Optimal models for a multi-stage supply chain system controlled by kanban under just-in-time philosophy

This research studies a multi-stage supply chain system that operates under a JIT (just-in-time) delivery policy. Kanbans play an important role in the information and material flows in a supply chain system. Thus, a kanban mechanism is employed to assist in linking different production processes in a supply chain system to implement the scope of JIT philosophy. For a multi-stage supply chain system, a mixed-integer nonlinear programming (MINLP) problem is formulated from the perspective of JIT delivery policy where a kanban may reflect to a transporter such as a truck or a fork-lifter. The number of kanbans, the batch size, the number of batches and the total quantity over one period are determined optimally. It is solved optimally by branch and bound method. A greedy heuristic to avoid the large computational time in branch-and-bound algorithm is developed for solving a large MINLP. Coupled with plant-wide efforts for cost control and management commitment, a logistic system for controlling the production as well as the supply chain is built, which results in minimizing the total cost of the supply chain system. The results show that the improvements in reduction of inventory, wasted labor and customer service in a supply chain are significantly accomplished through the kanban mechanism.     

Single Supplier�CBuyer Integrated Inventory Model Under Multiple JIT Delivery and Stock-Dependent Demand

In this paper, an integrated inventory model for a supply chain comprising of single buyer and single supplier is studied when demand is stock-dependent and units in inventory deteriorate at a constant rate. The total cost of the integrated system consists of the transportation cost, inspection cost and the cost of less flexibility under the assumption of JIT deliveries. The total integrated cost of single-supplier and single-buyer is minimized with respect to number of inspections and deliveries, the cycle time of deliveries and the delivery size for the replenishment time. A numerical example is given to validate the model. The sensitivity analysis carried out suggests that the unit inspection cost, deterioration rate of units in inventory and stock-dependent parameter are the critical factors.     

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.     

Integrated inventory management and supplier base reduction in a supply chain with multiple uncertainties

This paper considers a manufacturing supply chain with multiple suppliers in the presence of multiple uncertainties such as uncertain material supplies, stochastic production times, and random customer demands. The system is subject to supply and production capacity constraints. We formulate the integrated inventory management policy for raw material procurement and production control using the stochastic dynamic programming approach. We then investigate the supplier base reduction strategies and the supplier differentiation issue under the integrated inventory management policy. The qualitative relationships between the supplier base size, the supplier capabilities and the total expected cost are established. Insights into differentiating the procurement decisions to different suppliers are provided. The model further enables us to quantitatively achieve the trade-off between the supplier base reduction and the supplier capability improvement, and quantify the supplier differentiation in terms of procurement decisions. Numerical examples are given to illustrate the results.     

Determining the optimal procurement policy and maximum allowable lifespan for machining tools with stochastically distributed toollife

For high-value added products, machining tools’ lifespan significantly influences the quantity of procurement in machining process. Preemption of tools from the workpiece while processing is continuing is sometime beneficial to safeguard the product from the damage due to tool failure or its malfunction. Also an early discard of a tool is costly for the manufacturing operation. Therefore an optimal strategy for the tool life is sought here to determine the maximum allowable tool lifespan to preempt from the workpiece and to have an appropriate amount of tool stock in the crib to ascertain the proper running of the production schedule and tool inventory. Therefore, an impact of the machining tool lifespan on the production-inventory policy of the system is investigated in this paper. An integrated lifespan related inventory model for machining tools is developed to meet the responding accurate requirement of procurement and inventory. Two numerical examples are presented to illustrate the integrated model. The results show that the practical lifespan adoption of machining tools has significant impact on the whole quantity of procurement, and eventually influences the coordinating economic decision making.     

Fuzzy multi-objective vendor selection under lean procurement

This paper investigates a fuzzy multi-objective vendor selection program under lean procurement based on cost minimization, delivery schedule violation minimization, and maximizing the quality level of the purchased quantity. Specifically, the paper incorporates the vendor production capacity uncertainty into the model to identify an appropriate selection policy for vendors under practical operating conditions. The use of a soft time-window mechanism for the vendor selection model enables decision makers to further incorporate a time based performance metric for vendor evaluation, based on the degree of urgency or need for a part. A solution algorithm using fuzzy AHP is proposed. The results of a numerical example suggest that decision makers prefer vendors who can promise tighter delivery schedules rather than on cost or quality. A sensitivity analysis of the soft time-window on the achievement of the lean procurement objectives is also conducted.     

Integrated Production Inventory Policies for Multistage Multiproduct Batch Production Systems

An integrated production inventory model is considered in this paper, for a flow shop type multiproduct batch production system, with a multifacility structure. Instantaneous production is allowed in each facility. The model aims to determine simultaneously the optimal manufacturing cycle for the multiple products and the corresponding optimal procurement policies for the raw material. The cycle concept of multiproduct batch processing is extended to multifacility system and is integrated with the concept of production-inventory system for a single product, single facility system.     

Global optimal policy for vendor–buyer integrated inventory system within just in time environment

Traditionally, inventory problems for the vendor and the buyer are treated separately. In modern enterprises, however, the integration of vendor–buyer inventory system is an important issue. This co-operative approach to inventory management contributes to the success of supply chain management by minimizing the joint inventory cost. The joint inventory cost and the response time can further be reduced when the buyer orders and the vendor replenishes the required items just in time (JIT) for their consumption. The inclusion of the JIT concept in this model contributes significantly to a joint inventory cost reduction. A numerical example and sensitivity analysis are carried out. The derived results show an impressive cost reduction when compared with Goyal’s model.     

A new approach towards integrated cell formation and inventory lot sizing in an unreliable cellular manufacturing system

This paper presents a comprehensive mathematical model for integrated cell formation and inventory lot sizing problem. The proposed model seeks to minimize cell formation costs as well as the costs associated with production, while dynamic conditions, alternative routings, machine capacity limitation, operations sequences, cell size constraints, process deterioration, and machine breakdowns are also taken into account. The total cost consists of machine procurement, cell reconfiguration, preventive and corrective repairs, material handling (intra-cell and inter-cell), machine operation, part subcontracting, finished and unfinished parts inventory cost, and defective parts replacement costs. With respect to the multiple products, multiple process plans for each product and multiple routing alternatives for each process plan which are assumed in the proposed model, the model is combinatorial. Moreover, unreliability conditions are considered, because moving from “in-control” state to “out-of-control” state (process deterioration) and machine breakdowns make the model more practical and applicable. To conquer the breakdowns, preventive and corrective actions are adopted. Finally, a Particle Swarm Optimization (PSO)-based meta-heuristic is developed to overcome NP-completeness of the proposed model.     

Scheduling parallel machines with single vehicle delivery

We investigate the integrated production and distribution scheduling problem in a supply chain. The manufacturer’s production environment is modeled as a parallel machine system. A single capacitated vehicle is employed to deliver products in batches to multiple customers. The scheduling problem can also be viewed as either parallel machines with delivery considerations or a flexible flowshop. Different inventory holding costs, job sizes (volume or storage space required in the transportation unit), and job priorities are taken into account. Efficient mathematical modeling and near-optimal heuristic approaches are presented for minimizing total weighted completion time.     

考虑横向整合战略的库存路径动态区域定价

库存路径和定价是供货商管理库存(Vendor Management Inventory, VMI)中三个互相制约和影响的决策问题,是降低供货商成本,提高其利润的关键。针对VMI拉式供应链中多供货商、多商品和多区域的库存路径定价问题,提出了对不同区域客户、在不同时段进行商品差异化定价策略,并设计一种共同配送车辆司机成本和燃油成本分摊方案,据此构建基于横向整合战略的库存路径动态区域定价模型。算例结果显示,在横向整合战略下,供货商商品定价会有所降低,配送车辆行驶距离显著缩短,各时段配货量更为均衡,期末库存数量显著降低。研究表明,无论供货商之间供货规模比例差异多大,开展库存路径动态区域定价,供货商联盟成员的利润均能得到显著提高,实现合作共赢的目标。     

Coordination mechanism for a deteriorating item in a two-level supply chain system

The subject of the coordination between the suppliers and the buyers in multi-echelon inventory-distribution systems has been studied by many researchers. This paper considers a supply chain including a manufacturer and several buyers and assumes that the inventory items deteriorate over time and its inventory level decreases. In order to determine the order policies, coordination over the supply chain is achieved by scheduling the buyers’ delivery days and their coordination with the manufacturer’s production cycle. A mathematical model is developed and analyzed. To test the efficiency of the proposed model, two other models with the supposition of lot-sizing policies with common order cycle and independent deciding are also developed. In comparison to the other two models, the numerical results show that the synchronizing model of production and delivery cycles works better and has less total cost. In addition, in order to encourage the buyers in cooperation, a model on profit sharing is proposed that equitably shares the total savings with all the parties.     

Planning performance based contracts considering reliability and uncertain system usage

This paper investigates a novel quantitative approach for planning and contracting performance-based logistics in the presence of uncertain system usage. Our efforts focus on an integrated service delivery environment where the manufacturer develops capital-intensive systems and also provides after-sales support. We propose an analytical model to characterize system operational availability by comprehending five performance drivers: inherent failure rate, usage rate, spare parts inventory, repair time, and the fleet size. This analytical insight into the system performance allows the service supplier to minimize the total cost across system design, production, maintenance, and repair. Two contracting schemes are investigated under cost minimization and profit maximization schemes. For the first time in literature, reliability design and service parts logistics are seamlessly integrated into one decision support model for improving operational availability while lowering the lifecycle cost. Numerical examples are provided to demonstrate the applicability and the effectiveness of the proposed decision support tool.     

A hybrid optimization approach for multi-level capacitated lot-sizing problems

Solving multi-level capacitated lot-sizing problems is still a challenging task, in spite of increasing computational power and faster algorithms. In this paper a new approach combining an ant-based algorithm with an exact solver for (mixed-integer) linear programs is presented. A MAX–MIN ant system is developed to determine the principal production decisions, a LP/MIP solver is used to calculate the corresponding production quantities and inventory levels. Two different local search methods and an improvement strategy based on reduced mixed-integer problems are developed and integrated into the ant algorithm. This hybrid approach provides superior results for small and medium-sized problems in comparison to the existing approaches in the literature. For large-scale problems the performance of this method is among the best.     

A just-in-time three-level integrated manufacturing system for linearly time-varying demand process

This paper considers a just-in-time (JIT) manufacturing system in which a single manufacturer procures raw materials from a single supplier, process them to produce finished products, and then deliver the products to a single-buyer. The customer demand rate is assumed to be linearly decreasing time-varying. In the JIT system, in order to minimize the suppliers as well as the buyers holding costs, the supply of raw materials and the delivery of finished products are made in small quantities. In this case, both the supply and the delivery may require multiple installments for a single production lot. We develop a mathematical model for this problem, propose a simple methodology for solving the model, and illustrate the effectiveness of the method with numerical examples.     

Production–shipment policy for EPQ model with quality assurance and an improved delivery schedule

This article is concerned with determining the production–shipment policy for an economic production quantity model with quality assurance and an improved delivery schedule. We extend a recent work by Chiu et al. [Y.-S.P. Chiu, C.-A.K. Lin, H.-H. Chang, and V. Chiu, Mathematical modeling for determining economic batch size and optimal number of deliveries for EPQ model with quality assurance, Math. Comput. Model. Dyn. Sys. 16 (4) (2010), pp. 373–388] by incorporating an alternative delivery plan that aims at lowering the inventory holding cost for both supplier and buyer in such an integrated inventory system. Mathematical modelling along with Hessian matrix equations is used, and as a result the optimal production batch size and optimal number of deliveries are derived. A numerical example is provided to demonstrate the practical use of the results and the significant savings in stock holding costs for both vendor and buyer.     

Optimal control policy for a standing order inventory system

In this paper, we consider a standing order inventory system in which an order of fixed size arrives in each period. Since demand is stochastic, such a system must allow for procurement of extra units in the case of an emergency and sell-offs of excess inventory. Assuming the average-cost criterion, Rosenshine and Obee (Operations Research 24 (1976) 1143–1155) first studied such a system and devised a 4-parameter inventory control policy that is not generally optimal. The current paper uses dynamic programming to determine the optimal control policy for a standing order system, which consists of only two operational parameters: the dispose-down-to level and order-up-to level. Either the average-cost or discounted-cost criterion can be assumed in the proposed model. Also, both the backlogged and lost-sales problems are investigated in this paper. By using a convergence theorem, we stop the dynamic programming computation and obtain the two optimal parameters.     

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.     

Optimal configuration of a decentralized, market-driven production/inventory system

Pull systems are inherently easier to implement on the shop-floor; however, they are quite difficult to plan and design for optimal operation, leaving little guidelines to system designers and practitioners. In this paper we use an effective and relatively fast numerical method to understand the optimal configuration of a multi-stage, multi-product, decentralized, market-driven production/inventory system that minimizes average inventory holding subject to a service level constraint through selection of various production and procurement control parameters. We have also conducted a number of numerical experiments to understand how the control policies respond to changes in the system parameters, such as the number of stages, system workload, demand arrival rates of products, and inventory holding costs.     

Integrated multi-item production-inventory systems

We study an integrated multi-item production-inventory system with stochastic demands and capacitated production. The problem is to find the base stock levels which minimize expected inventory costs per unit time, for an infinite time horizon. When unit manufacturing times are deterministic or exponentially distributed, we derive analytical expressions that lead to the optimal base stock levels. Our results provide several implications about the interaction of inventories, capacity utilization, and variation in the production environment.