On the determination of the control parameters of the optimal can-order policy

This paper considers the well-known class of can-order policies. This type of coordinated replenishment policies accounts for a joint set-up cost structure, where a major set-up cost is incurred for any order and an individual minor set-up cost is charged for each item in the replenishment. Recent comparative studies have pointed out that the performance of the optimal can-order policy is poor, compared to other coordinated replenishment strategies, when the major set-up cost is high. This paper shows that it is the approximate decomposition method to calculate the optimal canorder parameters which performs bad in such situations and not the policy itself. Attention is focused to a subclass of can-order policies, which is close to the optimal can-order policy for high major set-up costs. A solution procedure is developed to calculate the optimal control parameters of this policy. It is shown that a properly chosen combination of the solution procedures to calculate can-order parameters leads to a can-order strategy which performs as well as other coordinated replenishment policies.     

Multi-item lot-sizing with joint set-up costs

We consider a multi-item lot-sizing problem with joint set-up costs and constant capacities. Apart from the usual per unit production and storage costs for each item, a set-up cost is incurred for each batch of production, where a batch consists of up to C units of any mix of the items. In addition, an upper bound on the number of batches may be imposed. Under widely applicable conditions on the storage costs, namely that the production and storage costs are nonspeculative, and for any two items the one that has a higher storage cost in one period has a higher storage cost in every period, we show that there is a tight linear program with O(mT ²) constraints and variables that solves the joint set-up multi-item lot-sizing problem, where m is the number of items and T is the number of time periods. This establishes that under the above storage cost conditions this problem is polynomially solvable. For the problem with backlogging, a similar linear programming result is described for the uncapacitated case under very restrictive conditions on the storage and backlogging costs. Computational results are presented to test the effectiveness of using these tight linear programs in strengthening the basic mixed integer programming formulations of the joint set-up problem both when the storage cost conditions are satisfied, and also when they are violated.     

Order selection on a single machine with high set-up costs

We study the problem of allocating a limited quantity of a single manufacturing resource to produce a subset of possible part-types. Customer orders require one or more part-types. We assume that revenue is received for an order only if it is completely filled, and that set-up costs and order revenues dominate the variable costs of production. We present a heuristic for the solution of our problem, as well as families of cutting-planes for an integer programming formulation. Computational results on a set of random test problems indicate that the heuristic is quite effective in producing near optimal solutions. The cutting-planes appear to be quite useful in reducing the number of linear programming solutions required by branch-and-bound.     

Deterministic lot-sizing for coordinated families of production/inventory items

Coordination of order placing points, in a multi-item environment, becomes desirable as it reduces the set-up costs and eases the problem of order-control implementation. Because of the computational complexities most of the analysis in the literature is confined to single families of items. In this paper, we establish the basic property of item consecutiveness for the multi-family situation which facilitates a shortest-path formulation of optimal families. We also develop an efficient algorithm for lot size computations of a single family to be incorporated in the shortest-path model.     

Constrained Lot-Sizes under Conditions of Inventory Growth

When average aggregate inventory levels are constrained to equal a constant level over time, optimal lot sizes can be identified which strike a balance between holding costs and set-up costs among items which form the aggregate. However, when it is desirable to change aggregate inventory levels over time, assumptions implicit in the traditional formulation are violated. The procedure proposed generates lot sizes which are consistent not only with the current average aggregate inventory level but also with its projected growth over the planning horizon. Comparison is made to lot sizes generated by the misapplication of traditional lot sizing methods to the inventory growth situation.     

An inventory system with investment to reduce yield variability and set-up cost

The set-up cost and yield variability are given and fixed in existing production/inventory models with random yields. However, in many practical situations, they can be reduced by investment in modern production technology. In this paper, we consider an inventory system with random yield in which both the set-up cost and yield variability can be reduced through capital investment. The objective is to determine the optimal capital investment and ordering policies that minimize the expected total annual costs for the system. In addition, an iterative solution procedure is presented to find the optimal order quantity and reorder point and then the optimal set-up cost and yield standard deviation. Numerical examples are given to illustrate the results obtained and assess the cost savings by adopting capital investments. Managerial implications are also included.     

Nonlinear freight costs in the EOQ problem

This note gives a solution to a qualification of the standard EOQ problem in which freight costs are at least partially determined by the integer number of carloads required to fill the order. The model also applies to a broad class of problems in which there are multiple set-up costs.     

An Optimal Heuristic For Coordinated Multi-Item Inventory Replenishments

The inventory control problem can be vastly simplified if the replenishments of inventory items are coordinated with one another. That is, whenever an item is replenished, n other items, where n is a decision variable, are also replenished. One way to ensure this would be to classify the inventory items into several groups with a common order interval for each group. In this paper we establish that the optimal groups will be consecutive by hD/A, where h, D and A are the holding cost, demand rate and set-up cost of an item respectively. Using this property of consecutiveness, we develop a fast converging heuristic to create m groups optimally, m = 2, 3,..., M. The heuristic is a substitute for the dynamic programme which would otherwise be necessary and it has the potential for nomographic applications.     

活动长度有限制的多工序批量加工生产计划研究

当前的化工制造中,有很多工厂使用柔性制造设备,并采用批生产模式来组织生产.由于对设备进行准备和清理的成本比较大,加工的排序一般采用多批次加工同一种产品的活动（campaign）模式.在实际的生产中,由于需要保证产品质量和减少库存,应该考虑限制活动的最大长度.本文针对活动长度有限制的多工序批量加工问题进行研究,利用状态-任务-网络概念和层级模型方法,提出了修正的活动计划模型.该模型是基于混合整数线性规划模型,并且以供应网络内总生产成本和物流成本最小化作为目标函数.最后用一个算例来说明所构建模型的有效性.     

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.     

Production strategies for a stochastic lot-sizing problem with constant capacity

This paper presents a single item capacitated stochastic lot-sizing problem motibated by a Dutch company operating in a Make-To-Order environment. Due to a highly fluctuating and unpredictable demand, it is not possible to keep any finished goods inventory. In response to a customer's order, a fixed delivery date is quoted by the company. The objective is to determine in each period of the planning horizon the optimal size of production lots so that delivery dates are met as closely as possible at the expense of minimal average costs. These include set-up costs, holding costs for orders that are finished before their promised delivery date and penalty costs for orders that are not satisfied on time and are therefore backordered. Given that the optimal production policy is likely to be too complex in this situation, attention is focused on the development of heuristic procedures. In this paper two heuristics are proposed. The first one is an extension of a simple production strategy derived by Dellaert [5] for the uncapacitated version of the problem. The second heuristic is based on the well-known Silver-Meal algorithm for the case of deterministic time-varying demand. Experimental results suggest that the first heuristic gives low average costs especially when the demand variability is low and there are large differences in the cost parameters. The Silver-Meal approach is usually outperformed by the first heuristic in situations where the available production capacity is tight and the demand variability is low.     

Medium Term Production Management for Cyclic Deliveries

The growing quality and delay requirements have catalyzed the emergence of new commercial paradigms, which have strongly modified the customer–supplier relationship. Customers and suppliers become more and more linked with contracts or global orders spanned over a relatively important period. This paper, examines a type of contract which specifies a fixed and cyclic delivery dates with delivery quantities varying between a min and a max values. The exact delivery quantities are usually known only few days before the delivery. A company which produces n items on a bottleneck facility is considered; each item is confronted to a cyclic demand and has an important holding cost in comparison to set-up costs. We propose heuristic approaches, to build, in a medium term level, cyclic production schedules. These schedules face the demand and minimize a total cost function composed of holding and set-up costs. An experiment is proposed in order to prove the effectiveness of our approaches.     

The effect of lifetime buys on warranty repair operations

Lifetime buys are a common practice in the electronics and telecommunication industries. Under this practice, manufacturers procure their repair parts inventory in one order to support the spare part needs of a product for the duration of its warranty repair period. In this paper, we consider a repair operation in which defective items under warranty are returned to a manufacturer who either repairs these items using its spare parts inventory or replaces each defective unit with a new product. We show how fixed repair capability costs, variable repair costs, inventory holding costs, and replacement costs affect a firm's optimal repair and replacement decisions. The model is used to gain insights for products from a major mobile device manufacturer in the United States.     

Unbounded knapsack problem with controllable rates: the case of a random demand for items

This paper focuses on a dynamic, continuous-time control generalization of the unbounded knapsack problem. This generalization implies that putting items in a knapsack takes time and has a due date. Specifically, the problem is characterized by a limited production horizon and a number of item types. Given an unbounded number of copies of each type of item, the items can be put into a knapsack at a controllable production rate subject to the available capacity. The demand for items is not known until the end of the production horizon. The objective is to collect items of each type in order to minimize shortage and surplus costs with respect to the demand. We prove that this continuous-time problem can be reduced to a number of discrete-time problems. As a result, solvable cases are found and a polynomial-time algorithm is suggested to approximate the optimal solution with any desired precision.     

Stock replenishment policies for a stochastic exponentially-declining demand process

This paper addresses the problem of determining stock replenishment policies to meet the demand for spare parts for items of equipment which are no longer manufactured. The assumptions that the number of items still in use is decreasing and that parts fail randomly lend credence to a Poisson demand process with an underlying mean which is decreasing exponentially. We use a dynamic programming formulation in continuous time to determine that replenishment policy which minimises the mean total discounted cost of set-up/order, unit production/purchase, unsatisfied demand and stock left over at the end of the time horizon.     

Batch sizing and job sequencing on a single machine

We study a single-machine scheduling problem in which the items to be processed have to be batched as well as sequenced. Since processed items become available in batches, flow times are defined to be the same for all items in the same batch. A constant set-up delay is incurred between consecutive batches. For any fixed, but arbitrary item sequence, we present an algorithm that finds a sequence of batches such that the total flow time of the items is minimized; we prove that for a set ofn items, the algorithm runs inO(n) time. We show that, among all sequences, the one leading to the minimum flow time has the items in non-decreasing order of running times. Thus, the optimal algorithm for the combined problem, called thebatch-sizing problem, runs inO(n logn) time. We also prove that this algorithm yields an improved solution to a scheduling problem recently studied by Baker [1].     

Optimal rebalancing of portfolios with transaction costs

Rebalancing of portfolios with a concave utility function is considered. It is proved that transaction costs imply that there is a no-trade region where it is optimal not to trade. For proportional transaction costs, it is optimal to rebalance to the boundary when outside the no-trade region. With flat transaction costs, the rebalance from outside the no-trade region should be to an internal state in the no-trade region but never a full rebalance. The standard optimal portfolio theory is extended to an arbitrary number of equally treated assets, general utility function and more general stochastic processes. Examples are discussed.     

A queueing model of delayed product differentiation

We consider a production system in which a supplier produces semi-finished items on a make-to-stock basis for a manufacturer that will customize the items on a make-to-order basis. The proportion of total processing time undertaken by the supplier determines how suitable the semi-finished items will be to meet customer demand. The manufacturer wishes to determine the optimal point of differentiation (the proportion of processing completed by the supplier) and its optimal semi-finished goods buffer size. We use matrix geometric methods to evaluate various performance measures for this system, and then, with enumeration techniques, obtain optimal solutions. We find that delayed product differentiation is attractive when the manufacturer can balance the costs of customer order fulfillment delay with the costs associated with unsuitable items.     

Optimal strategy in <Emphasis Type="Italic">N</Emphasis>-policy production system with early set-up

This paper considers a production system in which an early set-up is possible. The machine(server) is turned off when there are no units(customers) to process. When the accumulated number of units reaches m(<N), the operator starts a set-up that takes a random time. After the set-up, if there are N or more units waiting for processing, the machine begins to process the units immediately. Otherwise the machine remains dormant in the system until the accumulated number of units reaches N. We model this system by M/G/1 queue with early set-up and N-policy. We use the decomposition property of a vacation queue to derive the distribution of the number of units in the system. We, then, build a cost model and develop a procedure to find the optimal values of (m,N) that minimize a linear average cost.