreliable manufacturing systems with lost sale

In this paper, we formulate an analytical model for the joint determination of an optimal age-dependent buffer inventory and preventive maintenance policy in a production environment that is subject to random machine breakdowns. Traditional preventive maintenance policies, such as age and periodic replacements, are usually studied based on simplified and non-realistic assumptions, as well as on the expected costs criterion. Finished goods inventories and the age-dependent likelihood of machine breakdowns are usually not considered. As a result, these policies could significantly extend beyond the anticipated financial incomes of the system, and lead to crises. In order to solve this problem, a more realistic analysis model is proposed in this paper to consider the effects of both preventive maintenance policies and machine age on optimal safety stock levels. Hence, a unified framework is developed, allowing production and preventive maintenance to be jointly considered. We use an age-dependent optimization model based on the minimization of an overall cost function, including inventory holdings, lost sales, preventive and corrective maintenance costs. We provide optimality conditions for the manufacturing systems considered, and use numerical methods to obtain an optimal preventive maintenance policy and the relevant age-dependent threshold level production policy. In this work, this policy is called the multiple threshold levels hedging point policy. We include numerical examples and sensitivity analyses to illustrate the importance and the effectiveness of the proposed methodology. Compared with other available optimal production and maintenance policies, the numerical solution obtained shows that the proposed age-dependent optimal production and maintenance policies significantly reduce the overall cost incurred.     

Inventory rationing in an (<Emphasis Type="Italic">s,Q</Emphasis>) inventory model with lost sales and two demand classes

Whenever demand for a single item can be categorised into classes of different priority, an inventory rationing policy should be considered. In this paper we analyse a continuous review (s, Q) model with lost sales and two demand classes. A so-called critical level policy is applied to ration the inventory among the two demand classes. With this policy, low-priority demand is rejected in anticipation of future high-priority demand whenever the inventory level is at or below a prespecified critical level. For Poisson demand and deterministic lead times, we present an exact formulation of the average inventory cost. A simple optimisation procedure is presented, and in a numerical study we compare the optimal rationing policy with a policy where no distinction between the demand classes is made. The benefit of the rationing policy is investigated for various cases and the results show that significant cost reductions can be obtained.     

随机需求下考虑半成品库存的多周期生产决策优化

为了更好地应对需求的不确定性,在需求实现之前,企业既可以生产成品直接满足需求,亦可生产部分半成品,在观察到实际需求之后短时间内迅速完成剩余生产环节以满足需求。未加工的半成品和未售出的成品可用于满足后续周期的需求。作为一种提高生产灵活性的手段,分阶段生产的方式会产生更高的成本。企业需要在成本和灵活性之间作出权衡,优化生产决策。模型通过动态规划的方法,研究需求不确定情况下考虑半成品库存的多周期生产决策问题,通过分析目标函数以及最优值函数的结构性质,推导出最优的多周期生产策略为修正的目标库存策略,并且分析了不同参数对最优策略的影响。     

Base stock policy with retrial demands

In this work, we consider a continuous review base stock policy inventory system with retrial demands. The maximum storage capacity is S. It is assumed that primary demand is of unit size and primary demand time points form a Poisson process. A one-to-one ordering policy is adopted. According to this policy, orders are placed for one unit, as and when the inventory level drops due to a demand. We assume that the demands occur during the stock-out periods enter into the orbit of infinite size. The lead time is assumed to be exponential. The joint probability distribution of the inventory level and the number of demands in the orbit are obtained in the steady state case. Various system performance measures in the steady state are derived. The results are illustrated with suitable numerical examples.     

Inventory control by different service levels

This paper examines the multiple period inventory control problem of a single product with multiple (two) prices, depending on service level, in which optimal pricing and ordering decisions are made in each period. Traditional inventory and pricing models consider only single products, single prices, and single service levels. However, this research paper finds that a seller can improve inventory control and revenue by offering multiple prices depending on service level. This research considers a single product with multiple (two) pricing policies corresponding to service level as follows: if the customer is willing to delay the shipment, he/she will be offered a lower regular price. Otherwise, the customer will pay the regular price plus extra charges for express service. In this paper, I show the following: (1) there is an optimal pricing and replenishment policy that can control inventory and (2) there exists a finite threshold for inventory levels such that if the inventory level at the beginning of each period is higher than the threshold, the customer will be offered the express service at the regular price, without any extra charge.     

The influence of demand variability on the performance of a make-to-stock queue

Variability, in general, has a deteriorating effect on the performance of stochastic inventory systems. In particular, previous results indicate that demand variability causes a performance degradation in terms of inventory related costs when production capacity is unlimited. In order to investigate the effects of demand variability in capacitated production settings, we analyze a make-to-stock queue with general demand arrival times operated according to a base-stock policy. We show that when demand inter-arrival distributions are ordered in a stochastic sense, increased arrival time variability indeed leads to an augmentation of optimal base-stock levels and to a corresponding increase in optimal inventory related costs. We quantify these effects through several numerical examples.     

Optimal integrated production and inventory control of an assemble-to-order system with multiple non-unitary demand classes

We study a pure assemble-to-order system subject to multiple demand classes where customer orders arrive according to a compound Poisson process. The finished product is assembled from m different components that are produced on m distinct production facilities in a make-to-stock fashion. We show that the optimal production policy of each component is a state-dependent base-stock policy and the optimal inventory allocation policy is a multi-level state-dependent rationing policy. Using numerical experimentation, we first study the system behavior as a function of order size variability and order size. We show that the optimal average cost rate is more sensitive to order size variability than to order size. We also compare the optimal policy to the first-come first-serve policy and show that there is great benefit to inventory rationing. We also propose two simple heuristics and show that these can effectively mimic the optimal policy which is generally much more difficult to determine and, especially, to implement.     

Flexible capacity strategy with multiple market periods under demand uncertainty and investment constraint

We establish a flexible capacity strategy model with multiple market periods under demand uncertainty and investment constraints. In the model, a firm makes its capacity decision under a financial budget constraint at the beginning of the planning horizon which embraces n market periods. In each market period, the firm goes through three decision-making stages: the safety production stage, the additional production stage and the optimal sales stage. We formulate the problem and obtain the optimal capacity, the optimal safety production, the optimal additional production and the optimal sales of each market period under different situations. We find that there are two thresholds for the unit capacity cost. When the capacity cost is very low, the optimal capacity is determined by its financial budget; when the capacity cost is very high, the firm keeps its optimal capacity at its safety production level; and when the cost is in between of the two thresholds, the optimal capacity is determined by the capacity cost, the number of market periods and the unit cost of additional production. Further, we explore the endogenous safety production level. We verify the conditions under which the firm has different optimal safety production levels. Finally, we prove that the firm can benefit from the investment only when the designed planning horizon is longer than a threshold. Moreover, we also derive the formulae for the above three thresholds.