A production–inventory model in an imperfect production process

The paper develops a model to determine the optimal product reliability and production rate that achieves the biggest total integrated profit for an imperfect manufacturing process. The basic assumption of the classical Economic Manufacturing Quantity (EMQ) model is that all manufacturing items are of perfect quality. The assumption is not true in practice. Most of the production system produces perfect and imperfect quality items. In some cases the imperfect quality (non conforming) items are reworked at a cost to restore its quality to the original one. Rework cost may be reduced by improvements in product reliability (i.e., decreasing in product reliability parameter). Lower value of product reliability parameter results in increase development cost of production and also smaller quantity of nonconforming products. The unit production cost is a function of product reliability parameter and production rate. As a result, higher development cost increases unit production cost. The problem of optimal planning work and rework processes belongs to the broad field of production–inventory model which deals with all kinds of reuse processes in supply chains. These processes aim to recover defective product items in such a way that they meet the quality level of ‘good item’. The benefits from imperfect quality items are: regaining the material and value added on defective items and improving the environment protection. In this point of view, a model is introduced here to guide a firm/industry in addressing variable product reliability factor, variable unit production cost and dynamic production rate for time-varying demand. The paper provides an optimal control formulation of the problem and develops necessary and sufficient conditions for optimality of the dynamic variables. In this purpose, the Euler–Lagrange method is used to obtain optimal solutions for product reliability parameter and dynamic production rate. Finally, numerical examples are given to illustrate the proposed model.     

新产品定价决策的影响因素分析

新产品的成功销售取决于两个重要的因素:一是具有生产特性的工程变量,比如产品的可靠性水平;一是具有市场特征的影响因素,比如价格和保障机制。为了实现收益,制造商必须认真审视价格、产品可靠性和保障机制的选择。因此,本文将价格作为外生变量,将保障机制与可靠性作为决策变量,建立了以最大化为目标的收益模型,分析可靠性与保障机制的最优策略。另外,探讨当不同变量的敏感性参数发生变化时,最优保障机制与产品可靠性的变化规律。最后,通过算例分析收益函数的基本特性,结论显示消费者总是从产品保障机制的信号中判断产品的可靠性水平,这对新产品销售有一定的借鉴意义。     

Optimal warranties,reliabilities and prices for durable goods in an oligopoly

This paper addresses the problem of durable goods manufacturers in an oligopoly seeking optimal values for three decision variables: product warranty, reliability and price. Each firm seeks a warranty-reliability-price combination that maximizes expected profit subject to quite general constraints on the firm's decision variables. Warranty serves as a signal of product reliability, which is not observable by consumers. We present a game-theoretic model of warranty-reliability-price competition in such a market and examine Nash equilibria for this game. We show that under fairly general assumptions each firm can optimally set its warranty and reliability independently of price and competitors' actions. In addition, we show that optimal warranties and reliabilities are complementary, and we explore the impact of different market factors on the optimal warranty and reliability. Finally, we show that optimal warranties are longer and products more reliable when consumers are risk averse.     

An EOQ model with process reliability considerations

The classical economic order quantity (EOQ) model assumes that items produced are of perfect quality and that the unit cost of production is independent of demand. However, in realistic situations, product quality is never perfect, but is directly affected by the reliability of the production process. In this paper, we consider an EOQ model with imperfect production process and the unit production cost is directly related to process reliability and inversely related to the demand rate. In addition, a numerical example is given to illustrate the developed model. Sensitivity analysis is also performed and discussed.     

Dynamic resource allocation in a multi-product make-to-stock production system

We consider optimal policies for a production facility in which several (K) products are made to stock in order to satisfy exogenous demand for each. The single machine version of this problem in which the facility manufactures at most one product at a time to minimise inventory costs has been much studied. We achieve a major generalisation by formulating the production problem as one involving dynamic allocation of a key resource which drives the manufacture of all products under an assumption that each additional unit of resource allocated to a product achieves a diminishing return of increased production rate. A Lagrangian relaxation of the production problem induces a decomposition into K single product problems in which the production rate may be varied but is subject to charge. These reduced problems are of interest in their own right. Under mild conditions of full indexability the Lagrangian relaxation is solved by a production policy with simple index-like structure. This in turn suggests a natural index heuristic for the original production problem which performs strongly in a numerical study. The paper discusses the importance of full indexability and makes proposals for the construction of production policies involving resource idling when it fails.     

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 production stopping and restarting times for an EOQ model with deteriorating items

A perishable single item production-inventory system is studied in this paper. The objective is to describe a general model in which the production rate, the product demand rate, and the item deterioration rate are all considered as functions of time, and to discuss the optimal production stopping and restarting times which minimise the total relevant cost per unit time. In the general model, demand shortage is allowed, where some of the demand is lost and the rest is backlogged. Popular models, such as the pure inventory system and the zero shortage system, are shown to be special cases of our model. The conditions for a feasible stationary point to be optimal are given. The simplest cases with constant rates of production, demand and deterioration are discussed and shown as illustrative examples.     

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.     

基于微分对策的第三方回收再制造闭环供应链回收策略研究

动态环境下,研究了第三方回收的再制造闭环供应链最优控制策略。建立产品回收率为状态变量的微分方程,分别构建了集中式决策和第三方回收下的闭环供应链模型,利用最优控制和微分对策理论求解并得到供应链各方的最优控制策略。对最优策略进行分析发现:(1)系统的产品回收率随时间的推移而增加;(2)产品的零售价格和批发价格随时间减小,最优回收努力投入随时间增加;(3)相对于集中式决策,第三方回收下闭环供应链系统的产品回收率较低,产品市场价格较高,而市场需求较小。     

Possibility and necessity constraints and their defuzzification—A multi-item production-inventory scenario via optimal control theory

In this paper, analogous to chance constraints, real-life necessity and possibility constraints in the context of a multi-item dynamic production-inventory control system are defined and defuzzified following fuzzy relations. Hence, a realistic multi-item production-inventory model with shortages and fuzzy constraints has been formulated and solved for optimal production with the objective of having minimum cost. Here, the rate of production is assumed to be a function of time and considered as a control variable. Also the present system produces some defective units along with the perfect ones and the rate of produced defective units is constant. Here demand of the good units is time dependent and known and the defective units are of no use. The space required per unit item, available storage space and investment capital are assumed to be imprecise. The space and budget constraints are of necessity and/or possibility types. The model is formulated as an optimal control problem and solved for optimum production function using Pontryagin’s optimal control policy, the Kuhn–Tucker conditions and generalized reduced gradient (GRG) technique. The model is illustrated numerically and values of demand, optimal production function and stock level are presented in both tabular and graphical forms. The sensitivity of the cost functional due to the changes in confidence level of imprecise constraints is also presented.     

Raw materials and production control with random supply and demand,an outside market and production capacity

We study a capacitated periodic inventory review problem in which the optimal control of both raw materials and finished product inventories simultaneously involves optimal decisions on materials purchasing from suppliers, buying or selling of materials in spot market, and production quantity in each period. We found that the dynamic program model of the problem is decomposable, and there is an independent relationship between the decisions on materials purchasing/selling and finished product production. Optimal policies are characterized and extensions are discussed.     

三部门封闭经济系统资源配置的动态优化模型

通过建立一个三部门的封闭经济系统的资源配置动态优化模型,在理论上分析及证明,通过提高劳动力的素质及技能,劳动力可以从补偿劳动力再生产的生产部门向最终产品的生产部门及资本性资源的生产部门流动,使资本性资源增加生产,增量配置到其它生产部门,从而在保证劳动力再生产产品能满足需要的同时,激发整体经济的成长.最后运用数据分析方法对以上原理及模型进行了验证     

A general age-replacement model with minimal repair under renewing free-replacement warranty

A general age-replacement model in which incorporates minimal repair, planned and unplanned replacement, is considered in this paper for products under a renewing free-replacement warranty policy. For both warranted and non-warranted products, cost models from the user’s perspective are developed, and the corresponding optimal replacement ages are derived such that the long-run expected cost rate is minimized. The impacts of a product warranty on the optimal replacement model are investigated analytically. Furthermore, we show that the optimal replacement age for a warranted product is closer to the end of the warranty period than for a non-warranted product. Finally, numerical examples are given for illustration.     

Optimal budgetary and monetary policies under uncertainty: A stochastic control approach

In this paper, we determine optimal budgetary and monetary policies for Austria using a small macroeconometric model. We use a Keynesian model of the Austrian economy, called FINPOL1, estimated by ordinary least squares, which relates the main objective variables of Austrian economic policies, such as the growth rate of real gross domestic product, the rate of unemployment, the rate of inflation, the balance of payments, and the ratio of the federal budget deficit to GDP, to fiscal and monetary policy instruments, namely expenditures and revenues of the federal budget and money supply. Optimal fiscal and monetary policies are calculated for the model under a quadratic objective function using the algorithm OPTCON for the optimum control of nonlinear stochastic dynamic systems. Several control experiments are performed in order to assess the influence of different kinds of uncertainty on optimal budgetary and monetary policies. Apart from deterministic optimization runs, different assumptions about parameter uncertainties are introduced; the results of these different stochastic optimum control experiments are compared and interpreted.     

Human resources scheduling to improve the product quality according to exhaustion limit

The role of human resources in manufacturing systems is very significant, and without efficient human resources we encounter high-price products with low quality. To improve the efficiency of human resources, we need to provide an optimal working schedule for each worker in production period. In this paper, we proposed a mixed-integer nonlinear model to find the best working schedule based on product quality cost and workers reliability. In this model, if the worker’s exhaustion level reaches a specific limit, the worker can rest to increase his reliability level and an accommodator should work instead of him. Since the proposed model is NP-hard, we used an artificial immune system to provide the best working schedule. The results indicate that this model can provide efficient and effective human resources schedule in manufacturing systems.     

Dynamic pricing,product and process innovation

The question of simultaneous dynamic pricing, product and process investment policies is crucial for manufacturing and high-tech industries. This paper models these policies in an optimal control setting. On the supply side, the firm sets prices, product and process investment levels over time. On the demand side, current demand depends on price and quality. Under an additive separable demand function, dynamic pricing increases with quality and cost. Therefore, both product innovation and process innovation impact the pricing policy. Under a multiplicative separable demand function, dynamic pricing policy follows the dynamic of production cost and is independent of the evolution of product quality. Thus, process innovation is the main determinant of a firm’s pricing policy over time and product innovation has no impact.     

Integrated production scheduling and distribution planning in dairy supply chain by hybrid modelling

In this paper we address the production scheduling and distribution planning problem in a yoghurt production line of the multi-product dairy plants. A mixed integer linear programming model is developed for the considered problem. The objective function aims to maximize the benefit by considering the shelf life dependent pricing component and costs such as processing, setup, storage, overtime, backlogging, and transportation costs. Key features of the model include sequence dependent setup times, minimum and maximum lot sizes, overtime, shelf life requirements, machine speeds, dedicated production lines, typically arising in the dairy industry. The model obtains the optimal production plan for each product type, on each production line, in each period together with the delivery plan. The hybrid modelling approach is adopted to explore the dynamic behavior of the real world system. In the hybrid approach, operation time is considered as a dynamic factor and it is adjusted by the results of the simulation and optimization model iteratively. Thus, more realistic solutions are obtained for the scheduling problem in yoghurt industry by using the iterative hybrid optimization-simulation procedure. The efficiency and applicability of the proposed model and approach are demonstrated in a case study for a leading dairy manufacturing company in Turkey.     

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.     

Multiproduct single-machine production system with stochastic scrapped production rate, partial backordering and service level constraint

In this paper, a multiproduct single-machine production system under economic production quantity (EPQ) model is studied in which the existence of only one machine causes a limited production capacity for the common cycle length of all products, the production defective rates are random variables, shortages are allowed and take a combination of backorder and lost sale, and there is a service rate constraint for the company. The aim of this research is to determine the optimal production quantity, the allowable shortage level, and the period length of each product such that the expected total cost, including holding, shortage, production, setup and defective items costs, is minimized. The mathematical model of the problem is derived for which the objective function is proved to be convex. Then, a derivative approach is utilized to obtain the optimal solution. Finally, two numerical examples in each of which a sensitivity analysis is performed on the model parameters, are provided to illustrate the practical usage of the proposed methodology.     

Managing procurement and production outsourcing under dynamic prices

This paper proposes a procurement and production outsourcing model subject to a dynamic prices environment. Using the optimal control theory we obtain the necessary conditions of the optimal procurement and production policy. From the study of optimal control conditions, we derive qualitative properties of the optimal procurement and production decisions for a few exemplifying cases. Through these results we are able to provide some managerial implications for managers to make real decisions.