Characterization of facility assignment costs for a location-inventory model under truckload distribution

We consider a two-stage distribution system, where the first stage consists of potential distribution centres (DCs) and the second stage consists of geographically dispersed existing retailers. Our goal is to determine the set of open DCs and assignment of open DCs to retailers simultaneously with inventory decisions of retailers. In addition to the DC-specific fixed facility location costs, we explicitly model the inventory replenishment and holding costs at the retailers and truckload transportation costs between the DCs and the retailers. The transportation costs are subject to truck/cargo capacity, leading to an integrated location-inventory problem with explicit cargo costs. We develop a mixed-integer nonlinear model and analyse its structural properties leading to exact expressions for the so-called implied facility assignment costs and imputed per-unit per-mile transportation costs. These expressions analytically demonstrate the interplay between strategic location and tactical inventory/transportation decisions in terms of resulting operational costs. Although both the theory and practice of integrated logistics have recognized the fact that strategic and tactical decisions are interrelated, to the best of our knowledge, our paper is the first to offer closed-form results demonstrating the relationship explicitly. We propose an efficient solution approach utilizing the implied facility assignment costs and we demonstrate that significant savings are realizable when the inventory decisions and cargo costs are modelled explicitly for facility location purposes.     

Incorporating inventory and routing costs in strategic location models

We consider a supply chain design problem where the decision maker needs to decide the number and locations of the distribution centers (DCs). Customers face random demand, and each DC maintains a certain amount of safety stock in order to achieve a certain service level for the customers it serves. The objective is to minimize the total cost that includes location costs and inventory costs at the DCs, and distribution costs in the supply chain. We show that this problem can be formulated as a nonlinear integer programming model, for which we propose a Lagrangian relaxation based solution algorithm. By exploring the structure of the problem, we find a low-order polynomial algorithm for the nonlinear integer programming problem that must be solved in solving the Lagrangian relaxation sub-problems. We present computational results for several instances of the problem with sizes ranging from 40 to 320 customers. Our results show the benefits of having an integrated supply chain design framework that includes location, inventory, and routing decisions in the same optimization model.     

一个基于运输规模经济的库存选址模型

介绍了一种新的配送中心(DC)选址模型,在该模型中考虑了一般库存和安全库存成本,同时把从供应商到DC的运输成本也结合进去综合考虑,运输成本是由固定成本加可变成本两部分组成,反映了运输规模经济.     

A dynamic joint replenishment policy with auto-correlated demand

We consider a joint replenishment problem where the product demands are auto-correlated but independent of each other. A dynamic periodic review policy is developed, and its parameters are determined by a heuristic which aims at minimizing the total inventory cost, which includes the holding cost, the set up cost and the shortage cost. The heuristic updates the review interval and the target inventory level of every product at each review point based on the current inventory status and the past demand data. A simulation model is developed to compare the performance of this proposed policy with an existing periodic review policy. The results show that the proposed policy has consistently achieved significant saving in all the different experimental scenarios.     

Warehouse location with production,inventory, and distribution decisions: a case study in the lube oil industry

In this paper, a supply chain management problem from a real case study is modeled and solved. A company in Pakistan wanted to outsource part of its warehousing activity to a third party logistics (3PL) provider. Consequently, the company had to decide on where to rent space in the 3PL warehouses. Knowing that such a strategic decision is affected by tactical and operational decisions, the problem is presented as a facility location problem integrating production, inventory, and distribution decisions. The problem is formulated as a mixed integer linear programming model which minimizes the total cost composed of location, distribution, production, and inventory costs. Several constraints specific to the situation and policy of the company were considered. A thorough analysis was done on the results obtained with respect to formulation efficiency, sensitivity analysis, and distribution of costs. In addition to the solution of the company problem, a set of 1215 problem instances was generated by varying five types of relevant costs in a full factorial manner. The solution of the generated problems always suggests to open in the same two locations and the integrality gaps averaged 0.062 % with a maximum of 0.102 %. On average, the major components of the total cost are production cost (96.6 %), transportation costs (2.7 %), and inventory holding costs (0.38 %). The total warehouse opening cost accounted for less than 0.05 % of the total costs.     

Designing two-echelon supply networks

A modern distribution network design model needs to deal with the trade-offs between a variety of factors, including (1) location and associated (fixed) operating cost of distribution centers (DCs), (2) total transportation costs, and (3) storage holding and replenishment costs at DCs and retail outlets. In addition, network design models should account for factors such as (4) stockouts, by setting appropriate levels of safety stocks, or (5) capacity concerns, which may affect operating costs in the form of congestion costs. The difficulty of making such trade-offs is compounded by the fact that even finding the optimal two-echelon inventory policy in a fixed and uncapacitated distribution network is already a hard problem. In this paper, we propose a generic modeling framework to address these issues that continues and extends a recent stream of research aimed at integrating insights from modern inventory theory into the supply chain network design domain. Our approach is flexible and general enough to incorporate a variety of important side constraints into the problem.     

Monotonicity properties of a class of stochastic inventory systems

We consider inventory systems which are governed by an (r,q) or (r,nq) policy. We derive general conditions for monotonicity of the three optimal policy parameters, i.e., the optimal reorder level, order quantity and order-up-to level, as well as the optimal cost value, as a function of the various model primitives, be it cost parameters or complete cost rate functions or characteristics of the demand and leadtime processes. These results are obtained as corollaries from a few general theorems, with separate treatment given to the case where the policy parameters are continuous variables and that where they need to be restricted to integer values. The results are applied both to standard inventory models and to those with general shelf age and delay dependent inventory costs.     

A stochastic model for joint spare parts inventory and planned maintenance optimisation

Spare parts demands are usually generated by the need of maintenance either preventively or at failures. These demands are difficult to predict based on historical data of past spare parts usages, and therefore, the optimal inventory control policy may be also difficult to obtain. However, it is well known that maintenance costs are related to the availability of spare parts and the penalty cost of unavailable spare parts consists of usually the cost of, for example, extended downtime for waiting the spare parts and the emergency expedition cost for acquiring the spare parts. On the other hand, proper planned maintenance intervention can reduce the number of failures and associated costs but its performance also depends on the availability of spare parts. This paper presents the joint optimisation for both the inventory control of the spare parts and the Preventive Maintenance (PM) inspection interval. The decision variables are the order interval, PM interval and order quantity. Because of the random nature of plant failures, stochastic cost models for spare parts inventory and maintenance are derived and an enumeration algorithm with stochastic dynamic programming is employed for finding the joint optimal solutions over a finite time horizon. The delay-time concept developed for inspection modelling is used to construct the probabilities of the number of failures and the number of the defective items identified at a PM epoch, which has not been used in this type of problems before. The inventory model follows a periodic review policy but with the demand governed by the need for spare parts due to maintenance. We demonstrate the developed model using a numerical example.     

Modelling and computing (Rn, Sn) policies for inventory systems with non-stationary stochastic demand

This paper addresses the single-item, non-stationary stochastic demand inventory control problem under the non-stationary (R, S) policy. In non-stationary (R, S) policies two sets of control parameters—the review intervals, which are not necessarily equal, and the order-up-to-levels for replenishment periods—are fixed at the beginning of the planning horizon to minimize the expected total cost. It is assumed that the total cost is comprised of fixed ordering costs and proportional direct item, inventory holding and shortage costs. With the common assumption that the actual demand per period is a normally distributed random variable about some forecast value, a certainty equivalent mixed integer linear programming model is developed for computing policy parameters. The model is obtained by means of a piecewise linear approximation to the non-linear terms in the cost function. Numerical examples are provided.     

Sensitivity of continuous review stochastic (s,S) inventory systems to ordering delays

This paper examines continuous review stochastic (s, S) inventory systems with ordering delays. That is, systems where the difference between the time the order should be placed and the time the order is actually placed is non-trivial. The traditional inventory ordering, holding and penalty costs are included and the average cost for an (s, S) policy is developed and examined. Computational results are presented for two cases. In the first case, the manager is aware of the delay and uses the policy that minimizes all costs. We present the increase in cost due to having a delay. In the second case the manager is unaware of the delay and uses the (integer) square root formula. We present the increase in cost due to using the square root formula when it is inappropriate and in fact our computational results indicate that there may very well be a large increase in cost due to being unaware of the ordering delay.     

An Inventory-Location Model: Formulation, Solution Algorithm and Computational Results

We introduce a distribution center (DC) location model that incorporates working inventory and safety stock inventory costs at the distribution centers. In addition, the model incorporates transport costs from the suppliers to the DCs that explicitly reflect economies of scale through the use of a fixed cost term. The model is formulated as a non-linear integer-programming problem. Model properties are outlined. A Lagrangian relaxation solution algorithm is proposed. By exploiting the structure of the problem we can find a low-order polynomial algorithm for the non-linear integer programming problem that must be solved in solving the Lagrangian relaxation subproblems. A number of heuristics are outlined for finding good feasible solutions. In addition, we describe two variable forcing rules that prove to be very effective at forcing candidate sites into and out of the solution. The algorithms are tested on problems with 88 and 150 retailers. Computation times are consistently below one minute and compare favorably with those of an earlier proposed set partitioning approach for this model (Shen, 2000; Shen, Coullard and Daskin, 2000). Finally, we discuss the sensitivity of the results to changes in key parameters including the fixed cost of placing orders. Significant reductions in these costs might be expected from e-commerce technologies. The model suggests that as these costs decrease it is optimal to locate additional facilities.     

Coordinated control of distribution supply chains in the presence of fuzzy customer demand

This paper considers a single product inventory control in a Distribution Supply Chain (DSC). The DSC operates in the presence of uncertainty in customer demands. The demands are described by imprecise linguistic expressions that are modelled by discrete fuzzy sets. Inventories at each facility within the DSC are replenished by applying periodic review policies with optimal order up-to-quantities. Fuzzy customer demands imply fuzziness in inventory positions at the end of review intervals and in incurred relevant costs per unit time interval. The determination of the minimum of defuzzified total cost of the DSC is a complex problem which is solved by applying decomposition; the original problem is decomposed into a number of simpler independent optimisation subproblems, where each retailer and the warehouse determine their optimum periodic reviews and order up-to-quantities. An iterative coordination mechanism is proposed for changing the review periods and order up-to-quantities for each retailer and the warehouse in such a way that all parties within the DSC are satisfied with respect to total incurred costs per unit time interval. Coordination is performed by introducing fuzzy constraints on review periods and fuzzy tolerances on retailers and warehouse costs in local optimisation subproblems.     

Inventory control with indivisible units of stock transfer

We consider an infinite horizon, single item inventory model with backorders and a fixed lead time. Demand is stationary stochastic and review is periodic. Inventory may only be replenished in multiples of a fixed package size q but demands may be of any size. Ordering costs are linear and combined holding and shortage costs can be expressed as a convex function of the inventory position. The control policy is defined as (s, S, q), where an order is placed if the inventory position falls to or below s and the order size is the largest multiple of q which results in the inventory position not exceeding S. The parameters s and S are restricted to be multiples of q. The objective is to find the control policy that minimizes the long run average cost per unit time. The optimal solution procedure requires renewal theory and a structured search. Fortunately, a heuristic based on the ‘quantized ordering’ approach of Zheng and Chen provides solutions that are near optimal over a broad range of parameter values.     

An effective heuristic for the review period in an inventory model with staggered deliveries and normal demands

Consider a single-item, periodic review, infinite-horizon, undiscounted, inventory model with stochastic demands, proportional holding and shortage costs, and full backlogging. Orders can arrive in every period, and the cost of receiving them is negligible (as in JIT). Every T periods, one audits the stocks and chooses a delivery schedule for each of the next T periods, thus incurring a fixed audit cost and—when one schedules actual deliveries—a fixed order cost. The problem is to find a review period T and an ordering policy minimizing the average cost. An earlier article developed an algorithm for computing an optimal T, and undertook a numerical study to evaluate various approximations. Assuming normal demands, we characterize the asymptotic behavior (for large μ/σ) of the optimal T and establish the asymptotic optimality of a heuristic, calculable on a spreadsheet. A numerical study indicates that patterns established here for large μ/σ hold for σ/μ above 2.     

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.     

模糊随机需求的连续盘点存储策略研究

考虑到需求的模糊随机性,建立模糊随机需求情况下连续盘点存储策略的模糊随机成本模型。利用模糊随机变量的期望值理论,推导出了其成本期望值模型的解析表达式,进而给出了最优再订货点所属区间的判别条件以及最优再订货点和经济订货量的计算式;基于此,设计了一模糊随机需求的连续盘点最优存储策略算法。最后结合数值算例,分析了模糊随机需求概率分布及缺货成本对最优存储策略的影响。     

Profit maximization in an inventory system with time-varying demand,partial backordering and discrete inventory cycle

In this paper, an inventory problem where the inventory cycle must be an integer multiple of a known basic period is considered. Furthermore, the demand rate in each basic period is a power time-dependent function. Shortages are allowed but, taking necessities or interests of the customers into account, only a fixed proportion of the demand during the stock-out period is satisfied with the arrival of the next replenishment. The costs related to the management of the inventory system are the ordering cost, the purchasing cost, the holding cost, the backordering cost and the lost sale cost. The problem is to determine the best inventory policy that maximizes the profit per unit time, which is the difference between the income obtained from the sales of the product and the sum of the previous costs. The modeling of the inventory problem leads to an integer nonlinear mathematical programming problem. To solve this problem, a new and efficient algorithm to calculate the optimal inventory cycle and the economic order quantity is proposed. Numerical examples are presented to illustrate how the algorithm works to determine the best inventory policies. A sensitivity analysis of the optimal policy with respect to some parameters of the inventory system is developed. Finally, conclusions and suggestions for future research lines are given.

     

An inventory control system for products with optional components under service level and budget constraints

Modularization and customization have made enterprises face the multi-item inventory problems and the interactions among those items. A powerful, affordable information technology system can make the continuous review inventory policy more convenient, efficient, and effective. In this study, a (Q, r) model is developed to find the optimal lot size and reorder point for a multi-item inventory with interactions between necessary and optional components. In order to accurately approximate costs, the service cost is introduced and defined in proportion to the service level. In addition, the service cost and purchasing cost are taken simultaneously, and are treated as a budget constraint for executives to consider because the firm’s strategy could influence the choice of service level. The proposed model is formulated as a nonlinear optimization problem, as the service level is nonlinear. Thus, some known procedures are revised to solve this problem and the results are compared with other models. The results show that the revised procedure performs better than the N–R procedure, leading to important insights about inventory control policy.     

Location of a distribution center for a perishable product

A model that combines an inventory and location decision is presented, analyzed and solved. In particular, we consider a single distribution center location that serves a finite number of sales outlets for a perishable product. The total cost to be minimized, consists of the transportation costs from the distribution center to the sales outlets as well as the inventory related costs at the sales outlets. The location of the distribution center affects the inventory policy. Very efficient solution approaches for the location problem in a planar environment are developed. Computational experiments demonstrate the efficiency of the proposed solution approaches.     

Inventory control in multi-channel retail

In recent years multi-channel retail systems have received increasing interest. Partly due to growing online business that serves as a second sales channel for many firms, offering channel specific prices has become a common form of revenue management. We analyze conditions for known inventory control policies to be optimal in presence of two different sales channels. We propose a single item lost sales model with a lead time of zero, periodic review and nonlinear non-stationary cost components without rationing to realistically represent a typical web-based retail scenario. We analyze three variants of the model with different arrival processes: demand not following any particular distribution, Poisson distributed demand and a batch arrival process where demand follows a Pòlya frequency type distribution. We show that without further assumptions on the arrival process, relatively strict conditions must be imposed on the penalty cost in order to achieve optimality of the base stock policy. We also show that for a Poisson arrival process with fixed ordering costs the model with two sales channels can be transformed into the well known model with a single channel where mild conditions yield optimality of an (s, S) policy. Conditions for optimality of the base stock and (s, S) policy for the batch arrival process with and without fixed ordering costs, respectively, are presented together with a proof that the batch arrival process provides valid upper and lower bounds for the optimal value function.