The Common Cycle Economic Lot Scheduling Problem with Backorders: Benefits of Controllable Production Rates

In this paper, we deal with the production scheduling ofseveral products that are produced periodically, in a fixed sequence, ona single machine. In the literature, this problem is usually referred to asthe Common Cycle Economic Lot Scheduling Problem. We extend thelatter to allow the production rates to be controllable at the beginningof as well as during each production run of a product. Also, we assumethat unsatisfied demand is completely backordered. The objective is todetermine the optimal schedule that satisfies the demand for all theproducts and that realizes the minimum average setup, inventoryholding and backlog cost per unit time. Comparison with previousresults (when production rates are fixed) reveals that averagecosts can be reduced up to 66% by allowing controllable productionrates.     

On a production-inventory system of deteriorating items subject to random machine breakdowns with a fixed repair time

This paper considers the impact of random machine breakdowns on the classical Economic Production Quantity (EPQ) model for a product subject to exponential decay and under a no-resumption (NR) inventory control policy. A product is manufactured in batches on a machine that is subject to random breakdowns in order to meet a constant demand over an infinite planning horizon. The product is assumed to have a significant rate of deterioration and time to deterioration is described by an exponential distribution. Also, the time-to-breakdown is a random variable following an exponential distribution. Under the NR policy, when a breakdown occurs during a production run, the run is immediately aborted. A new run will not be started until all available inventories are depleted. Corrective maintenance of the production system is carried out immediately after a breakdown and it takes a fixed period of time to complete such an activity. The objective is to determine the optimal production uptime that minimizes the expected total cost per unit time consisting of setup, corrective maintenance, inventory carrying, deterioration, and lost sales costs. A near optimal production uptime is derived under conditions of continuous review, deterministic demand, and no shortages.     

A fuzzy algorithm for continuous capacitated location allocation model with risk consideration

This paper presents a continuous capacitated location-allocation model with fixed cost as a risk management model. In the presented model, the fixed cost consists of production and installation costs. The model considers risk as percent of unsatisfied demands. The fixed cost is assigned to a zone with a predetermined radius from its center. Because of uncertain environment, demand in each zone is investigated as a fuzzy number. The model is solved by a fuzzy algorithm based on α-cut method. After solving the model based on different α-values, the zones with the largest possibilities are determined for locating new facilities and the best locations are calculated based on the obtained possibilities. Then, the model is solved based on different α-values to determine best allocation values. Also, this paper proposes a Cross Entropy (CE) algorithm considering multivariate normal and multinomial density functions for solving large scale instances and is compared with GAMS. Finally, a numerical example is expressed to illustrate the proposed model.     

A stochastic programming approach to cash management in banking

The treasurer of a bank is responsible for the cash management of several banking activities. In this work, we focus on two of them: cash management in automatic teller machines (ATMs), and in the compensation of credit card transactions. In both cases a decision must be taken according to a future customers demand, which is uncertain. From historical data we can obtain a discrete probability distribution of this demand, which allows the application of stochastic programming techniques. We present stochastic programming models for each problem. Two short-term and one mid-term models are presented for ATMs. The short-term model with fixed costs results in an integer problem which is solved by a fast (i.e. linear running time) algorithm. The short-term model with fixed and staircase costs is solved through its MILP equivalent deterministic formulation. The mid-term model with fixed and staircase costs gives rise to a multi-stage stochastic problem, which is also solved by its MILP deterministic equivalent. The model for compensation of credit card transactions results in a closed form solution. The optimal solutions of those models are the best decisions to be taken by the bank, and provide the basis for a decision support system.     

A Multi-Objective Production Inventory Model with Backorder for Fuzzy Random Demand Under Flexibility and Reliability

In this paper, an Economic Production Quantity (EPQ) model is developed with flexibility and reliability consideration of production process in an imprecise and uncertain mixed environment. The model has incorporated fuzzy random demand, an imprecise production preparation time and shortage. Here, the setup cost and the reliability of the production process along with the backorder replenishment time and production run period are the decision variables. Due to fuzzy-randomness of the demand, expected average demand is a fuzzy quantity and also imprecise preparation time is represented by fuzzy number. Therefore, both are first transformed to a corresponding interval number and then using the interval arithmetic, the single objective function for expected profit over the time cycle is changed to respective multi-objective functions. Due to highly nonlinearity of the expected profit functions it is optimized using a multi-objective genetic algorithm (MOGA). The associated profit maximization problem is illustrated by numerical examples and also its sensitivity analysis is carried out.     

应急管理中车辆受限的生产_库存及配送整合模型

针对突发事件发生后,救灾物资不足、车辆数量及容量有限的情况,本文考虑了制造商生产、包装新的救灾物资,构造了车辆返回制造商需要等待订单完成生产的时间函数,建立了一个生产、库存及配送整合的混合整数规划模型。该模型由原材料供应商、制造商、配送中心及客户需求点四部分构成,以完成原材料的运输、制造商中的订单生产并运送到需求点及配送中心的库存订单运送到需求点的总花费时间最短为目标。本文将模型分为两层子模型进行求解:第一层模型采用改进的遗传算法求解;第二层模型采用隐枚举法求解。最后给出一个具体的案例以验证模型的合理性及算法的有效性。     

生产线随机崩坍情形下的变质品EPQ策略

变质品生产过程,可能率先出现"次品"的不稳定生产情形,随后机器崩坍;生产状态稳定性迁移时机、机器崩坍时间、维修时间皆乃随机变量;同时,企业无法观测当期需求,只能根据前期需求而随机地安排启动生产时刻.理论模型及数值算例皆表明,此种情况下,企业可以非等周期生产,存在组织生产次数(N)与生产率(P)的优解.敏感度分析看出,当需求拖后率增加、变质率+次品率降低时,企业成本显著降低,但首期生产启动时刻、生产率几乎没有变化.     

基于时变需求的集成多级供应链生产订货策略研究

考虑一个时变需求环境下集成多级供应链问题,在有限的规划时间内销售商以固定周期订货,而生产商以不同的周期生产,目的是寻找销售商最优的订货周期和生产商最佳的生产策略,从而使供应链系统的总运营成本最少.建立了该问题的混合整数非线性规划模型,求解该模型分为两步：先求对应一个订货周期的最佳生产策略,再求最优的订货周期,第一步用到了图论里求最短路方法.给出了两个步骤的算法和程序,实验证明它们是有效的.通过算例对模型进行了分析,研究了各参数对最优解及最小费用的影响.     

Optimal production run time for two-stage production system with imperfect processes and allowable shortages

This paper considers a two-stage production system with imperfect processes. Shortages are allowed, and the unsatisfied demand is completely backlogged. In addition, the capital investment in process quality improvement is adopted. Under these assumptions, we first formulate the proposed problem as a cost minimization model where the production run time and process quality are decision variables. Then we develop the criterion for judging whether the optimal solution not only exists but also is unique. If the criterion is not satisfied, the production system should not be opened. An algorithm for the computations of the optimal solutions is also provided. Finally, a numerical example and sensitivity analysis are carried out to illustrate the model.     

Optimal deteriorating items production inventory models with random machine breakdown and stochastic repair time

This study develops deteriorating items production inventory models with random machine breakdown and stochastic repair time. The model assumes the machine repair time is independent of the machine breakdown rate. The classical optimization technique is used to derive an optimal solution. A numerical example and sensitivity analysis are shown to illustrate the models. The stochastic repair models with uniformly distributed repair time tends to have a larger optimal total cost than the fixed repair time model, however the production up time is less than the fixed repair time model. Production and demand rate are the most sensitive parameters for the optimal production up time, and demand rate is the most sensitive parameter to the optimal total cost for the stochastic model with exponential distribution repair time.     

Optimizing a Production System with a Fixed Delivery Schedule

This note considers a model in which a manufacturing company purchases a raw material, manufactures a product (at a finite rate) and ships a fixed quantity of the product to a single customer at fixed and regular intervals of time, as specified by the customer. In general there are several shipments made during each production run. The objective is to determine a purchasing and production schedule which minimises the total cost of purchasing, manufacturing and stockholding. It extends previously published work by considering the possibility that a single raw material purchase provides stock for several production runs or that several raw material purchases provide stock for a single production run.     

Production strategies for a stochastic lot-sizing problem with constant capacity

This paper presents a single item capacitated stochastic lot-sizing problem motibated by a Dutch company operating in a Make-To-Order environment. Due to a highly fluctuating and unpredictable demand, it is not possible to keep any finished goods inventory. In response to a customer's order, a fixed delivery date is quoted by the company. The objective is to determine in each period of the planning horizon the optimal size of production lots so that delivery dates are met as closely as possible at the expense of minimal average costs. These include set-up costs, holding costs for orders that are finished before their promised delivery date and penalty costs for orders that are not satisfied on time and are therefore backordered. Given that the optimal production policy is likely to be too complex in this situation, attention is focused on the development of heuristic procedures. In this paper two heuristics are proposed. The first one is an extension of a simple production strategy derived by Dellaert [5] for the uncapacitated version of the problem. The second heuristic is based on the well-known Silver-Meal algorithm for the case of deterministic time-varying demand. Experimental results suggest that the first heuristic gives low average costs especially when the demand variability is low and there are large differences in the cost parameters. The Silver-Meal approach is usually outperformed by the first heuristic in situations where the available production capacity is tight and the demand variability is low.     

A production-transportation problem with stochastic demand and concave production costs

Well known extensions of the classical transportation problem are obtained by including fixed costs for the production of goods at the supply points (facility location) and/or by introducing stochastic demand, modeled by convex nonlinear costs, at the demand points (the stochastic transportation problem, [STP]). However, the simultaneous use of concave and convex costs is not very well treated in the literature. Economies of scale often yield concave cost functions other than fixed charges, so in this paper we consider a problem with general concave costs at the supply points, as well as convex costs at the demand points. The objective function can then be represented as the difference of two convex functions, and is therefore called a d.c. function. We propose a solution method which reduces the problem to a d.c. optimization problem in a much smaller space, then solves the latter by a branch and bound procedure in which bounding is based on solving subproblems of the form of [STP]. We prove convergence of the method and report computational tests that indicate that quite large problems can be solved efficiently. Problems up to the size of 100 supply points and 500 demand points are solved. Received October 11, 1993 / Revised version received July 31, 1995 Published online November 24, 1998     

Managing manufacturing risks by using capacity options

In this study, we investigate the strategy of increasing production capacity temporarily through contingent contractual agreements with short-cycle manufacturers to manage the risks associated with demand volatility. We view all these agreements as capacity options. More specifically, we consider a manufacturing company that produces a replenishment product that is sold at a retailer. The demand for the product switches randomly between a high level and a low level. The production system has enough capacity to meet the demand in the long run. However, when the demand is high, it does not have enough capacity to meet the instantaneous demand and thus has to produce to stock in advance. Alternatively, a contractual agreement with a short-cycle manufacturer can be made. This option gives the right to receive additional production capacity when needed. There is a fixed cost to purchase this option for a period of time and, if the option is exercised, there is an additional per unit exercise price which corresponds to the cost of the goods produced at the short-cycle manufacturer. We formulate the problem as a stochastic optimal control problem and analyse it analytically. By comparing the costs between two cases where the contract with the short-cycle manufacturer is used or not, the value of this option is evaluated. Furthermore, the effect of demand variability on this contract is investigated.     

Plant location and procurement planning in knockdown production systems

We consider an integrated problem of plant location and capacity planning for components procurement in knockdown production systems. The problem is that of determining the schedule of opening components manufacturing plants, plans for acquisition of capacities in opened components manufacturing plants, and plans for components procurement in final assembly plants with the objective of minimizing the sum of fixed costs for opening plants, acquisition and operation costs of facilities, and delivery and subcontracting costs of components. The problem is formulated as a mixed integer linear program and solved by a two-stage solution procedure. In the solution procedure, the problem is decomposed into two tractable subproblems and these subproblems are solved sequentially. In the first stage, a dynamic plant location problem is solved using a cut and branch algorithm based on Gomory cuts, while a multiperiod capacity planning problem is solved in the second stage by a heuristic algorithm that uses a cut and branch algorithm and a variable reduction scheme. The solution procedure is tested on problems of a practical size and results show that the procedure gives reasonably good solutions.     

Dynamic Programming and Inventory Control

An expository account is given of the Dynamic Programming approach to inventory analysis in terms of the problem of the optimal storage policy for repair parts. The demand distribution is assumed to be Poisson or some modification thereof; the delivery time is assumed to be fixed or Gamma distributed while preserving the sequence of the orders. No demand is lost. It is shown that the demand distribution for the delivery period is negative binomial. Formulae are derived for the re-ordering point and the order quantity and these are solved for the geometric demand distribution. An example is calculated which is based on the stocking of repair parts by a can manufacturer in Chicago.     

Supply chain model for a deteriorating product with time-varying demand and production rate

The paper develops a two-echelon supply chain model with a single-buyer and a single-vendor. The buyer sells a seasonal product over a short selling period and its inventory is subject to deterioration at a constant rate over time. The vendor's production rate is dependent on the buyer's demand rate, which is a linear function of time. Also, the vendor's production process is not perfectly reliable; it may shift from an in-control state to an out-of-control state at any time during a production run and produce some defective (non-conforming) items. Assuming that the vendor follows a lot-for-lot policy for replenishment made to the buyer, the average total cost of the supply chain is derived and an algorithm for finding the optimal solution is developed. The numerical study shows that the supply chain coordination policy is more beneficial than those policies obtained separately from the buyer's and the vendor's perspectives.     

Capacitated dynamic lot sizing problems in closed-loop supply chain

In this paper, we address the capacitated dynamic lot sizing problem arising in closed-loop supply chain where returned products are collected from customers. These returned products can either be disposed or be remanufactured to be sold as new ones again; hence the market demands can be satisfied by either newly produced products or remanufactured ones. The capacities of production, disposal and remanufacturing are limited, and backlogging is not allowed. A general model of this problem is formulated, and several useful properties of the problem are characterized when cost functions are concave. Moreover, this problem is analyzed and solved to optimality using dynamic programming algorithms under different scenarios. It is shown that the problem with only disposal or remanufacturing can be converted into a traditional capacitated lot sizing problem and be solved by a polynomial algorithm if the capacities are constant. A pseudo-polynomial algorithm is proposed for the problem with both capacitated disposal and remanufacturing. The problem with capacitated production and remanufacturing and the problem with uncapacitated production and capacitated remanufacturing are also analyzed and solved. Through numerical experiments we show that the proposed algorithms perform well when solving problems of practical sizes. From the experimental results also indicates that it is worthwhile to expand the remanufacturing capacity only when returned products exist in a relatively long planning horizon, and production capacities have little effect on the remanufacturing plan when the demand is mainly satisfied by the production.     

Integrated production and distribution scheduling with lifespan constraints

We consider an integrated production and distribution scheduling problem in a make-to-order business scenario. A product with a short lifespan (e.g., perishable or seasonal) is produced at a single production facility with a limited production rate. This means that the product expires in a constant time after its production is finished. Orders are received from a set of geographically dispersed customers, where a demand for the product and a time window for the delivery is associated with each customer for the planning period. A single vehicle with non-negligible traveling times between the locations is responsible for the deliveries. Due to the limited production and distribution resources, possibly not all customers may be supplied within their time windows or the lifespan. The problem consists in finding a selection of customers to be supplied such that the total satisfied demand is maximized. We extend the work by Armstrong et al. (Annals of Operations Research 159(1):395–414, 2008) on the problem for fixed delivery sequences by pointing out an error in their branch and bound algorithm and presenting a corrected variant. Furthermore, we introduce model extensions for handling delays of the production start as well as for variable production and distribution sequences. Efficient heuristic solution algorithms and computational results for randomly generated instances are presented.     

Multi-product economic lot scheduling problem with separate production lines for manufacturing and remanufacturing

We study the economic lot scheduling problem with two production sources, manufacturing and remanufacturing, for which operations are performed on separate, dedicated lines. We develop an exact algorithm for finding the optimal common-cycle-time policy. The algorithm combines a search for the optimal cycle time with a mixed integer programming (MIP) formulation of the problem given a fixed cycle time. Using case study data from an auto part producer, we perform a sensitivity study on the effects of key problem parameters such as demand rates and return fractions. Furthermore, by comparing to results in Tang and Teunter [Tang, O., Teunter, R.H., 2006. Economic lot scheduling problem with returns. Production and Operations Management] for the situation where all operations are performed on the same line, we analyze the cost benefits of using dedicated lines.