Enhanced lateral transshipments in a multi-location inventory system

In managing an inventory network, two approaches to the pooling of stock have been proposed. Reactive transshipments respond to shortages at a location by moving inventory from elsewhere within the network, while proactive stock redistribution seeks to minimize the chance of future stockouts. This paper is the first to propose an enhanced reactive approach in which individual transshipments are viewed as an opportunity for proactive stock redistribution. We adopt a quasi-myopic approach to the development of a strongly performing enhanced reactive transshipment policy. In comparison to a purely reactive approach to transshipment, service levels are improved while a reduction in safety stock levels is achieved. The aggregate costs incurred in managing the system are significantly reduced, especially so for large networks. Moreover, an optimal policy is determined for small networks and it is shown that the enhanced reactive policy substantially closes the gap to optimality.     

Linear programming based decomposition methods for inventory distribution systems

We consider an inventory distribution system consisting of one warehouse and multiple retailers. The retailers face random demand and are supplied by the warehouse. The warehouse replenishes its stock from an external supplier. The objective is to minimize the total expected replenishment, holding and backlogging cost over a finite planning horizon. The problem can be formulated as a dynamic program, but this dynamic program is difficult to solve due to its high dimensional state variable. It has been observed in the earlier literature that if the warehouse is allowed to ship negative quantities to the retailers, then the problem decomposes by the locations. One way to exploit this observation is to relax the constraints that ensure the nonnegativity of the shipments to the retailers by associating Lagrange multipliers with them, which naturally raises the question of how to choose a good set of Lagrange multipliers. In this paper, we propose efficient methods that choose a good set of Lagrange multipliers by solving linear programming approximations to the inventory distribution problem. Computational experiments indicate that the inventory replenishment policies obtained by our approach can outperform several standard benchmarks by significant margins.     

Outbound shipment mode considerations for integrated inventory and delivery lot-sizing decisions

We present a two-echelon dynamic lot-sizing model with two outbound delivery modes where one mode has a fixed set-up cost structure while the other has a container-based cost structure. Studying the optimality properties of the problem, we provide a polynomial solution algorithm based on a dynamic programming approach.     

Finding and identifying optimal inventory levels for systems with common components

In this article, we consider the problem of finding the optimal inventory level for components in an assembly system where multiple products share common components in the presence of random demand. Previously, solution procedures that identify the optimal inventory levels for components in a component commonality problem have been considered for two product or one common component systems. We will here extend this to a three products system considering any number of common components. The inventory problem considered is modeled as a two stage stochastic recourse problem where the first stage is to set the inventory levels to maximize expected profit while the second stage is to allocate components to products after observing demand. Our main contribution, and the main focus of this paper, is the outline of a procedure that finds the gradient for the stochastic problem, such that an optimal solution can be identified and a gradient based search method can be used to find the optimal solution.     

A heuristic for triggering emergency orders in an inventory system

This paper considers a single-echelon inventory system with a warehouse facing compound Poisson customer demand. Normally the warehouse replenishes from an outside supplier according to a continuous review reorder point policy. However, it is also possible to use emergency orders. Such orders incur additional costs but have a much shorter lead time. We consider standard holding and backorder costs as well as ordering costs. A heuristic decision rule for triggering emergency orders is suggested. The decision rule minimizes the expected costs under the assumption that there is only a single possibility for an emergency replenishment, but the rule is used repeatedly as a heuristic. Given a certain reorder point policy for normal replenishments, our decision rule will always reduce the expected costs. A simulation study illustrates that the suggested technique performs well under different conditions.     

An intelligent decomposition of pairwise comparison matrices for large-scale decisions

A Pairwise Comparison Matrix (PCM) has been used to compute for relative priorities of elements and are integral components in widely applied decision making tools: the Analytic Hierarchy Process (AHP) and its generalized form, the Analytic Network Process (ANP). However, PCMs suffer from several issues limiting their applications to large-scale decision problems. These limitations can be attributed to the curse of dimensionality, that is, a large number of pairwise comparisons need to be elicited from a decision maker. This issue results to inconsistent preferences due to the limited cognitive powers of decision makers. To address these limitations, this research proposes a PCM decomposition methodology that reduces the elicited pairwise comparisons. A binary integer program is proposed to intelligently decompose a PCM into several smaller subsets using interdependence scores among elements. Since the subsets are disjoint, the most independent pivot element is identified to connect all subsets to derive the global weights of the elements from the original PCM. As a result, the number of pairwise comparison is reduced and consistency is of the comparisons is improved. The proposed decomposition methodology is applied to both AHP and ANP to demonstrate its advantages.     

The use of simple calibrations of individual locations in making transshipment decisions in a multi-location inventory network

Demands occur at each location in a network of stock-holding retail outlets. Should a location run out of stock between successive replenishments, then subsequent demands may be met either by transshipping from another location in the network or by an emergency supply from a central depot. We deploy an approximate stochastic dynamic programming approach to develop a class of interpretable and implementable heuristics for making transshipment decisions (whether and from where to transship) which make use of simple calibrations of the candidate locations. The calibration for a location depends upon its current stock, the time to its next replenishment and the identity of the location needing stock. A numerical investigation shows strong performance of the proposed policies in comparison with standard industry practice (complete pooling, no pooling) and a recently proposed heuristic. It points to the possibility of substantial cost savings over current practice.     

Joint pricing and inventory replenishment decisions with returns and expediting

We study a single-item periodic-review model for the joint pricing and inventory replenishment problem with returns and expediting. Demand in consecutive periods are independent random variables and their distributions are price sensitive. At the end of each period, after the demand is realized, a buyer can return excess stocks to a supplier. Or, if there are stockouts, the buyer can place an expediting order at the supplier to reduce the amount of shortage. Unfilled demands are fully backlogged. We characterize the optimal dynamic policy that determines the pricing, inventory replenishment, and adjustment decisions in each period so that the total expected discounted profit is maximized. For a very general stochastic demand function, we can show that the optimal replenishment policy is a modified base-stock policy, the optimal pricing policy is a modified base-stock-list-price policy, and the optimal policy for inventory adjustment follows a dual-threshold policy. We further study the operational effect of returns and expediting. Analytical and numerical results demonstrate that returns and expediting lead to a significant profit increase in a number of situations, including limited supply capacity, sufficient flexibility of the expediting order, high demand uncertainty, and a price-sensitive market.     

An arc-exchange decomposition method for multistage dynamic networks with random arc capacities

Multistage dynamic networks with random arc capacities (MDNRAC) have been successfully used for modeling various resource allocation problems in the transportation area. However, solving these problems is generally computationally intensive, and there is still a need to develop more efficient solution approaches. In this paper, we propose a new heuristic approach that solves the MDNRAC problem by decomposing the network at each stage into a series of subproblems with tree structures. Each subproblem can be solved efficiently. The main advantage is that this approach provides an efficient computational device to handle the large-scale problem instances with fairly good solution quality. We show that the objective value obtained from this decomposition approach is an upper bound for that of the MDNRAC problem. Numerical results demonstrate that our proposed approach works very well.     

A model for heuristic coordination of real life distribution inventory systems with lumpy demand

This paper presents an approximation model for optimizing reorder points in one-warehouse N-retailer inventory systems subject to highly variable lumpy demand. The motivation for this work stems from close cooperation with a supply chain management software company, Syncron International, and one of their customers, a global spare parts provider. The model heuristically coordinates the inventory system using a near optimal induced backorder cost at the central warehouse. This induced backorder cost captures the impact that a reorder point decision at the warehouse has on the retailers’ costs, and decomposes the multi-echelon problem into solving N + 1 single-echelon problems. The decomposition framework renders a flexible model that is computationally and conceptually simple enough to be implemented in practice.     

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.     

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.     

Optimal inventory policy with supply uncertainty and demand cancellation

We consider a periodic review model where the firm manages its inventory under supply uncertainty and demand cancellation. We show that because of supply uncertainty, the optimal inventory policy has the structure of re-order point type. That is, we order if the initial inventory falls below this re-order point, otherwise we do not order. This is in contrast to the work of Yuan and Cheung (2003) who prove the optimality of an order up to policy in the absence of supply uncertainty. We also investigate the impact of supply uncertainty and demand cancellation on the performance of the supply chain. Using our model, we are able to quantify the importance of reducing the variance of either the distribution of yield or the distribution of demand cancellation. The single, multiple periods and the infinite horizon models are studied.     

A stochastic program based lower bound for assemble-to-order inventory systems

In this paper we introduce a multi-stage stochastic program that provides a lower bound on the long-run average inventory cost of a general class of assemble-to-order (ATO) inventory systems. The stochastic program also motivates a replenishment policy for these systems. Our lower bound generalizes a previous result of Do?ru et al. (2010) [3] for systems with identical component replenishment lead times to those with general deterministic lead times. We provide a set of sufficient conditions under which our replenishment policy, coupled with an allocation policy, attains the lower bound (and is hence optimal). We show that these sufficient conditions hold for two examples, a single product system and a special case of the generalized W model.     

Optimal policies for inventory systems with two types of product sharing common hardware platforms: Single period and finite horizon

In this paper, we consider an inventory system whose products share a common hardware platform but are differentiated by two types of software. Choice of different software results in different installation cost and different selling price of the whole product. Product with different software also faces different customer demand. We investigate the optimal proportion of an order to be installed with software 1 or 2, that maximizes expected profit in the single and multiple period scenarios, respectively. The optimal policy is analytically obtained and proved to be an order-up-to policy in each scenario. Our investigation reveals that whether to replenish, and how much to replenish each product depend not only on its own initial inventory level, and system parameters, but also the initial inventory level of the other product. We perform numerical experiments using the optimal policies we have derived in the paper.     

An inventory sharing and allocation method for a multi-location service parts logistics network with time-based service levels

We consider a model to allocate stock levels at warehouses in a service parts logistics network. The network is a two-echelon distribution system with one central warehouse with infinite capacity and a number of local warehouses, each facing Poisson demands from geographically dispersed customers. Each local warehouse uses a potentially different base stock policy. The warehouses are collectively required to satisfy time-based service targets: Certain percentages of overall demand need to be satisfied from facilities within specified time windows. These service levels not only depend on the distance between customers and the warehouses, but also depend on the part availabilities at the warehouses. Moreover, the warehouses share their inventory as a way to increase achieved service levels, i.e., when a local warehouse is out of stock, demand is satisfied with an emergency shipment from another close-by warehouse. Observing that the problem of finding minimum-cost stock levels is an integer non-linear program, we develop an implicit enumeration-based method which adapts an existing inventory sharing model from the literature, prioritizes the warehouses for emergency shipments, and makes use of a lower bound. The results show that the proposed inventory sharing strategy results in considerable cost reduction when compared to the no-sharing case and the method is quite efficient for the considered test problems.     

Finite master programs in regularized stochastic decomposition

Stochastic decomposition is a stochastic analog of Benders' decomposition in which randomly generated observations of random variables are used to construct statistical estimates of supports of the objective function. In contrast to deterministic Benders' decomposition for two stage stochastic programs, the stochastic version requires infinitely many inequalities to ensure convergence. We show that asymptotic optimality can be achieved with a finite master program provided that a quadratic regularizing term is included. Our computational results suggest that the elimination of the cutting planes impacts neither the number of iterations required nor the statistical properties of the terminal solution.This work was supported in part by Grant No. AFOSR-88-0076 from the Air Force Office of Scientific Research and Grant Nos. DDM-89-10046, DDM-9114352 from the National Science Foundation.Corresponding author.     

Coherent risk measures in inventory problems

We analyze an extension of the classical multi-period, single-item, linear cost inventory problem where the objective function is a coherent risk measure. Properties of coherent risk measures allow us to offer a unifying treatment of risk averse and min–max type formulations. For the single period newsvendor problem, we show that the structure of the optimal solution of the risk averse model is similar to that of the classical expected value problem. For a finite horizon dynamic inventory model, we show that, again, the optimal policy has a similar structure as that of the expected value problem. This result carries over even to the case when there is a fixed ordering cost. We also analyze monotonicity properties of the optimal order quantity with respect to the degree of risk aversion for certain risk measures.     

A comparison of inventory policies for perishable goods

Past research on inventory management of perishables introduced models in which demand is sensitive to the age of the product. For such models, we prove that a fixed-order quantity policy is optimal under certain conditions and show that its expected cost is closer to optimal than that of the base-stock level policy when there is demand for units of all ages. We also show numerically when substituting older products to fulfill the demand for new (or vice versa) is beneficial.     

Joint management of capacity and inventory in make-to-stock production systems with multi-class demand

We evaluate the benefits of coordinating capacity and inventory decisions in a make-to-stock production environment. We consider a firm that faces multi-class demand and has additional capacity options that are temporary and randomly available. We formulate the model as a Markov decision process (MDP) and prove that a solution to the optimal joint control problem exists. For several special cases we characterize the structure of the optimal policy. For the general case, however, we show that the optimal policy is state-dependent, and in many instances non-monotone and difficult to implement. Therefore, we consider three pragmatic heuristic policies and assess their performance. We show that the majority of the savings originate from the ability to dynamically adjust capacity, and that a simple heuristic that can adjust production capacity (based on workload fluctuation) but uses a static production/rationing policy can result in significant savings.