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.     

Selective and periodic inventory routing problem for waste vegetable oil collection

We consider a biodiesel production company that collects waste vegetable oil from source points that generate waste in large amounts. The company uses the collected waste as raw material for biodiesel production. The manager of this company needs to decide which of the present source points to include in the collection program, which of them to visit on each day, which periodic routing schedule to repeat over an infinite horizon and how many vehicles to operate such that the total collection, inventory and purchasing costs are minimized while the production requirements and operational constraints are met. For this selective and periodic inventory routing problem, we propose two different formulations, compare them and apply the better performing one on a real-world problem with 36 scenarios. We generate lower bounds using a partial linear relaxation model, and observe that the solutions obtained through our model are within 3.28% of optimality on the average. Several insights regarding the customer selection, routing and purchasing decisions are acquired with sensitivity analysis.     

时变需求等量进货情形下集成供应链生产订货策略研究

构建了一个包含原料采购、生产和销售过程的集成供应链模型,研究了由原料、生产商和销售商产品构成的三层库存系统的生产订货问题。在有限的规划期内,销售商每次进货量相同,生产商按照EOQ模型采购原材料。以最小化供应链系统的总运营成本为目标,构建一个混合整数非线性规划模型,寻找销售商最优订货方案和生产商最佳生产策略。首先利用网络优化方法求解生产商的最优生产计划,其次利用定界穷举法寻求销售商最优的订货周期,给出了具体的计算方法和Matlab程序。通过算例分析验证了算法的有效性,并研究了各参数对最小费用及最优解的影响。     

A developed slope order index (SOI) for bottlenecks in projects and production lines

This paper finds a sequence of m jobs on one processor with the minimum total cost as a solution to the sequencing problem where the raw materials are either expensive to buy or carry. There have been numerous studies considering m jobs on one processor which consider various cost factors such as the total penalty cost. One of the important, but less investigated cost factors, in the previous studies, is the inventory carrying and its relevant capital costs. The inventory costs such as the holding cost and capital cost must be considered in proposing a solution to the sequencing problem. In this paper, by taking those costs into account to address the sequencing problem, a developed slope order index is computed to enable decision makers to a sufficient cost saving sequence of m jobs on one processor. This paper contributes the current knowledge by proposing a new sequencing solution in which some previously less observed costs are considered. The result of this paper can also be employed in scheduling of m jobs where there is a bottleneck and the inventories are expensive or their holding costs are considerable.     

A dynamic inventory model with supplier selection in a serial supply chain structure

Considering the inherent connection between supplier selection and inventory management in supply chain networks, this article presents a multi-period inventory lot-sizing model for a single product in a serial supply chain, where raw materials are purchased from multiple suppliers at the first stage and external demand occurs at the last stage. The demand is known and may change from period to period. The stages of this production–distribution serial structure correspond to inventory locations. The first two stages stand for storage areas for raw materials and finished products in a manufacturing facility, and the remaining stages symbolize distribution centers or warehouses that take the product closer to customers. The problem is modeled as a time-expanded transshipment network, which is defined by the nodes and arcs that can be reached by feasible material flows. A mixed integer nonlinear programming model is developed to determine an optimal inventory policy that coordinates the transfer of materials between consecutive stages of the supply chain from period to period while properly placing purchasing orders to selected suppliers and satisfying customer demand on time. The proposed model minimizes the total variable cost, including purchasing, production, inventory, and transportation costs. The model can be linearized for certain types of cost structures. In addition, two continuous and concave approximations of the transportation cost function are provided to simplify the model and reduce its computational time.     

An adaptive large neighborhood search algorithm for a selective and periodic inventory routing problem

We study a selective and periodic inventory routing problem (SPIRP) and develop an Adaptive Large Neighborhood Search (ALNS) algorithm for its solution. The problem concerns a biodiesel production facility collecting used vegetable oil from sources, such as restaurants, catering companies and hotels that produce waste vegetable oil in considerable amounts. The facility reuses the collected waste oil as raw material to produce biodiesel. It has to meet certain raw material requirements either from daily collection, or from its inventory, or by purchasing virgin oil. SPIRP involves decisions about which of the present source nodes to include in the collection program, and which periodic (weekly) routing schedule to repeat over an infinite planning horizon. The objective is to minimize the total collection, inventory and purchasing costs while meeting the raw material requirements and operational constraints. A single-commodity flow-based mixed integer linear programming (MILP) model was proposed for this problem in an earlier study. The model was solved with 25 source nodes on a 7-day cyclic planning horizon. In order to tackle larger instances, we develop an ALNS algorithm that is based on a rich neighborhood structure with 11 distinct moves tailored to this problem. We demonstrate the performance of the ALNS, and compare it with the MILP model on test instances containing up to 100 source nodes.     

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.     

Trade-off between capacity invested and inventory needed

A multi-item capacitated make-to-order production system with considerable demand fluctuations is discussed. The relationship between the available capacity and the inventory needed to meet customer requirements with a pre-defined service level is modeled. Furthermore, the total cost for both capacity and inventory is minimized and it is shown that, assuming negligible change-over times, the double of the surplus inventory cost has to be equal to the excess capacity cost to ensure minimum total cost.     

Perishable inventory management system with a minimum volume constraint

The federal government maintains large quantities of medical supplies in stock as part of its Strategic National Stockpile (SNS) to protect the American public in case of a public health emergency. Managing these large perishable inventories effectively can help reduce the cost of the SNS and improves national security. In this paper, we propose a modified Economic Manufacturing Quantity (EMQ) model for perishable inventory with a minimum volume constraint, which is applicable to managing the inventory of medicines for the Strategic National Stockpile. We demonstrate that minimizing the cost of maintaining such a system can be formulated as a non-convex non-smooth unconstrained optimization problem. The property of this model is analysed and an efficient exact algorithm is presented to solve this problem. In the numerical experiment part, we perform sensitivity analysis on several government-controlled system parameters to illustrate how the government can obtain lower costs or a larger stockpile at the same cost by allowing more freedom in the management of the stocks.     

Algorithms for Capacitated,Multi-Item Lot-Sizing without Set-Ups

The multi-item lot-sizing problem considered here is concerned with finding the lot sizes over a horizon of discrete time periods to meet known future demand without incurring backlogs, such that the total cost of production and inventory holding is minimized. The capacity constraints arise because the production of each item consumes capacitated production resources at a given rate. Production is assumed to occur without set-ups. The problem is formulated as a capacitated trans-shipment problem. Use of modern, minimum-cost network flow algorithms, coupled with appropriate starting procedures, allows realistically large problem instances to be solved efficiently; thus obviating the need for specialized algorithms based on restrictive assumptions regarding cost structures.     

Optimal pricing and production in an inventory model

This paper deals with the problem of simultaneously determining the optimal price policy and production rate over a given planning horizon. For nonlinear demand functions and convex inventory and shortage cost functions the optimal solution paths are derived by using optimal control theory. The treatment of linear nonsmooth cost functions requires the use of a generalized maximum principle. The solution method is a phase portrait analysis providing insight into the optimal pricing and production policies as well as the resulting inventory paths. Moreover, it is shown that in the case of nonsmooth piecewise linear cost functions the equilibrium is approached within finite time although the model is nonlinear in the control variables. Finally it is illustrated that exogenous fluctuations in the demand rate (seasonal demand pattern) amount to cyclical optimal solutions.     

需求率依赖于库存水平的离散性库存费的库存模型

传统的库存控制模型都视需求率为固定不变的,放松了这个假定,通过考虑库存费为存储时间的阶梯函数的情形:(1)全单位库存费用,(2)增量库存费用,并且在需求率依赖于库存水平,当库存水平下降到一定程度时,需求率变为常数的形式下,把变化的订购费引入,发展了两个离散性库存费的变质物品的库存控制模型。在模型中允许周期末库存水平不为零,并且提出了最优解的算法。     

多阶段生产系统最优生产批量和原材料订购决策模型

Sarker和Parija(1996)建立了生产系统最优生产批量和原材料订购决策模型。然而他们的模型仅局限于单阶段生产系统,本文将他们的模型扩展到多阶段生产系统,我们首先建立了使整个多阶段生产系统总成本最小的各阶段最优生产批量、原材料订购批量及阶段之间的运输批量模型,然后分析了原材料订购费、半成品运费及设备安装费的敏感性。最后,我们结合实例综合分析了原材料订购费、半成品运输费和设备安装费的变化及最小值点取整后对原材料订购决策、最优生产批量和总成本的影响。     

Myopic control of stochastic inventories with intermittent updates: continuous <Emphasis Type="Italic">versus</Emphasis> periodic replenishment

A manufacturer who is responsible for supplying a retailer with a single product is considered. The retailer sells the product in response to stochastic demand and provides the manufacturer with periodic updates about his inventories. Replenishing the retailer's inventory under two myopic base-stock policies is addressed. These policies, referred to as vendor managed inventory, represent a relatively new approach to allocating responsibility in the replenishment process. Specifically, the manufacturer, who is responsible for the retailer's inventories, can replenish them either continuously at any point in time or periodically, at one point in time for each period. The myopic replenishment policies that are considered are of a base-stock type. It is shown that the selected policies become optimal as the number of review periods tends to infinity. Furthermore, the two replenishment alternatives are compared in terms of both base-stock levels and expected costs, including those for inventory holding/shortage and transportation costs. Although continuous rather than periodic replenishment is evidently more expensive in terms of transportation costs, it is shown that even when the transportation cost constitutes more than 55% of the total average cost, it may still be preferable to replenish continuously rather than periodically.     

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.     

大庆油田物资采购及库存优化机制设计与模型研究

本文结合大庆油田物资采购中的实际问题, 考虑物资市场、需求、库存三方之间的不确定性和复杂性,分别讨论了物资采购价格时变、物资需求时变、以及不同仓储容量限制下的库存优化模型的研究进展。进一步,设计了针对大庆油田物资的采购及库存优化机制,并选取大庆油田实际采购中的4种A类物资,基于时间序列方法和0-1混合整数规划,分别对机制中的价格预测部分和策略优化部分进行了数值试算,结果表明,基于准确度较高的预测价格,运用混合0-1整数规划模型制定的多品种物资的最优联合采购策略,可以实现采购成本的节省,相比于4种物资2009年的实际采购成本,节约比率高达7.66%,同时价格预测的精度也得到了用户的认可。该机制为油田物资采购和库存优化管理项目中的辅助决策支持系统原型设计提供了参照。但考虑到大庆油田实际采购中的各种复杂因素的影响,还需进一步完善该优化机制,并对相关模型进行改进。     

Optimal policies for inventory usage,production and pricing of fashion goods over a selling season

A short selling season and highly uncertain demands prior to the season characterize production and selling of fashion goods. Once the season starts and demands turn up with a peak interest in the beginning, monopoly becomes under tremendous pressure to produce the required amount so as not to disappoint its customers. It motivates the monopoly to prepare significant inventories by the opening day. Unfortunately, even the most advanced techniques for demand forecasting are likely to induce either an overestimate or underestimate of the initial inventories. Both affect the monopoly's profit. Overestimation results in surplus, which may never be sold, and excessive inventory holding costs. Underestimation implies sales as well as customer loyalty losses. Given inventory level at the beginning of the selling season, we derive policies of handling this inventory, production capacity and product prices in order to maximize the profit and thus diminish the effect of inherent inaccuracy of initial inventory estimation of fashion goods. A case of bookstore management illustrates the effectiveness of the suggested strategies.     

Optimal Planning of a Multi-Station System with Sojourn Time Constraints

This paper studies a dynamic production system where multiple products must visit stations where inventories are constrained by maximum and minimum sojourn times with neither negative flow nor backlog being allowed. A resource availability constraint limits the aggregate throughput of the stations. The objective is to minimize the sum of flow and inventory cost. The problem is broken down into several single-product serial systems that serve as subroutines of a Lagrangian relaxation routine. This model is implemented in a spreadsheet so that it can be used by the officials of a Chilean institution for planning the operations and defining the optimal allocation of resources.