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.     

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.     

A new lot sizing and scheduling heuristic for multi-site biopharmaceutical production

Biopharmaceutical manufacturing requires high investments and long-term production planning. For large biopharmaceutical companies, planning typically involves multiple products and several production facilities. Production is usually done in batches with a substantial set-up cost and time for switching between products. The goal is to satisfy demand while minimising manufacturing, set-up and inventory costs. The resulting production planning problem is thus a variant of the capacitated lot-sizing and scheduling problem, and a complex combinatorial optimisation problem. Inspired by genetic algorithm approaches to job shop scheduling, this paper proposes a tailored construction heuristic that schedules demands of multiple products sequentially across several facilities to build a multi-year production plan (solution). The sequence in which the construction heuristic schedules the different demands is optimised by a genetic algorithm. We demonstrate the effectiveness of the approach on a biopharmaceutical lot sizing problem and compare it with a mathematical programming model from the literature. We show that the genetic algorithm can outperform the mathematical programming model for certain scenarios because the discretisation of time in mathematical programming artificially restricts the solution space.     

Joint Economic Ordering Policies of Multiple Wholesalers and a Single Manufacturer with Price-dependent Demand Functions

The economic ordering policies for multiple regional wholesalers and the production lot-sizing policy for a single manufacturer have been studied in a joint analysis under the assumption that the yearly demands of each region are functions of their respective retail proces. We obtained optimum EOQs for both linear and constant price elasticity demand functions. Although normally the wholesalers would order in quantities equal to their EOQs, they are encouraged to purchase in different quantities by the producer providing compensation to offset the wholesalers' increased costs. The production lot-size is determined to minimize the overall production cost.     

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.     

Heuristic procedures for a stochastic lot-sizing problem in make-to-order manufacturing

We consider a single item, uncapacitated stochastic lot-sizing problem motivated by a Dutch make-to-order company producing steel pipes. Since no finished goods inventory is kept, a delivery date is fixed upon arrival of each order. The objective is to determine the optimal size of production lots so that delivery dates are met as closely as possible with a limited number of set-ups. Orders that are not satisfied on time are backordered and a penalty cost is incurred in those cases. We formulate the problem as a Markov Decision Process and determine the optimal production policy by dynamic programming. Since this approach can only be applied to very small examples, attention is given to the development of three simple lot-sizing rules. The first strategy consists of producing the orders for a fixed numberT of periods whenever the demand for the current period reaches a pre-specified limitx. A simple set of tests is proposed leading to cost improvements in situations where the best combination for the decision variablesx andT deviates from the optimal policy. The second lot-sizing rule is based on the well-known Silver-Meal heuristic for the case of deterministic time-varying demand. A fixed cycle production strategy is also derived. Numerical examples taking into account different demand patterns are provided. The analysis of the results suggests that the first heuristic is particularly suitable for the problem under consideration. Finally, the model is incorporated in the operations control level of the hierarchical production planning system of the Dutch company and assists the management in the evaluation of the quality of the aggregate decisions. A consequence of this feedback mechanism is the modification of the aggregate plans.On leave from D.E.I.O. (Universidade de Lisboa, Portugal). This research was supported by J.N.I.C.T. (Portugal) under contract BD/2264/92.IA.     

A multicut L-shaped based algorithm to solve a stochastic programming model for the mobile facility routing and scheduling problem

This paper considers the mobile facility routing and scheduling problem with stochastic demand (MFRSPSD). The MFRSPSD simultaneously determines the route and schedule of a fleet of mobile facilities which serve customers with uncertain demand to minimize the total cost generated during the planning horizon. The problem is formulated as a two-stage stochastic programming model, in which the first stage decision deals with the temporal and spatial movement of MFs and the second stage handles how MFs serve customer demands. An algorithm based on the multicut version of the L-shaped method is proposed in which several lower bound inequalities are developed and incorporated into the master program. The computational results show that the algorithm yields a tighter lower bound and converges faster to the optimal solution. The result of a sensitivity analysis further indicates that in dealing with stochastic demand the two-stage stochastic programming approach has a distinctive advantage over the model considering only the average demand in terms of cost reduction.     

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.     

Two-stage minimax regret robust uncapacitated lot-sizing problems with demand uncertainty

In this paper, we consider the two-stage minimax robust uncapacitated lot-sizing problem with interval uncertain demands. A mixed integer programming formulation is proposed. Even though the robust uncapacitated lot-sizing problem with discrete scenarios is an NP-hard problem, we show that it is polynomial solvable under the interval uncertain demand set.     

A resource portfolio planning model using sampling-based stochastic programming and genetic algorithm

Resource portfolio planning optimization is crucial to high-tech manufacturing industries. One of the most important characteristics of such a problem is intensive investment and risk in demands. In this study, a nonlinear stochastic optimization model is developed to maximize the expected profit under demand uncertainty. For solution efficiency, a stochastic programming-based genetic algorithm (SPGA) is proposed to determine a profitable capacity planning and task allocation plan. The algorithm improves a conventional two-stage stochastic programming by integrating a genetic algorithm into a stochastic sampling procedure to solve this large-scale nonlinear stochastic optimization on a real-time basis. Finally, the tradeoff between profits and risks is evaluated under different settings of algorithmic and hedging parameters. Experimental results have shown that the proposed algorithm can solve the problem efficiently.     

Polyhedral analysis for the two-item uncapacitated lot-sizing problem with one-way substitution

We consider a production planning problem for two items where the high quality item can substitute the demand for the low quality item. Given the number of periods, the demands, the production, inventory holding, setup and substitution costs, the problem is to find a minimum cost production and substitution plan. This problem generalizes the well-known uncapacitated lot-sizing problem. We study the projection of the feasible set onto the space of production and setup variables and derive a family of facet defining inequalities for the associated convex hull. We prove that these inequalities together with the trivial facet defining inequalities describe the convex hull of the projection if the number of periods is two. We present the results of a computational study and discuss the quality of the bounds given by the linear programming relaxation of the model strengthened with these facet defining inequalities for larger number of periods.     

Fix and Relax Heuristic for a Stochastic Lot-Sizing Problem

This paper addresses a particular stochastic lot-sizing and scheduling problem. The evolution of the uncertain parameters is modelled by means of a scenario tree and the resulting model is a multistage stochastic mixed-integer program. We develop a heuristic approach that exploits the specific structure of the problem. The computational experiments carried out on a large set of instances have shown that the approach provides good quality solutions in a reasonable amount of time.     

随机需求下多供应商和多零售商的生产-库存-运输联合优化模型

考虑随机需求下多供应商和多零售商的生产-库存-运输联合优化问题.在联合优化时,首先利用最近邻算法将各零售商分成不同区域,分区后问题转化为随机需求下单供应商对多零售商的生产-库存-运输联合优化问题.在每个分区内,由供应商统一决策其分区内各零售商的送货量和送货时间.利用粒子群算法和模拟退火算法相结合的两阶段算法求出最优送货量、最优运输路径和最大期望总利润.然后采用收入共享契约将增加的利润合理分配给各供应商和各零售商,使各方利润都得到增加,从而促使各方愿意合作.通过数值算例验证了联合优化模型优于独立决策模型.     

Integrated production and allocation policies with one direct shipping option

We consider a single period inventory problem in which a supplier faces stochastic demands and customer specific waiting costs from multiple customers. The objective is to develop integrated production, allocation, and distribution policies so that the total production and customer waiting costs are minimized. We present an optimal policy for the two customer problem and derive a heuristic for a general problem based on the structural results of the two customer case. We show, numerically, that the heuristic performs very well with error bounds of less than 2% on average, while typical approximations may lead to significant sub-optimality.     

An integrated production and preventive maintenance planning model

We are given a set of items that must be produced in lots on a capacitated production system throughout a specified finite planning horizon. We assume that the production system is subject to random failures, and that any maintenance action carried out on the system, in a period, reduces the system’s available production capacity during that period. The objective is to find an integrated lot-sizing and preventive maintenance strategy of the system that satisfies the demand for all items over the entire horizon without backlogging, and which minimizes the expected sum of production and maintenance costs. We show how this problem can be formulated and solved as a multi-item capacitated lot-sizing problem on a system that is periodically renewed and minimally repaired at failure. We also provide an illustrative example that shows the steps to obtain an optimal integrated production and maintenance strategy.     

An integrated model for lot sizing with supplier selection and quantity discounts

Good inventory management is essential for a firm to be cost competitive and to acquire decent profit in the market, and how to achieve an outstanding inventory management has been a popular topic in both the academic field and in real practice for decades. As the production environment getting increasingly complex, various kinds of mathematical models have been developed, such as linear programming, nonlinear programming, mixed integer programming, geometric programming, gradient-based nonlinear programming and dynamic programming, to name a few. However, when the problem becomes NP-hard, heuristics tools may be necessary to solve the problem. In this paper, a mixed integer programming (MIP) model is constructed first to solve the lot-sizing problem with multiple suppliers, multiple periods and quantity discounts. An efficient Genetic Algorithm (GA) is proposed next to tackle the problem when it becomes too complicated. The objectives are to minimize total costs, where the costs include ordering cost, holding cost, purchase cost and transportation cost, under the requirement that no inventory shortage is allowed in the system, and to determine an appropriate inventory level for each planning period. The results demonstrate that the proposed GA model is an effective and accurate tool for determining the replenishment for a manufacturer for multi-periods.     

基于预约模式的移动充电车实时需求响应策略研究

预约模式下移动充电车实时需求响应问题是移动充电行业发展过程中的新问题,该问题包含了两类不同特点、存在动态交替影响关系的需求,不仅有时间窗约束、实时响应性要求,也有动态不确定性的特点。针对以上问题特点,本文以最大化整体收益为目标,提出联动的两阶段实时需求响应策略,引用近似动态规划求解决策未来价值,并融入到以下两阶段中:第一阶段基于多阶段随机动态决策模型与禁忌搜索算法生成了可以动态调整的充电服务方案;第二阶段基于第一阶段提出了针对动态需求的实时响应决策流程。最后,对比实验验证了本策略在不同客户规模与动态度下的有效性,并得出管理启示。本研究可以支持制定移动充电车的实时需求响应策略,对类似具有动态特征的需求响应问题具有启发意义。     

Hierarchical production planning and scheduling with random demand and production failure

A multiple-objective hierarchical production planning and scheduling model is developed that integrates aggregate type decisions, family disaggregate decisions, lotsizing and scheduling of the jobs. It is assumed that demand and production failure are subject to uncertainties. Stochastic programming with recourse using a constraint sample approximation method is used to incorporate random demand and production failure into the model. The model evaluates final production plans, updates the demand forecasts and proceeds on a rolling horizon manner. Experimental results show that it is sufficient to generate and incorporate into the aggregate type model a small sample of the stochastic constraints from an infinite set of scenarios. A heuristic scheduling algorithm provides detailed information regarding the progress of jobs through work centers. This information is extremely useful in resolving infeasibilities during the production process. Other features of the model are also reported.     

Alternate risk measures for emergency medical service system design

The stochastic nature of emergency service requests and the unavailability of emergency vehicles when requested to serve demands are critical issues in constructing valid models representing real life emergency medical service (EMS) systems. We consider an EMS system design problem with stochastic demand and locate the emergency response facilities and vehicles in order to ensure target levels of coverage, which are quantified using risk measures on random unmet demand. The target service levels for each demand site and also for the entire service area are specified. In order to increase the possibility of representing a wider range of risk preferences we develop two types of stochastic optimization models involving alternate risk measures. The first type of the model includes integrated chance constraints (ICCs ), whereas the second type incorporates ICCs  and a stochastic dominance constraint. We develop solution methods for the proposed single-stage stochastic optimization problems and present extensive numerical results demonstrating their computational effectiveness.     

Integrated sales and operations planning with multiple products: Jointly optimizing the number and timing of promotions and production decisions

This paper presents a modelling framework for sales and operations planning (S&OP) that considers the integration of price promotion and production planning for multiple products. Such a modelling framework takes into account the potential competition and cannibalization between products, as well as the allocation of shared production resources. The demand model that we adopt combines purchase incidence, consumer choice and purchase quantity in a sequential framework to obtain the dynamics and heterogeneity of consumer response to promotions. Due to large problem sizes, we develop a heuristic approach for solving the resulting joint optimization problem. The results of our numerical study show interesting findings on the optimal number and timing of promotions that take into account the mutual dependence of marketing and production related factors.