An exact solution procedure for multi-item two-echelon spare parts inventory control problem with batch ordering in the central warehouse

We consider a multi-item two-echelon inventory system in which the central warehouse operates under a (Q,R) policy, and the local warehouses implement basestock policy. An exact solution procedure is proposed to find the inventory control policy parameters that minimize the system-wide inventory holding and fixed ordering cost subject to an aggregate mean response time constraint at each facility.     

An efficient algorithm for a generalized joint replenishment problem

In most multi-item inventory systems, the ordering costs consist of a major cost and a minor cost for each item included. Applying for every individual item a cyclic inventory policy, where the cycle length is a multiple of some basic cycle time, reduces the major ordering costs. An efficient algorithm to determine the optimal policy of this type is discussed in this paper. It is shown that this algorithm can be used for deterministic multi-item inventory problems, with general cost rate functions and possibly service level constraints, of which the well-known joint replenishment problem is a special case. Some useful results in determining the optimal control parameters are derived, and worked out for piecewise linear cost rate functions. Numerical results for this case show that the algorithm significantly outperforms other solution methods, both in the quality of the solution and in the running time.     

Towards a normative model for inventory cost management in a generalized ABC classification system

This paper establishes a general ABC inventory classification system as the foundation for a normative model of the maintenance cost structure and stock turnover characteristics of a large, multi-item inventory system with constant demand. For any specified number of inventory classes, the model allows expression of the overall system combined ordering and holding cost in terms of (i) the re-ordering frequencies for the items in each inventory class and (ii) the inventory class structure, that is, the proportion of the total system's items that are in each inventory class. The model yields a minimum total maintenance cost function, which reflects the effect of class structure on inventory maintenance costs and turnover. If the Pareto curve (a.k.a. Distribution-by-value function) for the inventory system can be expressed (or approximated) analytically, the model can also be used to determine an optimal class structure, as well as an appropriate number of inventory classes. A special case of the model produces a simply structured, class-based ordering policy for minimizing total inventory maintenance costs. Using real data, the cost characteristics of this policy are compared to those of a heuristic, commonly used by managers of multi-item inventory systems. This cost comparison, expressed graphically, underscores the need for normative modelling approaches to the problem of inventory cost management in large, multi-item systems.     

Inventory control for point-of-use locations in hospitals

Most inventory management systems at hospital departments are characterised by lost sales, periodic reviews with short lead times, and limited storage capacity. We develop two types of exact models that deal with all these characteristics. In a capacity model, the service level is maximised subject to a capacity restriction, and in a service model the required capacity is minimised subject to a service level restriction. We also formulate approximation models applicable for any lost-sales inventory system (cost objective, no lead time restrictions etc). For the capacity model, we develop a simple inventory rule to set the reorder levels and order quantities. Numerical results for this inventory rule show an average deviation of 1% from the optimal service levels. We also embed the single-item models in a multi-item system. Furthermore, we compare the performance of fixed order size replenishment policies and (R,?s,?S) policies.     

Multi-item two-echelon spare parts inventory control problem with batch ordering in the central warehouse under compound Poisson demand

We consider a multi-item two-echelon spare part inventory system in which the central warehouse operates under an (nQ,?R) policy and the local warehouses implement order-up-to S policy, each facing a compound Poisson demand. The objective is to find the policy parameters minimizing expected system-wide inventory holding and fixed ordering costs subject to an aggregate mean response time constraint at each warehouse. In this paper, we propose four alternative approximations for the steady state performance of the system; and extend a heuristic and a lower bound proposed under Poisson demand assumption to the compound Poisson setting. In a computational study, we show that the performances of the approximations, the heuristic, and the lower bound are quite satisfactory; and the relative cost saving of setting an aggregate service level rather than individually for each part is quite high.     

Dynamic inventory and pricing policy in a capacitated stochastic inventory system with fixed ordering cost

We study a dynamic inventory and pricing optimization problem in a periodic review inventory system with setup cost and finite ordering capacity in each period. We show that the optimal inventory control is characterized by an (s,s^′,p) policy in four regions of the starting inventory level.     

Stochastic decomposition in production inventory with service time

We study an (s, S) production inventory system where the processing of inventory requires a positive random amount of time. As a consequence a queue of demands is formed. Demand process is assumed to be Poisson, duration of each service and time required to add an item to the inventory when the production is on, are independent, non-identically distributed exponential random variables. We assume that no customer joins the queue when the inventory level is zero. This assumption leads to an explicit product form solution for the steady state probability vector, using a simple approach. This is despite the fact that there is a strong correlation between the lead-time (the time required to add an item into the inventory) and the number of customers waiting in the system. The technique is: combine the steady state vector of the classical M/M/1 queue and the steady state vector of a production inventory system where the service is instantaneous and no backlogs are allowed. Using a similar technique, the expected length of a production cycle is also obtained explicitly. The optimal values of S and the production switching on level s have been studied for a cost function involving the steady state system performance measures. Since we have obtained explicit expressions for the performance measures, analytic expressions have been derived for calculating the optimal values of S and s.     

Modelling and analysis for capacity expansion planning in warehousing

In this paper, a dynamic programming model is developed for the purpose of establishing a warehouse capacity expansion schedule and underlying multi-item inventory policy that are jointly optimal. The optimal warehouse size over any segment of the planning horizon is obtained by solving a nonlinear optimisation problem, this being accomplished efficiently by exploiting the Kuhn–Tucker conditions. Repeating this procedure between each pair of time periods results in a discrete state space, so that the optimal capacity expansion schedule corresponds to a shortest path in a network. Managerial insights are provided through experimentation with the model.     

Periodic review inventory systems with a service level criterion

Full-cost inventory models are mostly studied in the literature, whereas service level constraints are more common to be observed in practical settings. In this paper, we consider periodic review inventory systems with service level restrictions. The control of such inventory systems is limited to (s, S)-type policies in the literature. To the best of our knowledge, we are the first authors to compare such policies with optimal replenishment policies, and illustrate an average cost difference of 0.64%. This justifies the use of these popular (s, S) policies in practice. Furthermore, we propose a new one-dimensional search procedure that is bounded to set the reorder level s and order-up-to level S, whereas the solution space is unbounded and two dimensional. Our heuristic procedure is guaranteed to satisfy the service level constraint and numerical experiments illustrate that it results in an average cost deviation of 1–2% compared with the best (s, S) policy. Consequently, it significantly outperforms all existing procedures from literature, both in service and costs.     

Service differentiation in spare parts inventory management

The contemporary after-sales market is of increasing importance. One of the features required by the market is to provide differentiated service levels to different groups of customers. We use critical levels as a means to offer differentiation. Critical level policies aim to exploit the differences in target service levels by inventory rationing. In our multi-item single-location spare parts inventory model, we aim to minimize the spare parts provisioning cost, that is inventory holding and transportation cost, under the condition that aggregate mean waiting time constraints for all customer groups are met. In a computational experiment and a case study with data from a company in the semiconductor supplier industry, we show that significant cost reductions can be obtained when critical level policies are used instead of base stock policies (ie policies without critical levels).     

A periodic-review inventory system with a capacitated backup supplier for mitigating supply disruptions

We consider a periodic-review inventory system with two suppliers: an unreliable regular supplier that may be disrupted for a random duration, and a reliable backup supplier that can be used during a disruption. The backup supplier charges higher unit purchasing cost and fixed order cost when compared to the regular supplier. Because the backup supplier is used at unplanned moments, its capacity to replenish inventory is considered limited. Analytical results partially characterize the structure of the optimal order policy: a state-dependent (X(i), Y(i)) band structure (with corresponding bounds of X(i) and Y(i) to be given), where i represents the status of the regular supplier. Numerical studies illustrate the structure of the optimal policy and investigate the impacts of major parameters on optimal order decisions and system costs.     

The scheduling of deliveries in a production-distribution system with multiple buyers

In a real production and distribution business environment with one supplier and multiple heterogeneous buyers, the differences in buyers’ ordering cycles have influence on production arrangements. Consequently, the average inventory level (AIL) at the supplier’s end is affected by both the production policy and the ordering policy, typically by the scheduling of deliveries. Consequently, the average inventory holding cost is most deeply affected. In this paper, it is proposed that the scheduling of deliveries be formulated as a decision problem to determine the time point at which deliveries are made to buyers in order to minimize the supplier’s average inventory. A formulation of the average inventory level (AIL) in a production cycle at the supplier’s end using a lot-for-lot policy is developed. Under the lot-for-lot policy, the scheduling of deliveries (SP) is formulated as a nonlinear programming model used to determine the first delivery point for each buyer with an objective to minimize the sum of the product of the individual demand quantity and the first delivery time for each buyer. Thus, the SP model determines not only the sequence of the first deliveries to individual buyers, but also the time when the deliveries are made. An iterative heuristic procedure (IHP) is developed to solve the SP model assuming a given sequence of buyers. Six sequence rules are considered and evaluated via simulation.     

Inventory models with minimal service level constraints

This paper investigates inventory models in which the stockout cost is replaced by a minimal service level constraint (SLC) that requires a certain level of service to be met in every period. The minimal service level approach has the virtue of simplifying the computation of an optimal ordering policy, because the optimal reorder level is solely determined by the minimal SLC and demand distributions. It is found that above a certain “critical” service level, the optimal (s,S) policy “collapses” to a simple base-stock or order-up-to level policy, which is independent on the cost parameters. This shows the minimal SLC models to be qualitatively different from their shortage cost counterparts. We also demonstrate that the “imputed shortage cost” transforming a minimal SLC model to a shortage cost model does not generally exist. The minimal SLC approach is extended to models with negligible set-up costs. The optimality of myopic base-stock policies is established under mild conditions.     

A simulation optimization approach for a two-echelon inventory system with service level constraints

In this paper, we present a simulation optimization algorithm for solving the two-echelon constrained inventory problem. The goal is to determine the optimal setting of stocking levels to minimize the total inventory investment costs while satisfying the expected response time targets for each field depot. The proposed algorithm is more adaptive than ordinary optimization algorithms, and can be applied to any multi-item multi-echelon inventory system, where the cost structure and service level function resemble what we assume. Empirical studies are performed to compare the efficiency of the proposed algorithms with other existing simulation algorithms.     

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.     

A coordinated location-inventory model

We consider a coordinated location-inventory model where distribution centers (DCs) follow a periodic-review (R, S) inventory policy and system coordination is achieved by choosing review intervals at the DCs from a menu of permissible choices. We introduce two types of coordination: partial coordination where each DC may choose its own review interval from the menu, and full coordination where all the DCs have an identical review interval. While full coordination increases the location and inventory costs, it likely reduces the overall costs of running the system (when the operational costs such as delivery scheduling are taken into account). The problem is to determine the location of the DCs to be opened, the assignment of retailers to DCs, and the inventory policy parameters at the DCs such that the total system-wide cost is minimized. The model is formulated as a nonlinear integer-programming problem and a Lagrangian relaxation algorithm is proposed to solve it. Computational results show that the proposed algorithm is very efficient. The results of our computational experiments and case study suggest that the location and inventory cost increase due to full coordination, when compared to partial coordination, is not significant. Thus, full coordination, while enhancing the practicality of the model, is economically justifiable.     

A displayed inventory model with L–R fuzzy number

In this study, we formulate a multi-item displayed inventory model under shelf-space constraint in fuzzy environment. Here demand rate of an item is considered as a function of the displayed inventory level. The problem is formulated to maximize average profit. In real life situation, the goals and inventory parameters are may not precise. Such type of uncertainty may be characterized by fuzzy numbers. Here, the constraint goal and the inventory cost parameters are assumed to be triangular shaped fuzzy numbers with different types of left and right membership functions. The fuzzy numbers are then approximated to a nearest interval number. Using arithmetic of interval numbers, the problem is described as a multi-objective inventory problem. The problem is then solved by fuzzy geometric programming approach. Finally a numerical example is given to illustrate the problem.     

Optimal EOQ Models for Deteriorating Items with Time-Varying Demand

In this paper, optimal inventory lot-sizing models are developed for deteriorating items with general continuous time-varying demand over a finite planning horizon and under three replenishment policies. The deterioration rate is assumed to be a constant fraction of the on-hand inventory. Shortages are permitted and are completely backordered. The proposed solution procedures are shown to generate global minimum replenishment schedules for both general increasing and decreasing demand patterns. An extensive empirical comparison using randomly generated linear and exponential demands revealed that the replenishment policy which starts with shortages in every cycle is the least cost policy and the replenishment policy which prohibits shortages in the last cycle exhibited the best service level effectiveness. An optimal procedure for the same problem with trended inventory subject to a single constraint on the minimum service level (maximum fraction of time the inventory system is out of stock during the planning horizon) is also proposed in this paper.     

An optimal replacement policy for a multistate degenerative simple system

In this paper, a degenerative simple system (i.e. a degenerative one-component system with one repairman) with k + 1 states, including k failure states and one working state, is studied. Assume that the system after repair is not “as good as new”, and the degeneration of the system is stochastic. Under these assumptions, we consider a new replacement policy T based on the system age. Our problem is to determine an optimal replacement policy T^∗ such that the average cost rate (i.e. the long-run average cost per unit time) of the system is minimized. The explicit expression of the average cost rate is derived, the corresponding optimal replacement policy can be determined, the explicit expression of the minimum of the average cost rate can be found and under some mild conditions the existence and uniqueness of the optimal policy T^∗ can be proved, too. Further, we can show that the repair model for the multistate system in this paper forms a general monotone process repair model which includes the geometric process repair model as a special case. We can also show that the repair model in the paper is equivalent to a geometric process repair model for a two-state degenerative simple system in the sense that they have the same average cost rate and the same optimal policy. Finally, a numerical example is given to illustrate the theoretical results of this model.     

Modeling and analysis for determining optimal suppliers under stochastic lead times

The policy of simultaneously splitting replenishment orders among several suppliers has received considerable attention in the last few years and continues to attract the attention of researchers. In this paper, we develop a mathematical model which considers multiple-supplier single-item inventory systems. The item acquisition lead times of suppliers are random variables. Backorder is allowed and shortage cost is charged based on not only per unit in shortage but also per time unit. Continuous review (s,Q)$(s\text{,}Q)$ policy has been assumed. When the inventory level depletes to a reorder level, the total order is split among n suppliers. Since the suppliers have different characteristics, the quantity ordered to different suppliers may be different. The problem is to determine the reorder level and quantity ordered to each supplier so that the expected total cost per time unit, including ordering cost, procurement cost, inventory holding cost, and shortage cost, is minimized. We also conduct extensive numerical experiments to show the advantages of our model compared with the models in the literature. According to our extensive experiments, the model developed in this paper is the best model in the literature which considers order splitting for n-supplier inventory systems since it is the nearest model to the real inventory system.