A fresh approach to performance evaluation in a multi-item production scenario

In a truly flexible production environment, it is feasible to interchange the production rate of two items, as long as this does not affect the constraint imposed on total manufacturing time. Performance evaluation in a multi-item production scenario has many facets, and its improvement is possible in many ways. After adopting certain benchmarking or analytical process, usually a facility runs at certain performance level with respect to total system cost. It may be a unique approach to explore the possibility of interchanging the production rate of any item with that of another appropriate item in the group. This is discussed in the present paper with the objective of further improvement in the total cost.     

Optimal batch sizing in a multi-stage production system with rework consideration

In a production system, rework process plays an important role in eliminating waste and effectively controlling the cost of manufacturing. Determining the optimal batch size in a system that allows for rework is, therefore, a worthwhile objective to minimize the inventory cost of work-in-processes and the finished goods. In this paper, models for the optimum batch quantity in a multi-stage system with rework process have been developed for two different operational policies. Policy 1 deals with the rework within the same cycle with no shortage and policy 2 deals with the rework done after N cycles, incurring shortages in each cycle. The major components that play a role in minimizing this cost of the system are manufacturing setups, work-in-processes, storage of finished goods, rework processing, waiting-time, and penalty costs to discourage the generation of defectives. The mathematical structure of this rework processing model falls under a nonlinear convex programming problems for which a closed-form solution has been proposed and results are demonstrated through numerical examples, followed by sensitivity analyses of different important parameters. It is concluded that the total cost in policy 2 tends to be smaller than that in policy 1 at lower proportion of defectives if the in-process carrying cost is low. Policy 2 may be preferred when the work-in-process carrying cost is low and the penalty cost is negligible.     

A Lot-sizing Model for Just-in-time Manufacturing

We consider the problem of determining lot sizes of multiple items that are manufactured by a single capacitated facility. The manufacturing facility may represent a bottleneck processing activity on the shop floor or a storeroom that provides components to the shop floor. Items flow from the facility to a downstream facility, where they are assembled according to a specified mix. Just-in-time (JIT) manufacturing requires a balanced flow of items, in the proper mix, between successive facilities. Our model determines lot sizes of the various items based on available capacity and four attributes of each item: demand rate, holding cost, set-up time and processing time. Holding costs for each item accrue until the appropriate mix of items is available for shipment downstream. We develop a lot-sizing heuristic that minimizes total holding cost per time unit over all items, subject to capacity availability and the required mix of items.     

An efficient algorithm for a generalized joint replenishment problem

In most multi-item inventory systems, the ordering costs consist of a major cost and a minor cost for each item included. Applying for every individual item a cyclic inventory policy, where the cycle length is a multiple of some basic cycle time, reduces the major ordering costs. An efficient algorithm to determine the optimal policy of this type is discussed in this paper. It is shown that this algorithm can be used for deterministic multi-item inventory problems, with general cost rate functions and possibly service level constraints, of which the well-known joint replenishment problem is a special case. Some useful results in determining the optimal control parameters are derived, and worked out for piecewise linear cost rate functions. Numerical results for this case show that the algorithm significantly outperforms other solution methods, both in the quality of the solution and in the running time.     

Batch scheduling of deteriorating reworkables

The problem of scheduling the production of new and recoverable defective items of the same product manufactured on the same facility is studied. Items are processed in batches. Each batch comprises two sub-batches processed consecutively. In the first sub-batch, all the items are newly manufactured. Some of them are of the required good quality and some are defective. The defective items are remanufactured in the second sub-batch. They deteriorate while waiting for rework. This results in increased time and cost for their remanufacturing. All the items in the same sub-batch complete at the same time, which is the completion time of the last item in the sub-batch. Each remanufactured defective item is of the required good quality. It is assumed that the percentage of defective items in each batch is the same. A setup time is required to start batch processing and to switch from manufacturing to remanufacturing. The demands for good quality items over time are given. The objective is to find batch sizes such that the total setup and inventory holding cost is minimized and all the demands are satisfied. Dynamic programming algorithms are presented for the general problem and some important special cases.     

A combinatorial approach to level of repair analysis

This paper presents an approach to optimise level of repair decisions taking into account submodular properties of standard life cycle cost functions, which include fixed and variable costs. It proposes an integer programming formulation to solve level of repair problems for multi-echelon multi-indenture level systems. The method converges quickly to the optimum solution relying on heuristics to obtain tight bounds for a subsequent branch-and-bound procedure. A software package called level of repair optimisation model (LOROM) was developed to implement the branch-and-bound method that does not rely on linear programming relaxations. This approach is rather generic and can be applied to a wide class of problems with convex total cost functions such as plant location problems or transportation problems with fixed costs.     

Lot sizing and testing for items with uncertain quality

We consider the problem where items are produced in lots and sold with warranty. Due to manufacturing variability, some items do not conform to the design specifications and their performance is inferior (for example, have higher failure rate). The warranty servicing cost for these is much higher than for those which conform. Two approaches have been advocated for reducing the warranty cost per item released and in both it is achieved at the expense of increased manufacturing cost. The first involves life testing to weed out nonconforming items and the second involves strategies to reduce nonconforming items being produced. In this paper, the authors develop a model which combines both approaches and quality control decisions are made optimally to minimize the total (manufacturing and warranty) cost. It extends the earlier models of the authors which deals with quality decisions based solely on either the first or the second approach.     

Computation of Optimum Re-order Levels and Quantities for a Re-order Level Stock Control System

The purpose of this article is to present a method of calculating optimum re-order levels and quantities for a re-order level stock control system where the criterion of optimality is the minimization of total expected cost. Many solutions to this, and similar, stock control problems exist in the literature; however, most of these incorporate approximations which simplify the mathematics, but give rise to non-optimal solutions for certain values of the basic parameters. The method described here enables optimum policies to be evaluated reasonably quickly for any item for which the basic parameters can be estimated.In the article we give the mathematical formulation and solution of the problem, together with a computing routine which finds optimum policies.     

Estimation of more than one parameters in stratified sampling with fixed budget

In a multivariate stratified sampling more than one characteristic are defined on every unit of the population. An optimum allocation which is optimum for one characteristic will generally be far from optimum for others. A compromise criterion is needed to work out a usable allocation which is optimum, in some sense, for all the characteristics. When auxiliary information is also available the precision of the estimates of the parameters can be increased by using it. Furthermore, if the travel cost within the strata to approach the units selected in the sample is significant the cost function remains no more linear. In this paper an attempt has been made to obtain a compromise allocation based on minimization of individual coefficients of variation of the estimates of various characteristics, using auxiliary information and a nonlinear cost function with fixed budget. A new compromise criterion is suggested. The problem is formulated as a multiobjective all integer nonlinear programming problem. A solution procedure is also developed using goal programming technique.     

A production-inventory model with probabilistic deterioration in two-echelon supply chain management

In this study, a production-inventory model is developed for a deteriorating item in a two-echelon supply chain management (SCM). An algebraical approach is applied to find the minimum cost related to this entire SCM. We consider three types of continuous probabilistic deterioration function to find the associated cost. The purpose of this study is to obtain the minimum cost with integer number of deliveries and optimum lotsize for the three different models. Some numerical examples, sensitivity analysis and graphical representation are given to illustrate the model. A numerical comparison between the three models is also given.     

The Trended Inventory Lot Sizing Problem with Shortages Under a New Replenishment Policy

In the past few years, considerable attention has been given to the inventory lot sizing problem with trended demand over a fixed horizon. The traditional replenishment policy is to avoid shortages in the last cycle. Each of the remaining cycles starts with a replenishment and inventory is held for a certain period which is followed by a period of shortages. A new replenishment policy is to start each cycle with shortages and after a period of shortages a replenishment should be made. In this paper, we show that this new type of replenishment policy is superior to the traditional one. We further propose four heuristic procedures that follow the new replenishment policy. These are the constant demand approximation method, the equal cycle length heuristic, the extended Silver approach, and the extended least cost solution procedure. We also examine the cost and computation time performances of these heuristic procedures through an empirical study. The number of test problems solved to optimality, average and maximum cost deviation from optimum were used as measures of cost performance. The results of the 10 000 test problems reveal that the extended least cost approach is most cost effective.     

Optimal design of a hoist structure frame

In an attempt to find the most cost effective design of a multipurpose hoisting device that can be easily mounted on and removed from a regular farm vehicle, cost optimisation including both material and manufacturing expenditure, is performed on the main frame supporting the device. The optimisation is constrained by local and global buckling and fatigue conditions. Implementation of Snyman’s gradient-based LFOPC optimisation algorithm to the continuous optimisation problem, results in the economic determination of an unambiguous continuous solution, which is then utilised as the starting point for a neighbourhood search within the discrete set of profiles available, to attain the discrete optimum.

This optimum is further investigated for a different steel grade and for the manufacturing and material cost pertaining to different countries. The effect of variations in the formulation of the objective function for optimisation is also investigated. The results indicate that considerable cost benefits can be obtained by optimisation, that costing in different countries do not necessarily result in the same most cost effective design, and that accurate formulation of the objective function, i.e. realistic mathematical modelling, is of utmost importance in obtaining the intended design optimum.     

Optimal production inventory policy for defective items with fuzzy time period

In this paper, an optimal production inventory model with fuzzy time period and fuzzy inventory costs for defective items is formulated and solved under fuzzy space constraint. Here, the rate of production is assumed to be a function of time and considered as a control variable. Also the demand is linearly stock dependent. The defective rate is taken as random, the inventory holding cost and production cost are imprecise. The fuzzy parameters are converted to crisp ones using credibility measure theory. The different items have the different imprecise time periods and the minimization of cost for each item leads to a multi-objective optimization problem. The model is under the single management house and desired inventory level and product cost for each item are prescribed. The multi-objective problem is reduced to a single objective problem using Global Criteria Method (GCM) and solved with the help of Fuzzy Riemann Integral (FRI) method, Kuhn–Tucker condition and Generalised Reduced Gradient (GRG) technique. In optimum results including production functions and corresponding optimum costs for the different models are obtained and then are presented in tabular forms.     

Multi-product lot-sizing and sequencing on a single imperfect machine

A problem of lot-sizing and sequencing several products on a single machine is studied. The machine is imperfect in two senses: it can produce defective items and it can breakdown. The number of defective items for each product is given as an integer valued non-decreasing function of the manufactured quantity. The total machine breakdown time is given as a real valued non-decreasing function of the manufactured quantities of all the products. A sequence-dependent setup time is required to switch the machine from manufacturing one product to another. Two problem settings are considered. In the first, the objective is to minimize the completion time of the last item, provided that all the product demands for the good quality items are satisfied. In the second, the goal is to minimize the total cost of demand dissatisfaction, subject to an assumption that the completion time of the last item does not exceed a given upper bound. Computational complexity and algorithmic results are presented, including an FPTAS for a special case of the cost minimization problem, and computer experiments with the FPTAS.     

Single-vendor multi-buyer integrated production-inventory model with controllable lead time and service level constraints

This paper presents an integrated production-inventory model where a vendor produces an item in a batch production environment and supplies it to a set of buyers. The buyer level demand is assumed to be independent normally distributed and lead time of every buyer can be reduced at an added crash cost. The buyers review their inventory using continuous review policy, and the unsatisfied demand at the buyers is completely backordered. A model is formulated to minimize the joint total expected cost of the vendor–buyers system to determine the optimal production-inventory policy. Since it is often difficult to estimate the stock-out cost in inventory systems, and so instead of having stock-out cost component in the objective function, a service level constraint (SLC) corresponding to each buyer is included in the model. A Lagrangian multiplier technique based algorithmic approach is proposed, which evaluates a very limited number of combinations of lead time of the buyers to find simultaneously the optimal lead time, order quantity and safety factor of the buyers and the number of shipments between the vendor and the buyers in a production cycle. Finally, a numerical example and effects of the key parameters are included to illustrate the results of the proposed model.     

Efficiency,effectiveness and productivity of marketing in services

In this paper we consider complex deterministic problems, where there are two models that can be used to predict the performance for a given design. One of the models can give a precise estimation, but is complex and time consuming. The other model is simple and fast, but can only give a very crude estimation. We have proposed a learning-based ordinal optimization approach to tackle this problem. In this approach, we first run a simple model for all the designs and a complex model for a few designs, and then, through regression analysis, we estimate the noise trend, and this noise trend together with the crude estimates from the simple model will be used to screen the designs. The proposed approach is applied to solve an integrally bladed rotor (IBR) manufacturing problem where the production sequence and the production parameters need to be determined in order to minimize the overall manufacturing cost while satisfying the manufacturing constraints. The results indicate that, by using a very crude and simple model, we are able to identify good designs with a high degree of confidence.     

A heuristic for BILP problems: The Single Source Capacitated Facility Location Problem

In the Single Source Capacitated Facility Location Problem (SSCFLP) each customer has to be assigned to one facility that supplies its whole demand. The total demand of customers assigned to each facility cannot exceed its capacity. An opening cost is associated with each facility, and is paid if at least one customer is assigned to it. The objective is to minimize the total cost of opening the facilities and supply all the customers. In this paper we extend the Kernel Search heuristic framework to general Binary Integer Linear Programming (BILP) problems, and apply it to the SSCFLP. The heuristic is based on the solution to optimality of a sequence of subproblems, where each subproblem is restricted to a subset of the decision variables. The subsets of decision variables are constructed starting from the optimal values of the linear relaxation. Variants based on variable fixing are proposed to improve the efficiency of the Kernel Search framework. The algorithms are tested on benchmark instances and new very large-scale test problems. Computational results demonstrate the effectiveness of the approach. The Kernel Search algorithm outperforms the best heuristics for the SSCFLP available in the literature. It found the optimal solution for 165 out of the 170 instances with a proven optimum. The error achieved in the remaining instances is negligible. Moreover, it achieved, on 100 new very large-scale instances, an average gap equal to 0.64% computed with respect to a lower bound or the optimum, when available. The variants based on variable fixing improved the efficiency of the algorithm with minor deteriorations of the solution quality.     

A composite model in the context of a production-inventory system

In the context of a manufacturing situation, the procurement of multiple input items has been considered along with the production of a finished item. A composite model has been developed for a generalized environment in which the fractional backordering is included. The model can be used for a variety of situations. The output parameters are provided for possible combinations of input parameters, which can be used directly and are also suitable for further analysis.     

On the Effect of Product Variety in Production–Inventory Systems

In this paper, we examine the effect of product variety on inventory costs in a production–inventory system with finite capacity where products are made to stock and share the same manufacturing facility. The facility incurs a setup time whenever it switches from producing one product type to another. The production facility has a finite production rate and stochastic production times. In order to mitigate the effect of setups, products are produced in batches. In contrast to inventory systems with exogenous lead times, we show that inventory costs increase almost linearly in the number of products. More importantly, we show that the rate of increase is sensitive to system parameters including demand and process variability, demand and capacity levels, and setup times. The effect of these parameters can be counterintuitive. For example, we show that the relative increase in cost due to higher product variety is decreasing in demand and process variability. We also show that it is decreasing in expected production time. On the other hand, we find that the relative cost is increasing in expected setup time, setup time variability and aggregate demand rate. Furthermore, we show that the effect of product variety on optimal base stock levels is not monotonic. We use the model to draw several managerial insights regarding the value of variety-reducing strategies such as product consolidation and delayed differentiation.     

Optimizing information using the EM algorithm in item response theory

Latent trait models such as item response theory (IRT) hypothesize a functional relationship between an unobservable, or latent, variable and an observable outcome variable. In educational measurement, a discrete item response is usually the observable outcome variable, and the latent variable is associated with an examinee’s trait level (e.g., skill, proficiency). The link between the two variables is called an item response function. This function, defined by a set of item parameters, models the probability of observing a given item response, conditional on a specific trait level. Typically in a measurement setting, neither the item parameters nor the trait levels are known, and so must be estimated from the pattern of observed item responses. Although a maximum likelihood approach can be taken in estimating these parameters, it usually cannot be employed directly. Instead, a method of marginal maximum likelihood (MML) is utilized, via the expectation-maximization (EM) algorithm. Alternating between an expectation (E) step and a maximization (M) step, the EM algorithm assures that the marginal log likelihood function will not decrease after each EM cycle, and will converge to a local maximum. Interestingly, the negative of this marginal log likelihood function is equal to the relative entropy, or Kullback-Leibler divergence, between the conditional distribution of the latent variables given the observable variables and the joint likelihood of the latent and observable variables. With an unconstrained optimization for the M-step proposed here, the EM algorithm as minimization of Kullback-Leibler divergence admits the convergence results due to Csiszár and Tusnády (Statistics & Decisions, 1:205–237, 1984), a consequence of the binomial likelihood common to latent trait models with dichotomous response variables. For this unconstrained optimization, the EM algorithm converges to a global maximum of the marginal log likelihood function, yielding an information bound that permits a fixed point of reference against which models may be tested. A likelihood ratio test between marginal log likelihood functions obtained through constrained and unconstrained M-steps is provided as a means for testing models against this bound. Empirical examples demonstrate the approach.