A two-echelon inventory model with lost sales

This paper considers a single-item, two-echelon, continuous-review inventory model. A number of retailers have their stock replenished from a central warehouse. The warehouse in turn replenishes stock from an external supplier. The demand processes on the retailers are independent Poisson. Demand not met at a retailer is lost. The order quantity from each retailer on the warehouse and from the warehouse on the supplier takes the same fixed value Q, an exogenous variable determined by packaging and handling constraints. Retailer i follows a (Q, R_i) control policy. The warehouse operates an (SQ, (S − 1)Q) policy, with non-negative integer S. If the warehouse is in stock then the lead time for retailer i is the fixed transportation time L_i from the warehouse to that retailer. Otherwise retailer orders are met, after a delay, on a first-come first-served basis. The lead time on a warehouse order is fixed. Two further assumptions are made: that each retailer may only have one order outstanding at any time and that the transportation time from the warehouse to a retailer is not less than the warehouse lead time. The performance measures of interest are the average total stock in the system and the fraction of demand met in the retailers. Procedures for determining these performance measures and optimising the behaviour of the system are developed.     

A two-level supply chain with partial backordering and approximated Poisson demand

We consider a two-level supply chain with a number of identical, independent ‘retailers’ at the lower echelon and a single supplier at the upper echelon controlled by continuous review inventory policy (R, Q). Each retailer experiences Poisson demand with constant transportation times. We assume constant lead time for replenishing supplier orders from an external warehouse to the supplier and unsatisfied retailer orders are backordered in the supplier. We assume that the unsatisfied demand is partially backordered in the identical retailers. The partially backordering policy is implemented in the identical retailers using an explicit control parameter ‘b’ which limits the maximum number of backorders allowed to be accumulated during the lead time. We develop an approximate cost function to find optimal reorder points for given batch sizes in all installations, the optimal value of b in the identical retailers and the related accuracy is assessed through simulation.     

Stock Rationing in a Continuous Review Two-Echelon Inventory Model

In this paper we consider a 1-warehouse, N-retailer inventory system where demand occurs at all locations. We introduce an inventory model which allows us to set different service levels for retailers and direct customer demand at the warehouse. For each retailer a critical level is defined, such that a retailer replenishment order is delivered from warehouse stock if and only if the stock level exceeds this critical level. It is assumed that retailer replenishment orders, which are not satisfied from warehouse stock, are delivered directly from the outside supplier, instead of being backlogged. We present an analytical upper bound on the total cost of the system, and develop a heuristic method to optimize the policy parameters. Numerical experiments indicate that our technique provides a very close approximation of the exact cost. Also, we show that differentiating among the retailers and direct customer demand can yield significant cost reductions.     

Two warehouse inventory models for single vendor multiple retailers with price and stock dependent demand

Here a single vendor multiple retailer inventory model of an item is developed where demand of the item at every retailer is linearly dependent on stock and inversely on some powers of selling price. Item is produced by the vendor and is distributed to the retailers following basic period policy. According to this policy item is replenished to the retailers at a regular time interval (T₁) called basic period (BP) and replenishment quantity is sufficient to last for the period T₁. Due to the scarcity of storage space at market places, every retailer uses a showroom at the market place and a warehouse to store the item, little away from the market place. Item is sold from the showroom and is filled up from the warehouse in a bulk release pattern. Some of the inventory parameters are considered as fuzzy in nature and model is formulated to maximize the average profit from the whole system. Imprecise objective is transformed to equivalent deterministic ones using possibility/necessity measure of fuzzy events with some degree of optimism/pessimism. A genetic algorithm (GA) is developed with roulette wheel selection, arithmetic crossover and random mutation and is used to solve the model. In some complex cases, with the help of above GA, fuzzy simulation process is used to derive the optimal decision. The model is illustrated through numerical examples and some sensitivity analyses are presented.     

Evaluation of (R,Q)-policies for two-level inventory systems with generally distributed customer inter-arrival times

In this paper we consider a two-level inventory system with a central warehouse and a number of retailers. All facilities apply continuous review (R,Q)-policies. We first extend Forsberg's exact Poisson model to the case with unit demand and customer inter-arrival times that are Erlang distributed. In the case with generally distributed customer inter-arrival times we approximate by Erlang distributions. We use two different methods to choose the approximate Erlang distribution. The first method means that we, for each retailer, choose the Erlang distribution that has the exact mean and minimum difference in standard deviation. Our second method means that we, for each retailer, choose the Erlang distribution of customer inter-arrival times that gives the exact mean and minimum difference in the standard deviation of the demand per unit of time instead of the inter-arrival time. Both methods are tested on 38 simulated cases. In all cases both methods give the same approximation.     

Exact evaluation of (R,Q)-policies for two-level inventory systems with Poisson demand

In this paper we show how to exactly evaluate holding and shortage costs for a two-level inventory system with one warehouse and N different retailers. Lead-times (transportation times) are constant, and the retailers face different Poisson demand processes. All facilities apply continuous review (R, Q)-policies. We express the policy costs as a weighted mean of costs for one-for-one ordering policies.     

Allocation of warehouse inventory with electronic data interchange and fixed order intervals

This paper considers the problem of allocating warehouse inventory to retailers where retailer orders and the replenishment of warehouse inventory occur periodically on a fixed schedule. We assume that the warehouse and the retailers have the opportunity to exchange demand information through Electronic Data Interchange (EDI). At the warehouse level, for instance, the available information on the retailer's demand may be utilized in determining the shipment quantities needed to meet the desired service level to the retailers. Unlike similar models focusing primarily on optimizing systems wide performance measures, in this paper we focus on the service level furnished to the retailers by the warehouse. To this end, three different allocation policies are considered: static, myopic, and dynamic rules characterizing the impact of available demand information on the resulting service levels. Numerical illustrations exemplify the allocation rules considered. An interesting though counter intuitive observation is that the existence of additional demand information cannot, a prior, be assumed superior.     

A periodic-review inventory control policy for a two-level supply chain with multiple retailers and stochastic demand

We consider a time-based inventory control policy for a two-level supply chain with one warehouse and multiple retailers in this paper. Let the warehouse order in a fixed base replenishment interval. The retailers are required to order in intervals that are integer-ratio multiples of the base replenishment interval at the warehouse. The warehouse and the retailers each adopt an order-up-to policy, i.e. order the needed stock at a review point to raise the inventory position to a fixed order-up-to level. It is assumed that the retailers face independent Poisson demand processes and no transshipments between them are allowed. The contribution of the study is threefold. First, we assume that when facing a shortage the warehouse allocates the remaining stock to the retailers optimally to minimize system cost in the last minute before delivery and provide an approach to evaluate the exact system cost. Second, we characterize the structural properties and develop an exact optimal solution for the inventory control system. Finally, we demonstrate that the last minute optimal warehouse stock allocation rule we adopt dominates the virtual allocation rule in which warehouse stock is allocated to meet retailer demand on a first-come first-served basis with significant cost benefits. Moreover, the proposed time-based inventory control policy can perform equally well or better than the commonly used stock-based batch-ordering policy for distribution systems with multiple retailers.     

A solution approach to the inventory routing problem in a three-level distribution system

We consider the infinite horizon inventory routing problem in a three-level distribution system with a vendor, a warehouse and multiple geographically dispersed retailers. In this problem, each retailer faces a demand at a deterministic, retailer-specific rate for a single product. The demand of each retailer is replenished either from the vendor through the warehouse or directly from the vendor. Inventories are kept at both the retailers and the warehouse. The objective is to determine a combined transportation (routing) and inventory strategy minimizing a long-run average system-wide cost while meeting the demand of each retailer without shortage. We present a decomposition solution approach based on a fixed partition policy where the retailers are partitioned into disjoint and collectively exhaustive sets and each set of retailers is served on a separate route. Given a fixed partition, the original problem is decomposed into three sub-problems. Efficient algorithms are developed for the sub-problems by exploring important properties of their optimal solutions. A genetic algorithm is proposed to find a near-optimal fixed partition for the problem. Computational results show the performance of the solution approach.     

Evaluation of stock allocation policies in a divergent inventory system with shipment consolidation

In this paper we consider a one-warehouse N-retailer inventory system characterized by access to real-time point-of-sale data, and a time based dispatching and shipment consolidation policy at the warehouse. More precisely, inventory is reviewed continuously, while a consolidated shipment (for example, a truck) to all retailers is dispatched from the warehouse at regular time intervals. The focus is on investigating the cost benefits of using state-dependent myopic allocation policies instead of a simple FCFS (First-Come-First-Serve) rule to allocate shipped goods to the retailers. The analysis aims to shed some light on when, if ever, FCFS is a reasonable policy to use in this type of system? The FCFS allocations of items to retailers are determined by the sequence in which retailer orders (or equivalently customer demands) arrive to the warehouse. Applying the myopic policy enables the warehouse to postpone the allocation decision to the moment of shipment (from the warehouse) or the moments of delivery (to the different retailers), and to base it on the inventory information available at those times. The myopic allocation method we study is often used in the literature on periodic review systems.     

Controlling distribution inventory systems with shipment consolidation and compound Poisson demand

We consider a one-warehouse-multiple-retailer inventory system where the retailers face stochastic customer demand, modelled as compound Poisson processes. Deliveries from the central warehouse to groups of retailers are consolidated using a time based shipment consolidation policy. This means that replenishment orders have to wait until a vehicle departures, which increases the lead time for the retailers and therefore also the safety stock. Thus, a trade-off exists between expected shipment costs and holding costs. Our aim is to determine the shipment intervals and the required amount of safety stock for each retailer and the warehouse to minimize total cost, both for backorder costs and fill rate constraints. Previous work has focused on exact solutions which are computationally demanding and not applicable for larger real world problems. The focus of our present work is on the development of computationally attractive heuristics that can be applied in practice. A numerical study shows that the proposed heuristics perform well compared to the exact cost minimizing solutions. We also illustrate that the approaches are appropriate for solving real world problems using data from a large European company.     

A two-echelon base-stock inventory model with Poisson demand and the sequential processing of orders at the upper echelon

We consider a two-echelon inventory system with a number of non-identical, independent ‘retailers’ at the lower echelon and a single ‘supplier’ at the upper echelon. Each retailer experiences Poisson demand and operates a base stock policy with backorders. The supplier manufactures to order and holds no stock. Orders are produced, in first-come first-served sequence, with a fixed production time. The supplier therefore functions as an M/D/1 queue. We are interested in the performance characteristics (average inventory, average backorder level) at each retailer. By finding the distribution of order lead time and hence the distribution of demand during order lead time, we find the steady state inventory and backorder levels based on the assumption that order lead times are independent of demand during order lead time at a retailer. We also propose two alternative approximation procedures based on assumed forms for the order lead time distribution. Finally we provide a derivation of the steady state inventory and backorder levels which will be exact as long as there is no transportation time on orders between the supplier and retailers. A numerical comparison is made between the exact and approximate measures. We conclude by recommending an approach which is intuitive and computationally straightforward.     

On contracts for VMI program with continuous review (r, Q) policy

Based on continuous review (r, Q) policy, this paper deals with contracts for vendor managed inventory (VMI) program in a system comprising a single vendor and a single retailer. Two business scenarios that are popular in VMI program are “vendor with ownership” and “retailer with ownership”. Taking the system performance in centralized control as benchmark, we define a contract “perfect” if the contract can enable the system to be coordinated and can guarantee the program to be trusted. A revenue sharing contract is designed for vendor with ownership, and a franchising contract is designed for retailer with ownership. Without consideration of order policy and related costs at the vendor site, it is shown that one contract can perform satisfactorily and the other one is a perfect contract. With consideration of order policy and related costs at the vendor site, it is shown that one contract can perform satisfactorily and the performance of the other one depends on system parameters.     

An inventory-transportation system with stochastic demand

We study a logistic system in which a supplier has to deliver a set of products to a set of retailers to face a stochastic demand over a given time horizon. The transportation from the supplier to each retailer can be performed either directly, by expensive and fast vehicles, or through an intermediate depot, by less expensive but slower vehicles. At most one time period is required in the former case, while two time periods are needed in the latter case. A variable transportation cost is charged in the former case, while a fixed transportation cost per journey is charged in the latter case. An inventory cost is charged at the intermediate depot. The problem is to determine, for each time period and for each product, the quantity to send from the supplier to the depot, from the depot to each retailer and from the supplier to each retailer, in order to minimize the total expected cost. We first show that the classical benchmark policy, in which the demand of each product at each retailer is set equal to the average demand, can give a solution which is infinitely worse with respect to the optimal solution. Then, we propose two classes of policies to solve this problem. The first class, referred to as Horizon Policies, is composed of policies which require the solution of the overall problem over the time horizon. The second class, referred to as Reoptimization Policies, is composed of a myopic policy and several rolling-horizon policies in which the problem is reoptimized at each time period, once the demand of the time period is revealed. We evaluate the performance of each policy dynamically, by using Monte Carlo Simulation.     

A collaborative decentralized distribution system with demand forecast updates

In this paper, we study inventory pooling coalitions within a decentralized distribution system consisting of a manufacturer, a warehouse (or an integration center), and n retailers. At the time their orders are placed, the retailers know their demand distribution but do not know the exact value of the demand. After certain production and transportation lead time elapses, the orders arrive at the warehouse. During this time, the retailers can update their demand forecasts.We first focus on cooperation among the retailers - the retailers coordinate their initial orders and can reallocate their orders in the warehouse after they receive more information about their demand and update their demand forecasts. We study two types of cooperation: forecast sharing and joint forecasting. By using an example, we illustrate how forecast sharing collaboration might worsen performance, and asymmetric forecasting capabilities of the retailers might harm the cooperation. However, this does not happen if the retailers possess symmetric forecasting capabilities or they cooperate by joint forecasting, and the associated cooperative games have non-empty cores.Finally, we analyze the impact that cooperation and non-cooperation of the retailers has on the manufacturer’s profit. We focus on coordination of the entire supply chain through a three-parameter buyback contract. We show that our three-parameter contract can coordinate the system if the retailers have symmetric margins. Moreover, under such a contract the manufacturer benefits from retailers’ cooperation since he can get a share of improved performance.     

A real-time decision rule for an inventory system with committed service time and emergency orders

In this paper, we study the inventory system of an online retailer with compound Poisson demand. The retailer normally replenishes its inventory according to a continuous review (nQ, R) policy with a constant lead time. Usually demands that cannot be satisfied immediately are backordered. We also assume that the customers will accept a reasonable waiting time after they have placed their orders because of the purchasing convenience of the online system. This means that a sufficiently short waiting time incurs no shortage costs. We call this allowed waiting time “committed service time”. After this committed service time, if the retailer is still in shortage, the customer demand must either be satisfied with an emergency supply that takes no time (which is financially equivalent to a lost sale) or continue to be backordered with a time-dependent backorder cost. The committed service time gives an online retailer a buffer period to handle excess demands. Based on real-time information concerning the outstanding orders of an online retailer and the waiting times of its customers, we provide a decision rule for emergency orders that minimizes the expected costs under the assumption that no further emergency orders will occur. This decision rule is then used repeatedly as a heuristic. Numerical examples are presented to illustrate the model, together with a discussion of the conditions under which the real-time decision rule provides considerable cost savings compared to traditional systems.     

A normal approximation model for safety stock optimization in a two-echelon distribution system

This paper presents an approximation model for the retailer replenishment lead-times in a two-echelon distribution system, and discusses its implementation for safety stock optimization in a one-warehouse and N-identical retailers system. The model assumes normality of demand and nominal lead times. It takes into account not only the averages of these parameters but also their variances. This approximation model is first tested on a two-echelon, one-warehouse and N-identical retailers system using discrete event simulation. It is then applied to optimize the safety stock in a two-echelon distribution system of a European market leader in the production and distribution of air conditioning equipment. Results of this implementation are analysed and discussed in detail.     

Stochastic inventory system with lead time flexibility: offered by a manufacturer/transporter

This paper studies lead time flexibility in a two-stage continuous review supply chain in which the retailer uses the (R, Q) inventory system: when his inventory position reaches R, the retailer places orders with size Q to the manufacturer, who uses a transportation provider to deliver them with different lead time options. According to the contract, the manufacturer is able to expedite or postpone the delivery if the retailer makes such a request. Hence, the retailer has the flexibility to modify the lead time by using the most up-to-date demand information. The optimal lead time policy is found to be a threshold-type policy. The sensitivity analysis also shows that R is much more sensitive to the change of lead time than Q, and thus, the paper is primarily focused on finding optimal R. We also provide a cost approximation which yields unimodal cost in R. Furthermore, we analyze the order crossing problem and derive an upper bound for the probability of order crossing. Finally, we conduct an extensive sensitivity analysis to illustrate the effects of lead time flexibility on supply chain performance and discuss the managerial insights.     

Approximate evaluation of multi-location inventory models with lateral transshipments and hold back levels

We consider a continuous-time, single-echelon, multi-location inventory model with Poisson demand processes. In case of a stock-out at a local warehouse, a demand can be fulfilled via a lateral transshipment (LT). Each warehouse is assigned a pre-determined sequence of other warehouses where it will request for an LT. However, a warehouse can hold its last part(s) back from such a request. This is called a hold back pooling policy, where each warehouse has hold back levels determining whether a request for an LT by another warehouse is satisfied. We are interested in the fractions of demand satisfied from stock (fill rate), via an LT, and via an emergency procedure from an external source. From these, the average costs of a policy can be determined. We present a new approximation algorithm for the evaluation of a given policy, approximating the above mentioned fractions. Whereas algorithms currently known in the literature approximate the stream of LT requests from a warehouse by a Poisson process, we use an interrupted Poisson process. This is a process that is turned alternatingly On and Off for exponentially distributed durations. This leads to the On/Off overflow algorithm. In a numerical study we show that this algorithm is significantly more accurate than the algorithm based on Poisson processes, although it requires a longer computation time. Furthermore, we show the benefits of hold back levels, and we illustrate how our algorithm can be used in a heuristic search for the setting of the hold back levels.     

Single-manufacturer,multi-retailer consignment policy for retailers’ generalized demand distributions

Consignment policy (CP) is a novel approach to the inventory management in supply chains. It is based on strong interaction and reliable collaboration between vendor(s) and buyer(s), which is acquiring growing importance in today's industrial reality. Unlike most literature focusing on single-vendor single-buyer models and deterministic customer demand, a single-manufacturer (vendor) multi-retailer (buyer) generic model is developed under stochastic customer demand in this study. In order to understand the potential benefits of CP, it is compared with a traditional policy (TP) model developed in the similar approach. The models are tested with two scenarios of uniform and exponential demand distributions of the retailers. The results show how CP works better than the traditional uncoordinated optimization. It not only helps the manufacturer to generate higher profit, but also coordinates retailers to achieve a higher supply chain profit. At the same time, each retailer earns at least as much as they do in TP. Further price discount sensitivity analysis demonstrates the efficiency of CP when facing price-demand fluctuation.