Managing stochastic inventory systems with free shipping option

In many industries, customers are offered free shipping whenever an order placed exceeds a minimum quantity specified by suppliers. This allows the suppliers to achieve economies of scale in terms of production and distribution by encouraging customers to place large orders. In this paper, we consider the optimal policy of a retailer who operates a single-product inventory system under periodic review. The ordering cost of the retailer is a linear function of the ordering quantity, and the shipping cost is a fixed constant K whenever the order size is less than a given quantity – the free shipping quantity (FSQ), and it is zero whenever the order size is at least as much as the FSQ. Demands in different time periods are i.i.d. random variables. We provide the optimal inventory control policy and characterize its structural properties for the single-period model. For multi-period inventory systems, we propose and analyze a heuristic policy that has a simple structure, the (s, t, S) policy. Optimal parameters of the proposed heuristic policy are then computed. Through an extensive numerical study, we demonstrate that the heuristic policy is sufficiently accurate and close to optimal.     

Joint pricing and inventory control with a Markovian demand model

We consider the joint pricing and inventory control problem for a single product over a finite horizon and with periodic review. The demand distribution in each period is determined by an exogenous Markov chain. Pricing and ordering decisions are made at the beginning of each period and all shortages are backlogged. The surplus costs as well as fixed and variable costs are state dependent. We show the existence of an optimal (s, S, p)-type feedback policy for the additive demand model. We extend the model to the case of emergency orders. We compute the optimal policy for a class of Markovian demand and illustrate the benefits of dynamic pricing over fixed pricing through numerical examples. The results indicate that it is more beneficial to implement dynamic pricing in a Markovian demand environment with a high fixed ordering cost or with high demand variability.     

A multi-period ordering and clearance pricing model considering the competition between new and out-of-season products

The joint management of pricing and inventory for perishable products has become an important problem for retailers. This paper investigates a multi-period ordering and clearance pricing model under consideration of the competition between new and out-of-season products. In each period, the ordering quantity of the new product and the clearance price of the out-of-season product are determined as decision variables before the demand is realized, and the unsold new product becomes the out-of-season one of the next period. We establish a finite-horizon Markov decision process model to formulate this problem and analyze its properties. A traditional dynamic program (DP) approach with two-dimensional search is provided. In addition, a myopic policy is derived in which only the profit of the current period is considered. Finally, we apply genetic algorithm (GA) to this problem and design a GA-based heuristic approach, showing by comparison among different algorithms that the GA-based heuristic approach is more performance sound than the myopic policy and much less time consuming than the DP approach.     

Multi-item two-echelon spare parts inventory control problem with batch ordering in the central warehouse under compound Poisson demand

We consider a multi-item two-echelon spare part inventory system in which the central warehouse operates under an (nQ,?R) policy and the local warehouses implement order-up-to S policy, each facing a compound Poisson demand. The objective is to find the policy parameters minimizing expected system-wide inventory holding and fixed ordering costs subject to an aggregate mean response time constraint at each warehouse. In this paper, we propose four alternative approximations for the steady state performance of the system; and extend a heuristic and a lower bound proposed under Poisson demand assumption to the compound Poisson setting. In a computational study, we show that the performances of the approximations, the heuristic, and the lower bound are quite satisfactory; and the relative cost saving of setting an aggregate service level rather than individually for each part is quite high.     

Failure replacement and preventive maintenance spare parts ordering policy

This paper addresses inventory policy for spare parts, when demand for the spare parts arises due to regularly scheduled preventive maintenance, as well as random failure of units in service. A stochastic dynamic programming model is used to characterize an ordering policy which addresses both sources of demand in a unified manner. The optimal policy has the form (s(k),S(k)), where k is the number of periods until the next scheduled preventive maintenance operation. The nature of the (s(k),S(k)) policy is characterized through numeric evaluation. The efficiency of the optimal policy is evaluated, relative to a simpler policy which addresses the failure replacement and preventive maintenance demands with separate ordering policies.     

The two-group heuristic to solve the multi-product,economic lot sizing and scheduling problem in flow shops

This paper presents a new and efficient heuristic to solve the multi-product, economic lot sizing and scheduling problem in flow shops. The problem addressed is that of making sequencing, lot sizing and scheduling decisions for a number of products so as to minimize the sum of setup costs, work-in-process inventory holding costs and final-products inventory holding costs while a given demand is fulfilled without backlogging. The proposed heuristic, called the two-group method (TG), assumes that the cycle time of each product is an integer multiple of a basic period and restricts these multiples to take either the value 1 or K where K is a positive integer. The products to be produced once each K basic period are then partitioned into K sub-groups and each sub-group is assigned to one and only one of the K basic periods of the global cycle. This method first determines a value for K and a feasible partition. Then, a production sequence is determined for each sub-group of products and a non-linear program is solved to determine lot sizes and a feasible schedule. We also show how to adapt our method to the case of batch streaming (transportation of sub-batches from one machine to the next). To evaluate its performance, the TG method was compared to both the common cycle method and a reinforced version of El-Najdawi’s job-splitting heuristic. Numerical results show that the TG method outperforms both of these methods.     

Joint-optimization of inventory policies on a multi-product multi-echelon pharmaceutical system with batching and ordering constraints

This paper presents a methodology to find near-optimal joint inventory control policies for the real case of a one-warehouse, n-retailer distribution system of infusion solutions at a University Medical Center in France. We consider stochastic demand, batching and order-up-to level policies as well as aspects particular to the healthcare setting such as emergency deliveries, required service level rates and a new constraint on the ordering policy that fits best the hospital’s interests instead of abstract ordering costs. The system is modeled as a Markov chain with an objective to minimize the stock-on-hand value for the overall system. We provide the analytical structure of the model to show that the optimal reorder point of the policy at both echelons is easily derived from a simple probability calculation. We also show that the optimal policy at the care units is to set the order-up-to level one unit higher than the reorder point. We further demonstrate that optimizing the care units in isolation is optimal for the joint multi-echelon, n-retailer problem. A heuristic algorithm is presented to find the near-optimal order-up-to level of the policy of each product at the central pharmacy; all other policy parameters are guaranteed optimal via the structure provided by the model. Comparison of our methodology versus that currently in place at the hospital showed a reduction of approximately 45% in the stock-on-hand value while still respecting the service level requirements.     

Augmenting the lot sizing order quantity when demand is probabilistic

In this paper we consider a single item, discrete time, lot sizing situation where demand is random and its parameters (e.g., mean and standard deviation) can change with time. For the appealing criterion of minimizing expected total relevant costs per unit time until the moment of the next replenishment we develop two heuristic ways of selecting an appropriate augmentation quantity beyond the expected total demand through to the planned (deterministic) time of the next replenishment. The results of a set of numerical experiments show that augmentation is important, particularly when orders occur frequently (i.e., the fixed cost of a replenishment is low relative to the costs of carrying one period of demand in stock) and the coefficient of variability of demand is relatively low, but also under other specified circumstances. The heuristic procedures are also shown to perform very favourably against a hindsight, baseline (s, S) policy, especially for larger levels of non-stationarity.     

A note on inventory policies for products with residual-life-dependent demand

We study inventory ordering policies for products that attract demand at a decreasing rate as they approach the end of their usable lifetime, for example, perishable items nearing expiration. We consider the “product freshness’’, or equivalently, the time until expiration (“residual life”) as a factor influencing the customer demand. In a profit-maximizing framework, we build on the Economic Order Quantity (EOQ) replenishment model and formulate the inventory ordering problem using a deterministic demand function that is concave decreasing in the the age of the product. We provide analytical results on the optimal ordering policy, including an explicit characterization of the decisions in the linear-demand case, and we develop an easy-to-implement adaptive heuristic policy for the general case. Numerical examples show that the optimal policy generates significant profit gains compared to the traditional cost-based policies and the adaptive heuristic policy performs highly satisfactorily in the tested instances.     

On the value of customer information for an independent supplier in a continuous review inventory system

We consider the inventory control problem of an independent supplier in a continuous review system. The supplier faces demand from a single customer who in turn faces Poisson demand and follows a continuous review (R, Q) policy. If no information about the inventory levels at the customer is available, reviews and ordering are usually carried out by the supplier only at points in time when a customer demand occurs. It is common to apply an installation stock reorder point policy. However, as the demand faced by the supplier is not Markovian, this policy can be improved by allowing placement of orders at any point in time. We develop a time delay policy for the supplier, wherein the supplier waits until time t after occurrence of the customer demand to place his next order. If the next customer demand occurs before this time delay, then the supplier places an order immediately. We develop an algorithm to determine the optimal time delay policy. We then evaluate the value of information about the customer’s inventory level. Our numerical study shows that if the supplier were to use the optimal time delay policy instead of the installation stock policy then the value of the customer’s inventory information is not very significant.     

Inventory Problems with Partially Observed Demands and Lost Sales

This paper considers the case of partially observed demand in the context of a multi-period inventory problem with lost sales. Demand in a period is observed if it is less than the inventory level in that period and the leftover inventory is carried over to the next period. Otherwise, only the event that it is larger than or equal to the inventory level is observed. These observations are used to update the demand distributions over time. The state of the resulting dynamic program consists of the current inventory level and the current demand distribution, which is infinite dimensional. The state evolution equation for the demand distribution becomes linear with the use of unnormalized probabilities. We study two demand cases. First, the demands evolve according to a Markov chain. Second, the demand distribution has an unknown parameter which is updated in the Bayesian manner. In both cases, we prove the existence of an optimal feedback ordering policy. Permanent address of J. Adolfo Minjárez-Sosa: Departamento de Matemáticas, Universidad de Sonora, Hermosillo, Sonora, México. This project was partially supported by NSF Grant 0509278, ARPATP Grant 009741-0019-2006, and CONACYT (Mexico) Grant 46633-F.     

Capacity and Production Managment in a Single Product Manufacturing System

In planning and managing production systems, manufacturers have two main strategies for responding to uncertainty: they build inventory to hedge against periods in which the production capacity is not sufficient to satisfy demand, or they temporarily increase the production capacity by “purchasing” extra capacity. We consider the problem of minimizing the long-run average cost of holding inventory and/or purchasing extra capacity for a single facility producing a single part-type and assume that the driving uncertainty is demand fluctuation. We show that the optimal production policy is of a hedging point policy type where two hedging levels are associated with each discrete state of the system: a positive hedging level (inventory target) and a negative one (backlog level below which extra capacity should be purchased). We establish some ordering of the hedging levels, derive equations satisfied by the steady-state probability distribution of the inventory/backlog, and give a more detailed analysis of the optimal control policy in a two state (high and low demand rate) model.     

Dual sourcing using capacity reservation and spot market: Optimal procurement policy and heuristic parameter determination

This contribution focuses on the cost-effective management of the combined use of two procurement options: the short-term option is given by a spot market with random price, whereas the long-term alternative is characterized by a multi period capacity reservation contract with fixed purchase price and reservation level. A reservation cost, proportional with the reservation level, has to be paid for the option of receiving any amount per period up to the reservation level. A long-term decision has to be made regarding the reserved capacity level, and then it has to be decided – period by period – which quantities to procure from the two sources. Considering the multi-period problem with stochastic demand and spot price, the structure of the optimal combined purchasing policy is derived using stochastic dynamic programming. Exploiting these structural properties, an advanced heuristic is developed to determine the respective policy parameters. This heuristic is compared with two rolling-horizon approaches which use the one-period and two-period optimal solution. A comprehensive numerical study reveals that the approaches based on one-period and two-period solutions have considerable drawbacks, while the advanced heuristic performs very well compared to the optimal solution. Finally, by exploiting our numerical results we give some insights into the system’s behavior under problem parameter variations.     

Transshipment and rebalancing policies for library books

Library customers can soon order books online and specify a location to collect them from. Libraries exchange books between locations to meet these requests. Two types of exchanges take place: transshipments from library to library to fulfill the requests and rebalancing to redistribute books between libraries. This research determines optimal decisions for transshipments and rebalancing, so that logistic costs in the library system are minimized. In current practice, libraries typically send the book back to the original library after return. We consider a more general policy, in which we rebalance books in anticipation of demand. Moreover, we determine the optimal location from which to transship a book when it is unavailable at the location of demand. By means of stochastic dynamic programming, we derive the optimal policy for small instances. For larger instances we present two heuristics: the cluster and the expected shortage reduction (ESR) heuristic. The ESR heuristic proves to be near-optimal and significantly outperforms current practice.     

Time-dependent and independent control rules for coordinated production and pricing under demand uncertainty and finite planning horizons

We address the effect of uncertainty on a manufacturer’s dynamic production and pricing decisions over a finite planning horizon. The demand for products, which depends on their price, is characterized by two stochastic processes: potential demand and customer price sensitivity. An optimal policy for coordinating production and pricing is a time-dependent feedback rule with respect to the state of the manufacturer’s inventories. We show that when the volatility of customer sensitivity to the product price is negligible, the optimal policy can be obtained analytically. Moreover, our simulations demonstrate that the volatility of stochastic customer price sensitivity does not have a strong effect on the manufacturer’s expected profit. Therefore, the solution derived for the case of customer price sensitivity with zero volatility can serve as a good approximation heuristic for the optimal policy if the true volatility of customer price sensitivity is within 40 % of its mean and the volatility of potential demand is within 25 % of its mean. Moreover, under these conditions, a simplified, time-independent control rule deteriorates expected profits by only 1.5 %.     

Sourcing from suppliers with random yield for price-dependent demand

We study a multi-period inventory planning problem. In each period, the firm under consideration can source from two possibly unreliable suppliers for a price-dependent demand. Our analysis suggests that the optimal procurement policy is neither a simple reorder-point policy nor a complex one without any structure, as previous studies suggest. Instead, we prove the existence of a reorder point for each supplier. No order is placed to that supplier for any inventory level above the reorder point and a positive order is issued to that supplier for almost every inventory level below the reorder point. We characterize conditions under which the optimal policy reveals monotone response to changes in the inventory level. Furthermore, two special cases of our model are examined in detail to demonstrate how our analysis generalizes a number of well-known results in the literature.     

Allocation of flexible and indivisible resources with decision postponement and demand learning

We consider a firm that uses two perishable resources to satisfy two demand types. Resources are flexible such that each resource can be used to satisfy either demand type. Resources are also indivisible such that the entire resource must be allocated to the same demand type. This type of resource flexibility can be found in different applications such as movie theater complexes, cruise lines, and airlines. In our model, customers arrive according to independent Poisson processes, but the arrival rates are uncertain. Thus, the manager can learn about customer arrival rates from earlier demand figures and potentially increase the sales by postponing the resource allocation decision. We consider two settings, and derive the optimal resource allocation policy for one setting and develop a heuristic policy for the other. Our analysis provides managerial insights into the effectiveness of different resource allocation mechanisms for flexible and indivisible resources.     

Inventory models with minimal service level constraints

This paper investigates inventory models in which the stockout cost is replaced by a minimal service level constraint (SLC) that requires a certain level of service to be met in every period. The minimal service level approach has the virtue of simplifying the computation of an optimal ordering policy, because the optimal reorder level is solely determined by the minimal SLC and demand distributions. It is found that above a certain “critical” service level, the optimal (s,S) policy “collapses” to a simple base-stock or order-up-to level policy, which is independent on the cost parameters. This shows the minimal SLC models to be qualitatively different from their shortage cost counterparts. We also demonstrate that the “imputed shortage cost” transforming a minimal SLC model to a shortage cost model does not generally exist. The minimal SLC approach is extended to models with negligible set-up costs. The optimality of myopic base-stock policies is established under mild conditions.     

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.     

A two-echelon inventory system with transportation capacity constraint

Consider a one-warehouse multi-retailer system under constant and deterministic demand, which is subjected to transportation capacity for every delivery period. To search for the best stationary zero inventory ordering (ZIO) policy, or the best power-of-two policy, or the best nested policy, the problem is formulated as a 0–1 integer linear program in which the objective function comprises of a fixed transportation cost whenever a delivery is made and the inventory costs for both the warehouse and retailers. To overcome the transportation capacity limitation, we extend the policies to allow for staggering deliveries. It is shown that with transportation capacity constraint the non-staggering policy can have its effectiveness close to 0% from the best staggering policy and the power-of-two policy with staggering allowed can have its effectiveness close to 0% from the optimal policy. Nevertheless in general, the power-of-two policy fairs well on a number of randomly generated problems. To solve the large distribution network problem, an efficient heuristic based on the power-of-two policy with staggering of deliveries is suggested.