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.     

Operations planning with VERT

The Venture Evaluation and Review Technique (VERT) is a computerized, mathematically oriented network-based simulation technique designed to analyze risk existing in three parameters of most concern to managers in new projects or ventures--time, cost, and performance. As such, the VERT technique is more powerful than techniques such as GERT, which are basically time and cost oriented. VERT has been successfully utilized to assess the risks involved in new ventures and projects, in the estimation of future capital requirements, in control monitoring, and in the overall evaluation of ongoing projects, programs, and systems. It has been helpful to management in cases where there is a requirement to make decisions with incomplete or inadequate information about the alternatives. An example describing the application of VERT to an operational planning problem--the evaluation of electric power generating methods--is illustrated.     

Decision architectures for production planning in multi-stage multi-product manufacturing systems

Recent trends in automated manufacturing call for hierarchical decision architectures for production planning, suitable for integration with part flow controls. Different design approaches are currently adopted for implementing production planning architectures, depending either on the objective of defining a centralized production plan for the whole manufacturing system (as in the case of MRP and OPT), or on the desire of coordinating local plans for the component work cells (as for JIT). The paper analyzes such approaches by use of a unifying mathematical formulation of the production plan optimization problem, to recognize the main features of the existing planning approaches, and compare their usefulness in different manufacturing processes.     

Operations research and environmental planning

This paper aims at specifying the contribution of OR to environmental planning. To this purpose a framework for classifying relevant literature is proposed, according to which the literature has been reviewed and discussed with respect to both thematic and methodological aspects. It is shown that during the last few years, OR has extended its scope to include notably environmental applications. Several OR methods and tools are employed either to identify the type and intensity of environmental problems, or to assist environmental planners to effectively cope with these problems. It is illustrated that OR's relationship with environmental planning is dynamic and interactive in the sense that from the complexity of the issues examined stems the need to develop and/or adapt specific methodological tools and thus contributes to the development of both scientific fields.     

Analysis of a synchronization station for the performance evaluation of a kanban system with a general arrival process of demands

The kanban system has attracted wide interest in recent years, and a lot of work has been devoted to the modeling of such systems, as well as to methods to evaluate their performance. Especially, in a previous work, we proposed an analytical method to evaluate the performance of a kanban system producing a single part type; we assumed that demands for the finished product arrive in single unit, according to a Poisson process. The present paper proposes an extension of this method to the case where the demands arrive according to a general process. We are more particularly interested in the analysis in isolation of the synchronization station between the finished parts of the system and the external demands. This leads to the resolution of a quasi-birth-and-death process with an infinite number of states and with a very regular structure. We thus propose a matrix-geometric solution of this problem.     

Production capacity planning and control in multi-stage manufacturing

This paper develops a mathematical model for determining the optimum lot-sizes for a set of products and the capacity required to produce them in a multi-stage production system. The purpose of the modelling is to support capacity planning at the production function level and the basic criterion considered for the optimisation is the minimisation of the total system cost (TSC) per unit time. The TSC consists of (i) set-up cost, (ii) cost due to the quenching of batches, and (iii) hiring cost of the machines. An example is presented to explain the model.     

A Benders decomposition algorithm for a multi-area,multi-stage integrated resource planning in power systems

The aim of this paper is to propose an integrated model for resource planning in power systems by taking into account both supply and demand sides options simultaneously. At supply-side, investment in generation capacity and transmission lines is considered. Demand side management (DSM) technologies are also incorporated to correct the shape of the load duration curve in terms of peak clipping and load shifting programmes. A mixed integer non-linear programming model is developed to find the optimal location and timing of electricity generation/transmission as well as DSM options. To solve the resulting complex model, nonlinearity caused by transmission loss terms are first eliminated using the piecewise linearization technique. Then, a Benders decomposition (BD) algorithm is developed to solve the linearized model. The performance of the proposed BD algorithm is validated via applying it to the 6-bus Garver test system and a modified 21-bus IEEE reliability test system.     

An approximation for kanban controlled assembly systems

An approximation is proposed to evaluate the steady-state performance of kanban controlled two-stage assembly systems. The development of the approximation is as follows. The considered continuous-time Markov chain is aggregated keeping the model exact, and this aggregate model is approximated replacing some state-dependent transition rates with constant rates. The approximate aggregate model is, then, decomposed into submodels and a product-form steady-state distribution is obtained for each submodel. Finally, the submodels are combined in such a way that the size of the problem becomes independent of the number of kanbans. This leads to the computational advantage in solving the combined model using numerical matrix-geometric solution algorithms. Numerical comparisons of the combined model with simulation, exact model, approximate aggregate model and an approximation in the literature show that the proposed approximation performs well in terms of accuracy and computational burden.     

A single-stage supply chain system controlled by kanban under just-in-time philosophy

The production system using kanban was pioneered by Toyota Motor Company in Japan and subsequently it was adopted by numerous other Japanese and US companies for applying the just-in-time manufacturing principles. This research studies a single-stage supply chain system that is controlled by kanban mechanism. The supply chain system is modelled as a mixed-integer nonlinear programming (MINLP) problem. It is solved optimally by branch-and-bound method to determine the number of kanbans, batch size, number of batches, and the total quantity over one period. Meanwhile, the kanban operation between two adjacent plants is worked out considering the factors of loading and unloading time, and transport time. Coupled with plant-wide efforts for cost control and management commitment to enhance other measures of performance, a logistics system for controlling the production as well as the supply chain system is developed, which results in minimizing the total cost of the supply chain system. The results show that the improvements in reduction of inventory, wasted labour, and customer service in a supply chain are accomplished through the kanban mechanism.     

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.     

Electron optics in multi-stage lens system I

Zusammenfassung Die Fokussierungseigenschaften eines aus schwachen Linsen bestehenden Systems unterhalb eines Beschleunigungsrohres sind studiert worden. Das System wird als dicke Linse in der Näherung der paraxialen Bahn behandelt. Die Kardinalelemente des Linsensystems können als Ganzes für den Fall, dass das Feld periodisch ist, in einfacher Form dargestellt werden.Im besondern sind die Ausdrücke für die Kardinalelemente eines Systems, das aus den Zweirohr-Immersionslinsen mit bestimmter Länge der Lücke zwischen den Rohren besteht, wiedergegeben. Die beigefügten Figuren erlauben, diese Elemente bequem zu berechnen.     

Operations policy for a supply chain system with fixed-interval delivery and linear demand

This research addresses a production-supply problem for a supply-chain system with fixed-interval delivery. A strategy that determines the optimal batch sizes, cycle times, numbers of orders of raw materials, and production start times is prescribed to minimize the total costs for a given finite planning horizon. The external demands are time-dependent following a life-cycle pattern and the shipment quantities follow the demand pattern. The shipment quantities to buyers follow various phases of the demand pattern in the planning horizon where demand is represented by piecewise linear model. The problem is formulated as an integer, non-linear programming problem. The model also incorporates the constraint of inventory capacity. The problem is represented using the network model where an optimal characteristic has been analysed. To obtain an optimal solution with N shipments in a planning horizon, an algorithm is proposed that runs with the complexity of Θ(N²) for problems with a single-phase demand and O(N³) for problems with multi-phase demand.     

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

Recently, Sarker et al. [Sarker, B.R., Jamal, A.M.M., Mondal, S., 2008. Optimal batch sizing in a multi-stage production system with rework consideration. European Journal of Operational Research 184(3) 915–929] presented an EPQ inventory model for a multi-stage manufacturing system with rework process; basically they proposed two operational inventory policies. In the paper, there are some mathematical expressions which are to be corrected. At first, this paper presents the mathematical expressions corrected and the appropriate solution to the numerical example. We also established the closed forms for the optimal total inventory cost, the conditions for which there is an optimal solution, and the mathematical expressions for determining the total additional cost for working with a non optimal solution for both policies that were not given by Sarker et al. (2008).     

Optimizing a multi-stage production/inventory system by DC programming based approaches

This paper deals with optimizing the cost of set up, transportation and inventory of a multi-stage production system in presence of bottleneck. The considered optimization model is a mixed integer nonlinear program. We propose two methods based on DC (Difference of Convex) programming and DCA (DC Algorithm)—an innovative approach in nonconvex programming framework. The mixed integer nonlinear problem is first reformulated as a DC program and then DCA is developed to solve the resulting problem. In order to globally solve the problem, we combine DCA with a Branch and Bound algorithm (BB-DCA). A convex minorant of the objective function is introduced. DCA is used to compute upper bounds while lower bounds are calculated from a convex relaxation problem. The numerical results compared with those of COUENNE (http://www.coin-or.org/download/binary/Couenne/), a solver for mixed integer nonconvex programming, show the rapidity and the ?-globality of DCA in almost cases, as well as the efficiency of the combined DCA-Branch and Bound algorithm. We also propose a simple heuristic algorithm which is proved by experimental results to be better than an existing heuristic in the literature for this problem.     

Operations risk management by optimally planning the qualified workforce capacity

Operational risks are defined as risks of human origin. Unlike financial risks that can be handled in a financial manner (e.g. insurances, savings, derivatives), the treatment of operational risks calls for a “managerial approach”. Consequently, we propose a new way of dealing with operational risk, which relies on the well known aggregate planning model. To illustrate this idea, we have adapted this model to the case of a back office of a bank specializing in the trading of derivative products. Our contribution corresponds to several improvements applied to stochastic programming techniques. First, the model is transformed into a multistage stochastic program in order to take into account the randomness associated with the volume of transaction demand and with the capacity of work provided by qualified and non-qualified employees over the planning horizon. Second, as advocated by Basel II, we calculate the probability distribution based on a Bayesian Network to circumvent the difficulty of obtaining data which characterizes uncertainty in operations. Third, we go a step further by relaxing the traditional assumption in stochastic programming that imposes a strict independence between the decision variables and the random elements. Comparative results show that in general these improved stochastic programming models tend to allocate more human expertise in order to hedge operational risks. Finally, we employ the dual solutions of the stochastic programs to detect periods and nodes that are at risk in terms of the expertise availability.     

Operations planning test bed under rolling horizons,multiproduct, multiechelon,multiprocess for capacitated production planning modelling with strokes

One of the problems when conducting research in mathematical programming models for operations planning is having an adequate database of experiments that can be used to verify advances and developments with enough factors to understand different consequences. This paper presents a test bed generator and instances database for a rolling horizons analysis for multiechelon planning, multiproduct with alternatives processes, multistroke, multicapacity with different stochastic demand patterns to be used with a stroke-like bill of materials considering production costs, setup, storage and delays for operations management. From the analysis of the operations planning obtained from this test bed, it is concluded that a product structure with an alternative process obtains the lowest total cost and the highest service level. In addition, decreasing seasonal demand could present a lower total cost than constant demand, but would generate a worse service level. This test bed will allow researchers further investigation so as to verify improvements in forecast methods, rolling horizons parameters, employed software, etc.

     

Electron optics in multi-stage lens system (II)

Zusammenfassung Die Ausdrücke für die relativistischen Kardinalelemente einer elektrischen Zweirohr-Linse werden vermittels eines Störungsverfahrens hergeleitet und auf den Fall schwacher Linsen angewendet. Es wird angenommen, dass das Potential auf der Achse den vonSpangenberg gegebenen Wert besitzt.Hierauf werden die relativistischen Kardinalelemente eines aus solchen Linsen bestehenden Systems in ähnlichen Formen wie im nichtrelativistischen Fall ausgedrückt, unter Heranziehung der Ausdrücke für eine Linse. Die Ergebnisse der Rechnung werden an einem typischen Fall erläutert.