A stochastic production planning model with a dynamic chance constraint

This paper deals with the optimal production planning for a single product over a finite horizon. The holding and production costs are assumed quadratic as in Holt, Modigliani, Muth and Simon (HMMS) [7] model. The cumulative demand is compound Poisson and a chance constraint is included to guarantee that the inventory level is positive with a probability of at least α at each time point. The resulting stochastic optimization problem is transformed into a deterministic optimal control problem with control variable and of the optimal solution is presented. The form of state variable inequality constraints. A discussion the optimal control (production rate) is obtained as follows: if there exists a time t₁ such that t₁?[O, T]where T is the end of the planning period, then (i) produce nothing until t₁ and (ii) produce at a rate equal to the expected demand plus a ‘correction factor’ between t₁ and T. If t₁ is found to be greater than T, then the optimal decision is to produce nothing and always meet the demand from the inventory.     

Production strategies for a stochastic lot-sizing problem with constant capacity

This paper presents a single item capacitated stochastic lot-sizing problem motibated by a Dutch company operating in a Make-To-Order environment. Due to a highly fluctuating and unpredictable demand, it is not possible to keep any finished goods inventory. In response to a customer's order, a fixed delivery date is quoted by the company. The objective is to determine in each period of the planning horizon the optimal size of production lots so that delivery dates are met as closely as possible at the expense of minimal average costs. These include set-up costs, holding costs for orders that are finished before their promised delivery date and penalty costs for orders that are not satisfied on time and are therefore backordered. Given that the optimal production policy is likely to be too complex in this situation, attention is focused on the development of heuristic procedures. In this paper two heuristics are proposed. The first one is an extension of a simple production strategy derived by Dellaert [5] for the uncapacitated version of the problem. The second heuristic is based on the well-known Silver-Meal algorithm for the case of deterministic time-varying demand. Experimental results suggest that the first heuristic gives low average costs especially when the demand variability is low and there are large differences in the cost parameters. The Silver-Meal approach is usually outperformed by the first heuristic in situations where the available production capacity is tight and the demand variability is low.     

Dynamic economic lot size model with perishable inventory and capacity constraints

In this study, we consider a dynamic economic lot sizing problem for a single perishable item under production capacities. We aim to identify the production, inventory and backlogging decisions over the planning horizon, where (i) the parameters of the problem are deterministic but changing over time, and (ii) producer has a constant production capacity that limits the production amount at each period and is allowed to backorder the unmet demand later on. All cost functions are assumed to be concave. A similar problem without production capacities was studied in the literature and a polynomial time algorithm was suggested (Hsu, 2003 [1]). We assume age-dependent holding cost functions and the deterioration rates, which are more realistic for perishable items. Backordering cost functions are period-pair dependent. We prove the NP-hardness of the problem even with zero inventory holding and backlogging costs under our assumptions. We show the structural properties of the optimal solution and suggest a heuristic that finds a good production and distribution plan when the production periods are given. We discuss the performance of the heuristic. We also give a Dynamic Programing-based heuristic for the solution of the overall problem.     

Dynamic cost allocation for economic lot sizing games

We consider a cooperative game defined by an economic lot sizing problem with concave ordering costs over a finite time horizon, in which each player faces demand for a single product in each period and coalitions can pool orders. We show how to compute a dynamic cost allocation in the strong sequential core of this game, i.e. an allocation over time that exactly distributes costs and is stable against coalitional defections at every period of the time horizon.     

3.1. OR in banking

In this paper, we describe a deterministic multiperiod capacity expansion model in which a single facility serves the demand for many products. Potential applications for the model can be found in the capacity expansion planning of communication systems as well as in the production planning of heavy process industries. The model assumes that each capacity unit simultaneously serves a prespecified (though not necessarily integer) number of demand units of each product. Costs considered include capacity expansion costs, idle capacity holding costs, and capacity shortage costs. All cost functions are assumed to be nondecreasing and concave. Given the demand for each product over the planning horizon, the objective is to find the capacity expansion policy that minimizes the total cost incurred. We develop a dynamic programming algorithm that finds optimal policies. The required computational effort is a polynomial function of the number of products and the number of time periods. When the number of products equals one, the algorithm reduces to the well-known algorithm for the classical dynamic lot size problem.     

Computing a Stationary Base-Stock Policy for a Finite Horizon Stochastic Inventory Problem with Non-linear Shortage Costs

Abstract

We consider a periodic-review stochastic inventory problem in which demands for a single product in each of a finite number of periods are independent and identically distributed random variables. We analyze the case where shortages (stockouts) are penalized via fixed and proportional costs simultaneously. For this problem, due to the finiteness of the planning horizon and non-linearity of the shortage costs, computing the optimal inventory policy requires a substantial effort as noted in the previous literature. Hence, our paper is aimed at reducing this computational burden. As a resolution, we propose to compute “the best stationary policy.” To this end, we restrict our attention to the class of stationary base-stock policies, and show that the multi-period, stochastic, dynamic problem at hand can be reduced to a deterministic, static equivalent. Using this important result, we introduce a model for computing an optimal stationary base-stock policy for the finite horizon problem under consideration. Fundamental analytic conclusions, some numerical examples, and related research findings are also discussed.     

A Finite Horizon Production Model with Variable Production Rates and Constant Demand Rate

In this paper we present a finite horizon single product single machine production problem. Demand rate and all the cost patterns do not change over time. However, end of horizon effects may require production rate adjustments at the beginning of each cycle. It is found that no such adjustments are required. The machine should be operated either at minimum speed (i.e. production rate = demand rate; shortage is not allowed), avoiding the buildup of any inventory, or at maximum speed, building up maximum inventories that are controlled by the optimal production lot size.     

An Exact Solution Algorithm for a Class of Production Planning and Scheduling Problems

This paper presents a formulation and an exact solution algorithm for a class of production planning and scheduling problems. The problem is one of optimally specifying production levels for each product in each period of the planning horizon. The objective is to minimize the sum of the set-up, regular time production, overtime and inventory holding costs. The problem has been formulated as a variation of fixed charge transportation problem. The problem discussed here is NP-hard in computational complexity. A numerical example is presented for better understanding of the algorithm.     

Unbounded knapsack problem with controllable rates: the case of a random demand for items

This paper focuses on a dynamic, continuous-time control generalization of the unbounded knapsack problem. This generalization implies that putting items in a knapsack takes time and has a due date. Specifically, the problem is characterized by a limited production horizon and a number of item types. Given an unbounded number of copies of each type of item, the items can be put into a knapsack at a controllable production rate subject to the available capacity. The demand for items is not known until the end of the production horizon. The objective is to collect items of each type in order to minimize shortage and surplus costs with respect to the demand. We prove that this continuous-time problem can be reduced to a number of discrete-time problems. As a result, solvable cases are found and a polynomial-time algorithm is suggested to approximate the optimal solution with any desired precision.     

Opportunistic supply chain formation from qualified partners for a new market demand

This paper addresses the problem of short-term supply chain design using the idle capacities of qualified partners in order to seize a new market opportunity. The new market opportunity is characterized by a deterministic forecast over a planning horizon. The production–distribution process is assumed to be organized in stages or echelons, and each echelon may have several qualified partners willing to participate. Partners within the echelon may differ in idle production capacity, operational cost, storage cost, etc, and we assume that idle capacity may be different from one period to another period. The objective is to design a supply chain by selecting one partner from each echelon to meet the forecasted demand without backlog and best possible production and logistics costs over the given planning horizon. The overall problem is formulated as a large mixed integer linear programming problem. We develop a decomposition-based solution approach that is capable of overcoming the complexity and dimensionality associated with the problem. Numerical results are presented to support the effectiveness of this approach.     

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.     

A dynamic production planning and scheduling algorithm for two products processed on one line

This paper presents a dynamic production planning and scheduling algorithm for two products processed on one line over a fixed time horizon. Production rates are assumed fixed, and restrictions are placed or inventory levels and production run lengths. The resulting problem is a nonlinear binary program, which is solved using an implicit enumeration strategy. The algorithm focuses on the run changeover period while developing tighter bounds on the length of the upcoming run to improve computational efficiency. About 99% pf 297 randomly generated problems with varying demand patterns are solved in less than 15 seconds of CPU time on a CDC Cyber 172 Computer. A mixed integer programming formulation of the generalized multi-product case under no-backlogging of demand is also given.     

Multi-item single source ordering problem with transportation cost: A Lagrangian decomposition approach

As a part of supply chain management literature and practice, it has been recognized that there can be significant gains in integrating inventory and transportation decisions. The problem we tackle here is a common one both in retail and production sectors where several items have to be ordered from a single supplier. We assume that there is a finite planning horizon to make the ordering decisions for the items, and in this finite horizon the retailer or the producer knows the demand of each item in each period. In addition to the inventory holding cost, an item-base fixed cost associated with each item included in the order, and a piecewise linear transportation cost are incurred. We suggest a Lagrangean decomposition based solution procedure for the problem and carry out numerical experiments to analyze the value of integrating inventory and transportation decisions under different scenarios.     

Managing capacity flexibility in make-to-order production environments

This paper addresses the problem of managing flexible production capacity in a make-to-order (MTO) manufacturing environment. We present a multi-period capacity management model where we distinguish between process flexibility (the ability to produce multiple products on multiple production lines) and operational flexibility (the ability to dynamically change capacity allocations among different product families over time). For operational flexibility, we consider two polices: a fixed allocation policy where the capacity allocations are fixed throughout the planning horizon and a dynamic allocation policy where the capacity allocations change from period to period. The former approach is modeled as a single-stage stochastic program and solved using a cutting-plane method. The latter approach is modeled as a multi-stage stochastic program and a sampling-based decomposition method is presented to identify a feasible policy and assess the quality of that policy. A computational experiment quantifies the benefits of operational flexibility and demonstrates that it is most beneficial when the demand and capacity are well-balanced and the demand variability is high. Additionally, our results reveal that myopic operating policies may lead a firm to adopt more process flexibility and form denser flexibility configuration chains. That is, process flexibility may be over-valued in the literature since it is assumed that a firm will operate optimally after the process flexibility decision. We also show that the value of process flexibility increases with the number of periods in the planning horizon if an optimal operating policy is employed. This result is reversed if a myopic allocation policy is adopted instead.     

A polynomial time algorithm to solve the single-item capacitated lot sizing problem with minimum order quantities and concave costs

This paper deals with the single-item capacitated lot sizing problem with concave production and storage costs, and minimum order quantity (CLSP-MOQ). In this problem, a demand must be satisfied at each period t over a planning horizon of T periods. This demand can be satisfied from the stock or by a production at the same period. When a production is made at period t, the produced quantity must be greater to than a minimum order quantity (L) and lesser than the production capacity (U). To solve this problem optimally, a polynomial time algorithm in O(T⁵) is proposed and it is computationally tested on various instances.     

Optimal spot market inventory strategies in the presence of cost and price risk

We consider a firm facing random demand at the end of a single period of random length. At any time during the period, the firm can either increase or decrease inventory by buying or selling on a spot market where price fluctuates randomly over time. The firm’s goal is to maximize expected discounted profit over the period, where profit consists of the revenue from selling goods to meet demand, on the spot market, or in salvage, minus the cost of buying goods, and transaction, penalty, and holding costs. We first show that this optimization problem is equivalent to a two-dimensional singular control problem. We then use a recently developed control-theoretic approach to show that the optimal policy is completely characterized by a simple price-dependent two-threshold policy. In a series of computational experiments, we explore the value of actively managing inventory during the period rather than making a purchase decision at the start of the period, and then passively waiting for demand. In these experiments, we observe that as price volatility increases, the value of actively managing inventory increases until some limit is reached.     

Multi-Item Single-Level Capacitated Dynamic Lot-Sizing Heuristics: A General Review

The multi-item single-level capacitated lot-sizing problem consists of scheduling N different items over a horizon of T periods. The objective is to minimize the sum of set-up and inventory-holding costs over the horizon, subject to a capacity restriction in each period. Different heuristic approaches have been suggested to solve this difficult mathematical problem. So far, only a few limited attempts have been made to analyse and compare these approaches. The paper can be divided into two main parts. The first part shows that current heuristics can be classified in two different categories: single-resource heuristics, which are special-purpose methods, and mathematical-programming-based heuristics, which can usually deal with more general problem environments. The second part is devoted to an extensive computational review. The general idea is to find relationships between the performance of the heuristic and the computational burden involved in finding the solution. Based on these computational results, suggestions can be given with respect to the usefulness of the various heuristics in different industrial settings.     

An integrated production and preventive maintenance planning model

We are given a set of items that must be produced in lots on a capacitated production system throughout a specified finite planning horizon. We assume that the production system is subject to random failures, and that any maintenance action carried out on the system, in a period, reduces the system’s available production capacity during that period. The objective is to find an integrated lot-sizing and preventive maintenance strategy of the system that satisfies the demand for all items over the entire horizon without backlogging, and which minimizes the expected sum of production and maintenance costs. We show how this problem can be formulated and solved as a multi-item capacitated lot-sizing problem on a system that is periodically renewed and minimally repaired at failure. We also provide an illustrative example that shows the steps to obtain an optimal integrated production and maintenance strategy.     

A stochastic programming approach for planning horizons of infinite horizon capacity planning problems

Planning horizon is a key issue in production planning. Different from previous approaches based on Markov Decision Processes, we study the planning horizon of capacity planning problems within the framework of stochastic programming. We first consider an infinite horizon stochastic capacity planning model involving a single resource, linear cost structure, and discrete distributions for general stochastic cost and demand data (non-Markovian and non-stationary). We give sufficient conditions for the existence of an optimal solution. Furthermore, we study the monotonicity property of the finite horizon approximation of the original problem. We show that, the optimal objective value and solution of the finite horizon approximation problem will converge to the optimal objective value and solution of the infinite horizon problem, when the time horizon goes to infinity. These convergence results, together with the integrality of decision variables, imply the existence of a planning horizon. We also develop a useful formula to calculate an upper bound on the planning horizon. Then by decomposition, we show the existence of a planning horizon for a class of very general stochastic capacity planning problems, which have complicated decision structure.     

Synchronized routing of seasonal products through a production/distribution network

This paper presents a multi-period vehicle routing problem for a large-scale production and distribution network. The vehicles must be routed in such a way as to minimize travel and inventory costs over a multi-period horizon, while also taking retailer demands and the availability of products at a central production facility into account. The network is composed of one distribution center and hundreds of retailers. Each retailer has its demand schedule representing the total number of units of a given product that should have been received on a given day. Many high value products are distributed. Product availability is determined by the production facility, whose production schedule determines how many units of each product must be available on a given day. To distribute these products, the routes of a heterogeneous fleet must be determined for a multiple period horizon. The objective of our research is to minimize the cost of distributing products to the retailers and the cost of maintaining inventory at the facility. In addition to considering product availability, the routing schedule must respect many constraints, such as capacity restrictions on the routes and the possibility of multiple vehicle trips over the time horizon. In the situation studied, no more than 20 product units could be carried by a single vehicle, which generally limited the number of retailers that could be supplied to one or two per route. This article proposes a mathematical formulation, as well as some heuristics, for solving this single-retailer-route vehicle routing problem. Extensions are then proposed to deal with the multiple-retailer-route situation.