Using the EPQ for coordinated planning of a product with partial backordering and its components

While there has been considerable work over the years on multistage lot-sizing models, particularly in an MRP environment, there has been relatively little work on systems recognizing the WIP effects when there is gradual conversion of the components into the final product, as in production planning using the EPQ model for planning the final product. Here we consider lot-sizing planning for a two-stage system in which the final product is planned using an EPQ model with partial backordering and the production of the components is controlled using basic EPQ models without backordering.     

Dynamic knapsack sets and capacitated lot-sizing

 A dynamic knapsack set is a natural generalization of the 0-1 knapsack set with a continuous variable studied recently. For dynamic knapsack sets a large family of facet-defining inequalities, called dynamic knapsack inequalities, are derived by fixing variables to one and then lifting. Surprisingly such inequalities have the simultaneous lifting property, and for small instances provide a significant proportion of all the facet-defining inequalities. We then consider single-item capacitated lot-sizing problems, and propose the joint study of three related sets. The first models the discrete lot-sizing problem, the second the continuous lot-sizing problem with Wagner-Whitin costs, and the third the continuous lot-sizing problem with arbitrary costs. The first set that arises is precisely a dynamic knapsack set, the second an intersection of dynamic knapsack sets, and the unrestricted problem can be viewed as both a relaxation and a restriction of the second. It follows that the dynamic knapsack inequalities and their generalizations provide strong valid inequalities for all three sets. Some limited computation results are reported as an initial test of the effectiveness of these inequalities on capacitated lot-sizing problems. Received: March 28, 2001 / Accepted: November 9, 2001 Published online: September 27, 2002 RID="★" ID="★" Research carried out with financial support of the project TMR-DONET nr. ERB FMRX–CT98–0202 of the European Union. Present address: Electrabel, Louvain-la-Neuve, B-1348 Belgium. Present address: Electrabel, Louvain-la-Neuve, B-1348 Belgium. Key words. knapsack sets – valid inequalities – simultaneous lifting – lot-sizing – Wagner-Whitin costs     

Design of mathematical models for the integration of purchase and production lot-sizing and scheduling problems under demand uncertainty

This study addresses the multi-level lot-sizing and scheduling problem with complex setups and considers supplier selection with quantity discounts and multiple modes of transportation. The present research proposes a mixed-integer linear programming (MILP) model in which the purchase lot-sizing from multiple suppliers, production lot-sizing with multiple machines and scheduling of various products of different families are accomplished at the same time. However, these decisions are not integrated in traditional environments and are taken separately. In this study, two different types of lot-sizing models called aggregated and disaggregated are developed for the problem to evaluate and compare the computational efficiency of them under deterministic and stochastic demands and provide some managerial insights. To deal with the stochastic demands, Chance-Constrained Programming (CCP) approach is applied. Based on the results of this study, the average profit of the separated (purchase from production) lot-sizing model under demand choice flexibility and stochastic demand is 24% and 22% less than the integrated model, respectively. Moreover, the results also confirm the effect of discount structure on the amount of purchases, productions, revenues and costs.     

Capacitated lot-sizing with extensions: a review

The capacitated lot-sizing problem (CLSP) is a standard formulation for big bucket lot-sizing problems with a discrete period segmentation and deterministic demands. We present a literature review on problems that incorporate one of the following extensions in the CLSP: back-orders, setup carry-over, sequencing, and parallel machines. We illustrate model formulations for each of the extensions and also mention the inclusion of setup times, multi-level product structures and overtime in a study. For practitioners, this overview allows to check the availability of successful solution procedures for a specific problem. For scientists, it identifies areas that are open for future research.      

Some Classes of Valid Inequalities and Convex Hull Characterizations for Dynamic Fixed-Charge Problems under Nested Constraints

This paper studies the polyhedral structure of dynamic fixed-charge problems that have nested relationships constraining the flow or activity variables. Constraints of this type might typically arise in hierarchical or multi-period models and capacitated lot-sizing problems, but might also be induced among choices of key variables via an LP-based post-optimality analysis. We characterize several classes of valid inequalities and inductively derive convex hull representations in a higher dimensional space using lifting constructs based on the Reformulation-Linearization Technique. Relationships with certain known classes of valid inequalities for single item capacitated lot-sizing problems are also identified.     

An evaluation of semidefinite programming based approaches for discrete lot-sizing problems

The present work is intended as a first step towards applying semidefinite programming models and tools to discrete lot-sizing problems including sequence-dependent changeover costs and times. Such problems can be formulated as quadratically constrained quadratic binary programs. We investigate several semidefinite relaxations by combining known reformulation techniques recently proposed for generic quadratic binary problems with problem-specific strengthening procedures developed for lot-sizing problems. Our computational results show that the semidefinite relaxations consistently provide lower bounds of significantly improved quality as compared with those provided by the best previously published linear relaxations. In particular, the gap between the semidefinite relaxation and the optimal integer solution value can be closed for a significant proportion of the small-size instances, thus avoiding to resort to a tree search procedure. The reported computation times are significant. However improvements in SDP technology can still be expected in the future, making SDP based approaches to discrete lot-sizing more competitive.     

Approximation algorithms for deterministic continuous-review inventory lot-sizing problems with time-varying demand

This work deals with the continuous time lot-sizing inventory problem when demand and costs are time-dependent. We adapt a cost balancing technique developed for the periodic-review version of our problem to the continuous-review framework. We prove that the solution obtained costs at most twice the cost of an optimal solution. We study the numerical complexity of the algorithm and generalize the policy to several important extensions while preserving its performance guarantee of two. Finally, we propose a modified version of our algorithm for the lot-sizing model with some restricted settings that improves the worst-case bound.     

Loss-based quality costs and inventory planning: General models and insights

In this paper, we examine a joint lot-sizing and process investment problem with random yield and backorders. We allow for inspection and develop stochastic models which provide the optimal inspection and lot-sizing policy as well as the optimal process investment for variance reduction. The process quality loss profile around the target is captured via a modification of the Reflected Normal loss function. We conduct numerical experiments assuming that the proportion of defectives follows a Uniform distribution while the process quality characteristic follows either a Normal or Uniform distribution. We also develop closed-form solutions that depend on at most the first two moments of any general probability distribution of defective units and which allow us to examine the nature of optimal policies. We demonstrate via numerical experiments the value of our integrated approach for jointly determining optimal inventory, inspection, and investment policies. Overall, our models and analyses provide some interesting insights into this reasonably complex inventory-quality problem and open up several avenues for future work in this area.     

Profit maximization in simultaneous lot-sizing and scheduling problem

This paper extends the simultaneous lot-sizing and scheduling problem, to include demand choice flexibility. The basic assumption in most research about lot-sizing and scheduling problems is that all the demands should be satisfied. However, in a business with a goal of maximizing profit, meeting all demands may not be an optimum decision. In the profit maximization simultaneous lot-sizing and scheduling problem with demand choice flexibility, the accepted demand in each period, lot-sizing and scheduling are three problems which are considered simultaneously. In other words the decisions pertaining to mid-term planning and short-term planning are considered as one problem and not hierarchically. According to this assumption, the objective function of traditional models changes from minimizing costs to maximizing profits.     

Sequential-analysis Based Randomized-regret-methods for Lot-sizing and Scheduling

Lot-sizing and scheduling comprises activities that have to be done repeatedly within MRP-systems. We consider the proportional multi-item, capacitated, dynamic lot-sizing and scheduling problem that is more general than the discrete lot-sizing and scheduling problem, as well as the continuous set-up lot-sizing problem. A greedy randomized algorithm with regret-based biased sampling is presented. We partition the parameter space of the stochastic algorithm and choose subspaces via sequential analysis based on hypothesis testing. The new methods provided in this paper, i.e. the randomized-regret-based backward algorithm, as well as the controlled search via sequential analysis, have three important properties: they are simple, effective and rather general. Computational results are also presented.     

A lot-sizing and scheduling model for multi-stage flow lines with zero lead times

We present a new model formulation for lot-sizing and scheduling of multi-stage flow lines which works without a fixed lead-time offset and still guarantees a feasible material flow. In the literature, multi-stage lot-sizing model formulations often use a fixed lead time offset of one period leading to increased planned lead times. Computational tests have shown that the total costs resulting from our new model formulation are at least 10% lower. Furthermore, we present a solution approach based on Fix-and-Relax and Fix-and-Optimize. Numerical results show that this solution approach generates high-quality solutions in moderate computational time.     

Strong formulations for mixed integer programs: valid inequalities and extended formulations

 We examine progress over the last fifteen years in finding strong valid inequalities and tight extended formulations for simple mixed integer sets lying both on the ``easy' and ``hard' sides of the complexity frontier. Most progress has been made in studying sets arising from knapsack and single node flow sets, and a variety of sets motivated by different lot-sizing models. We conclude by citing briefly some of the more intriguing new avenues of research. Received: January 15, 2003 / Accepted: April 10, 2003 Published online: May 28, 2003 Key words. mixed integer programming – strong valid inequalities – convex hull – extended formulations – single node flow sets – lot-sizing This paper presents research results of the Belgian Program on Interuniversity Poles of Attraction initiated by the Belgian State, Prime Minister's Office, Science Policy Programming. The scientific responsibility is assumed by the authors. Research carried out with financial support of the project TMR-DONET nr. ERB FMRX–CT98–0202 of the European Union.     

Performance modeling and analysis of integrated logistic chains: An analytic framework

This paper is geared toward developing a network of inventory-queue models for the performance modeling and analysis of an integrated logistic network. An inventory-queue is a queueing model that incorporates an inventory replenishment policy for a store, which is a basic modeling element for an integrated logistic network. To achieve this objective, first, this paper presents an analytical modeling framework for integrated logistic chains, in which the interdependencies between model components are captured. Second, a network of inventory-queue models for performance analysis of an integrated logistic network with inventory control at all sites is developed. Then this paper extends the previous work done on the supply network model with base-stock control and service requirements. Instead of one-for-one base stock policy, batch-ordering policy and lot-sizing problems are considered. In practice, the assumption of uncapacitated production is often not true, therefore, GI^x/G/1 queueing analysis is used to replace the M^x/G/∞ queue based method. To include lot-sizing issue in the analysis of stores, a fixed-batch target-level production authorization mechanism is employed to explicitly obtain performance measures of the logistic chain queueing model. The validity of the proposed model is illustrated by comparing the results from the analytical performance evaluation model and those obtained from the simulation study.     

SOS: A Quantile Estimation Procedure for Dynamic Lot-sizing Problems

This paper reviews some of the current approaches available for computing the demand quantiles required to plan the procurement of items with stochastic non-stationary demands. The paper first describes the stochastic single-item lot-sizing problem considered and then presents a practical solution approach based on a dynamic lot-sizing model. Three methods available to compute demand quantiles are then reviewed and a new procedure based on smoothed order statistics (SOS) is proposed. Finally, the behaviour of these estimation methods, when used to solve single-item lot-sizing problems with non-stationary stochastic demands, is studied by simulation.     

The effects of learning in production and group size on the lot-sizing problem

One of the lot-sizing problem extensions that received noticeable attention in the literature is the one that investigated the effects of learning in production. The studies along this line of research assumed learning to improve with the number of repetitions following a power form. There is evidence also that the group size, i.e., the number of workers learning in a group affects performance (time per unit). This note revisits the problem and modifies it by incorporating the group size, along with cumulative production, as a proxy for measuring performance. Numerical examples are provided to illustrate the behavior of the modified model. The results of the two models are also compared to draw some meaningful insights and conclusions. Although the results favor using a simple univariate learning curve, considering group size when modeling lot-sizing problems can significantly affect the unit production cost.     

Valid inequalities for separable concave constraints with indicator variables

We study valid inequalities for optimization models that contain both binary indicator variables and separable concave constraints. These models reduce to a mixed-integer linear program (MILP) when the concave constraints are ignored, or to a nonconvex global optimization problem when the binary restrictions are ignored. In algorithms designed to solve these problems to global optimality, cutting planes to strengthen the relaxation are traditionally obtained using valid inequalities for the MILP only. We propose a technique to obtain valid inequalities that are based on both the MILP constraints and the concave constraints. We begin by characterizing the convex hull of a four-dimensional set consisting of a single binary indicator variable, a single concave constraint, and two linear inequalities. Using this analysis, we demonstrate how valid inequalities for the single node flow set and for the lot-sizing polyhedron can be “tilted” to give valid inequalities that also account for separable concave functions of the arc flows. We present computational results demonstrating the utility of the new inequalities for nonlinear transportation problems and for lot-sizing problems with concave costs. To our knowledge, this is one of the first works that simultaneously convexifies both nonconvex functions and binary variables to strengthen the relaxations of practical mixed-integer nonlinear programs.     

Decomposition methods for the lot-sizing and cutting-stock problems in paper industries

We investigate the one-dimensional cutting-stock problem integrated with the lot-sizing problem in the context of paper industries. The production process in paper mill industries consists of producing raw materials characterized by rolls of paper and cutting them into smaller rolls according to customer requirements. Typically, both problems are dealt with in sequence, but if the decisions concerning the cutting patterns and the production of rolls are made together, it can result in better resource management. We investigate Dantzig–Wolfe decompositions and develop column generation techniques to obtain upper and lower bounds for the integrated problem. First, we analyze the classical column generation method for the cutting-stock problem embedded in the integrated problem. Second, we propose the machine decomposition that is compared with the classical period decomposition for the lot-sizing problem. The machine decomposition model and the period decomposition model provide the same lower bound, which is recognized as being better than the linear relaxation of the classical lot-sizing model. To obtain feasible solutions, a rounding heuristic is applied after the column generation method. In addition, we propose a method that combines an adaptive large neighborhood search and column generation method, which is performed on the machine decomposition model. We carried out computational experiments on instances from the literature and on instances adapted from real-world data. The rounding heuristic applied to the first column generation method and the adaptive large neighborhood search combined with the column generation method are efficient and competitive.     

Outbound shipment mode considerations for integrated inventory and delivery lot-sizing decisions

We present a two-echelon dynamic lot-sizing model with two outbound delivery modes where one mode has a fixed set-up cost structure while the other has a container-based cost structure. Studying the optimality properties of the problem, we provide a polynomial solution algorithm based on a dynamic programming approach.     

A dynamic uncapacitated lot-sizing problem with co-production

We consider an extension of the dynamic uncapacitated lot-sizing problem to account for co-production, where multiple products are produced simultaneously in a single production run. We formulate the problem as a mixed-integer linear programming problem. We then show that a variant of the well-known zero-inventory property holds for this problem, and use this property to extend a dynamic program given for the single-item lot-sizing to solve the problem with co-production. Finally, we provide an illustrative example for our approach.