A two-stage tandem queue attended by a moving server with holding and switching costs

We consider a two-stage tandem queue attended by a moving server, with homogeneous Poisson arrivals and general service times. Two different holding costs for stages 1 and 2 and different switching costs from one stage to the other are considered. We show that the optimal policy in the second stage is greedy; and if the holding cost rate in the second stage is greater or equal to the rate in the first stage, then the optimal policy in the second stage is also exhaustive. Then, the optimality condition for sequential service policy in systems with zero switchover times is introduced. Considering some properties of the optimal policy, we then define a Triple-Threshold (TT) policy to approximate the optimal policy in the first stage. Finally, a model is introduced to find the optimal TT policy, and using numerical results, it is shown that the TT policy accurately approximates the optimal policy. This revised version was published online in June 2006 with corrections to the Cover Date.     

Inventory control with two switch-over levels for a class of M/G/1 queueing systems with variable arrival and service rate

This paper deals with inventory control in a class of M/G/1 queueing systems. At each point of time the system can be switched from one of two possible stages to another. The rate of arrival process and the service rate depend on the stage of the system. The cost structure imposed on the model includes both fixed switch-over costs and a holding cost at a general rate depending on the stage of the system. The rule for controlling the inventory is specified by two switch-over levels.Using an embedding approach, we will derive a formula for the long-run average expected costs per unit time of this policy. By an appropriate choice of the cost parameters, we may obtain various operating characteristics for the system amongst which the stationary distribution of the inventory and the average number of switch-overs per unit time.     

Look-back policies for two-stage,pull-type production/inventory systems

We consider a two-stage, pull-type production/inventory system with a known service mechanism at the first stage. Set-ups and start-ups are involved in the operation of the second stage. We develop a production control policy for the second stage, within the class of (R, r) continuous-review policies, that minimizes the long run average total cost. We use a semi-Markov decision model to obtain an optimal policy for the operation of the second stage. The structure of the optimal policy suggests the use of a suboptimal look-back policy that delays the set-up at the second stage if the buffer lacks sufficient raw material. The performance of the system and the average total cost under the suboptimal policy can be obtained approximately using a decomposition algorithm. We show examples justifying the use of this suboptimal policy.This research is supported by the NSF Grant No. NSF-NCR-9110105, NSF Grant No. NSF-DDM-9014868 and by the North Atlantic Treaty Organization Grant No. NATO-CRG-900580.     

A possibilistic decision model for new product supply chain design

This paper models supply chain (SC) uncertainties by fuzzy sets and develops a possibilistic SC configuration model for new products with unreliable or unavailable SC statistical data. The supply chain is modeled as a network of stages. Each stage may have one or more options characterized by the cost and lead-time required to fulfill required functions and may hold safety stock to prevent an inventory shortage. The objective is to determine the option and inventory policy for each stage to minimize the total SC cost and maximize the possibility of fulfilling the target service level. A fuzzy SC model is developed to evaluate the performance of the entire SC and a genetic algorithm approach is applied to determine near-optimal solutions. The results obtained show that the proposed approach allows decision makers to perform trade-off analysis among customer service levels, product cost, and inventory investment depending on their risk attitude. It also provides an alternative tool to evaluate and improve SC configuration decisions in an uncertain SC environment.     

Optimal two-stage ordering policy with Bayesian information updating

We investigate in this paper an optimal two-stage ordering policy for seasonal products. Before the selling season, a retailer can place orders for a seasonal product from her supplier at two distinct stages satisfying the lead-time requirement. Market information is collected at the first stage and is used to update the demand forecast at the second stage by using Bayesian approach. The ordering cost at the first stage is known but the ordering cost at the second stage is uncertain. A two-stage dynamic optimization problem is formulated and an optimal policy is derived using dynamic programming. The optimal ordering policy exhibits nice structural properties and can easily be implemented by a computer program. The detailed implementation scheme is proposed. The service level and profit uncertainty level under the optimal policy are discussed. Extensive numerical analyses are carried out to study the performance of the optimal policy.     

Modified base-stock policies for semiconductor production system with dependent yield rates

We consider a two-stage production system faced by semiconductor manufacturing which produces a hierarchy of multiple grades of outputs. In the first stage, a single type of input (wafer) is used to produce multiple types of semi-finished parts with dependent yield rates, and in the second stage, each type of semi-finished parts can be transformed into a corresponding type of final products, or downgraded to a type of lower grade final products. Random customer demands are faced on the final products, and demands of different types of final products are not allowed to be substituted. The advantage of this production system is that it can prevent unhealthy ordering from customers who intentionally send out false demand signals for high grade products and revise the orders to lower grade products when the delivery time is close, which was observed in semiconductor manufacturing. The objective of the study is to plan the quantity of the input at the first stage and the respective downgrade quantities at the second stage so as to meet the required service level at the minimum cost. With some common assumptions, we propose a modified base-stock policy for this two-stage production system and show that the occurrence of nil excess inventory above the base-stock level follows a renewal process. We further extend the modified base-stock policy to a better policy that invokes risk pooling over multiple grade products. The performance of these two polices are evaluated via simulation to provide managerial insights.     

基于排队的库存服务系统最优控制策略

研究一个连续盘点的(s,Q)补货的库存服务系统。基于排队理论建立库存水平状态平衡方程,并推导出库存水平稳态概率分布以及作为库存控制的系统稳态性能指标。以库存成本最小化为目标,构建服务水平约束的库存控制模型。针对模型的非线性约束与整数型变量的特征,采用一种改进的遗传算法(IGA)用于决策变量的寻优。数值实验表明,当目标服务水平大于库存系统内生的服务水平时,实施服务水平约束能够降低库存控制成本。     

具有两类需求服务的随机库存系统控制策略研究

研究具有两类顾客排队需求服务的随机库存系统.系统采取(s,Q)补货策略且当库存水平下降到安全库存s时,到达的第二类顾客以概率P得到服务.首先,建立库存水平状态转移方程并通过递推算法求解获得库存水平稳态概率分布和系统稳态指标;接下来,构建库存成本函数;最后,采用数值试验的方法研究该库存系统的最优控制策略并考察系统参数的敏感性.     

Profitability ratio maximization in an inventory model with stock-dependent demand rate and non-linear holding cost

This paper studies a deterministic inventory model with a stock-dependent demand pattern where the cumulative holding cost is a non-linear function of both time and stock level. When the monetary resources are limited and the inventory manager can invest his/her money in buying different products, it seems reasonable to select the ones that provide a higher profitability. Thus, a new approach with the aim of maximizing the profitability ratio (defined as the profit/cost quotient) is considered in this paper. We prove that the profitability ratio maximization is equivalent to minimizing the inventory cost per unit of an item. The optimal policy is obtained in a closed form, whose general expression is a generalization of the classical EOQ formula for inventory models with a stock-dependent demand rate and a non-linear holding cost. This optimal solution is different from the other policies proposed for the problems of minimum cost or maximum profit per unit time. A complete sensitivity analysis of the optimal solution with respect to all the parameters of the model is developed. Finally, numerical examples are solved to illustrate the theoretical results and the solution methodology.     

Using aggregate fill rate for dynamic scheduling of multi-class systems

For dynamic scheduling of multi-class systems where backorder cost is incurred per unit backordered regardless of the time needed to satisfy backordered demand, the following models are considered: the cost model to minimize the sum of expected average inventory holding and backorder costs and the service model to minimize expected average inventory holding cost under an aggregate fill rate constraint. Use of aggregate fill rate constraint in the service model instead of an individual fill rate constraint for each class is justified by deriving equivalence relations between the considered cost and service models. Based on the numerical investigation that the optimal policy for the cost model is a base-stock policy with switching curves and fixed base-stock levels, an alternative service model is considered over the class of base-stock controlled dynamic scheduling policies to minimize the total inventory (base-stock) investment under an aggregate fill rate constraint. The policy that solves this alternative model is proposed as an approximation of the optimal policy of the original cost and the equivalent service models. Very accurate heuristics are devised to approximate the proposed policy for given base-stock levels. Comparison with base-stock controlled First Come First Served (FCFS) and Longest Queue (LQ) policies and an extension of LQ policy (Δ policy) shows that the proposed policy performs much better to solve the service models under consideration, especially when the traffic intensity is high.     

Deterministic hierarchical substitution inventory models

In this paper, we consider a deterministic nested substitution problem where there are multiple products which can be substituted one for the other, if necessary, at a certain cost. We consider the case when there are n products, and product j can substitute products j + 1,…,n at certain costs. The trade-off is the cost of storing products (for example, customised products) at a higher inventory holding stage versus the cost of transferring downwards from a lower inventory holding cost (generic product) stage. The standard approach to solving the problem yields an intractable formulation, but by reformulating the problem to determine the optimal run-out times, we are able to determine the optimal order and substitution quantities. Numerical examples showing the effect of various system parameters on the optimal order and substitution policy are also presented.     

Optimal policy for brownian inventory models with general convex inventory cost

We study an inventory system in which products are ordered from outside to meet demands, and the cumulative demand is governed by a Brownian motion. Excessive demand is backlogged. We suppose that the shortage and holding costs associated with the inventory are given by a general convex function. The product ordering from outside incurs a linear ordering cost and a setup fee. There is a constant leadtime when placing an order. The optimal policy is established so as to minimize the discounted cost including the inventory cost and ordering cost.     

Optimal inventory policy for specialty chemical products in multiple packages

Many products are inventoried and sold in multiple outer packages, which causes the manufacturer or distributor to maintain a segmented inventory. Oftentimes, this scenario leads to shortages in some packages and over-stock in other package types. The shortages are usually linked to specific shortage costs, and the over-stock is always associated with some sort of unnecessary holding cost that either erodes profit margins or results in increased costs for the consumer. In this paper, the inventory policy for a specialty chemical manufacturer's cleaner, which is inventoried in four unique packages, is studied. A mathematical model is developed to account for the costs associated with initial procurement, holding and repackaging (shortage), which are the primary costs associated with the inventory system. Based upon this model, an optimal inventory policy is generated that reduces the need for repackaging, without requiring a prohibitive amount of safety stock. A specific historical case is summarized, and the results of this example are compared with the results that the new inventory policy would have produced, given the same circumstances.     

Inventory control by different service levels

This paper examines the multiple period inventory control problem of a single product with multiple (two) prices, depending on service level, in which optimal pricing and ordering decisions are made in each period. Traditional inventory and pricing models consider only single products, single prices, and single service levels. However, this research paper finds that a seller can improve inventory control and revenue by offering multiple prices depending on service level. This research considers a single product with multiple (two) pricing policies corresponding to service level as follows: if the customer is willing to delay the shipment, he/she will be offered a lower regular price. Otherwise, the customer will pay the regular price plus extra charges for express service. In this paper, I show the following: (1) there is an optimal pricing and replenishment policy that can control inventory and (2) there exists a finite threshold for inventory levels such that if the inventory level at the beginning of each period is higher than the threshold, the customer will be offered the express service at the regular price, without any extra charge.     

Optimization of Single-Item Multi-Stage Stochastic Production — Inventory Systems

This paper presents a mathematical model developed for optimization of single-item multi-stage production-inventory systems. The demands are assumed to occur randomly at the same rate whereas processing and setup times are different, each following exponential distributions with different means. The model assumes a "one-for-one ordering" inventory policy and that on total system cost expression comprising setup, holding and penalty costs is obtained for optimization. As a special case, single stage, cost expressions become the same as those obtained by Baker. Computational results for two stages are given. Implications of aggregating the two stages into an equivalent simple stage are discussed.     

Calculating safety stocks for assembly systems with random component procurement lead times: A branch and bound algorithm

In this paper, a discrete single-level multi-component inventory control model for assembly systems with random component procurement lead times is considered. The economic order quantity (EOQ) policy is used for a type of finished product. The requirements of the components are constant and cyclic (periodic), and their values per period are deduced from the EOQ for the finished product. The paper focuses on the components safety stock calculation. The objective is to minimise the average holding cost of the components while keeping the desired service level for the finished product. For this, an upper bound, two lower bounds, two dominance properties and an efficient branch and bound algorithm are suggested. Several tests are executed and conclusions are drawn. The proposed model provides a substantial saving for assembly systems with a large number and unreliable delivery of components as in semi-conductor and automotive industries.     

需求率依赖于库存水平的离散性库存费的库存模型

传统的库存控制模型都视需求率为固定不变的,放松了这个假定,通过考虑库存费为存储时间的阶梯函数的情形:(1)全单位库存费用,(2)增量库存费用,并且在需求率依赖于库存水平,当库存水平下降到一定程度时,需求率变为常数的形式下,把变化的订购费引入,发展了两个离散性库存费的变质物品的库存控制模型。在模型中允许周期末库存水平不为零,并且提出了最优解的算法。     

需求依赖于服务水平的易变质品库存策略研究

本文研究需求依赖于上一周期服务水平、缺货时订单部分损失的两周期易变质品库存问题。分别考虑一次订货和多次订货两种情况,以平均利润最大化为目标构建库存模型,证明了模型解的存在性和唯一性,得到了最优库存服务水平和最优补货策略。最后,通过算例给出两个模型的应用,对重要参数进行了灵敏度分析,并且将两种模型的结果进行了对比分析。结果表明:订单损失率的增加会提高服务水平,但会使得利润降低;顾客期望服务水平的提高会降低第一阶段的服务水平,同时使利润减少;单位库存持有成本或变质率的增加会降低服务水平和平均利润。通常情况,企业通过多次订货能获得更大的利润,而只有当库存持有成本极小时,一次订购才能够获得更大的利润。同时,结果也表明:服务水平对库存策略有较大的影响,因此在进行库存决策时考虑服务水平具有重要的作用。     

Sequencing and loading of products on a flowline

One of the main objectives of balancing a flowline is to achieve maximum throughput with minimum WIP. To that end, various methods have been proposed to control the loading of products (flow of material) on a flowline. However, the sequence in which the products are released is an issue that has rarely been addressed in conjunction with the material flow control mechanisms. In this paper, we address the problem of determining the optimal cyclic sequence in which to load different products on a flowline in order to achieve optimum throughput at minimum WIP. A lower bound on the WIP level is developed which is then used to determine the desired WIP level and the sequence in which to load the products so as to achieve optimum throughput. A new product release policy is also developed. Comparative results of the new product release policy and the sequencing procedure with other product release policies and sequencing heuristics are presented and they indicate superiority of the proposed methods.