A capacity constrained single-facility dynamic lot-size model

A computationally efficient algorithm for a multi-period single commodity production planning problem with capacity constraints is developed. The model differs from earlier well-known studies involving concave cost functions in the introduction of production capacity constraints which need not be equal in every period. The objective is to find an optimal production schedule that minimizes the total production and inventory costs. Backlogging is not allowed. The structure of the optimal solution is characterized and then used in an efficient algorithm.     

Production lot-sizing with dynamic capacity adjustment

In this paper we study a single-item lot-sizing model in which production capacity can be adjusted from time to time. There are a number of different production capacity levels available to be acquired in each period, where each capacity level is assumed to be a multiple of a base capacity unit. To reduce the waste of excess of capacity but guarantee meeting the demand, it is important to decide which level of capacity should be acquired and how many units of the item should be produced for every period in the planning horizon. Capacity adjustment cost incurs when capacity acquired in the current period differs from the one acquired in the previous period. Capacity acquisition costs, capacity adjustment costs, and production costs in each period are all time-varying and depend on the capacity level acquired in that period. Backlogging is allowed. Both production costs and inventory costs are assumed to be general concave. We provide optimal properties and develop an efficient exact algorithm for the general model. For the special cases with zero capacity adjustment costs or fixed-plus-linear production costs, we present a faster exact algorithm. Computational experiments show that our algorithm is able to solve medium-size instances for the general model in a few seconds, and that cost can be reduced significantly through flexible capacity adjustment.     

Optimal inventory threshold for a dynamic service make‐to‐stock system with strategic customers

We consider a make‐to‐stock production system with one product type, dynamic service policy, and delay‐sensitive customers. To balance the waiting cost of customers and holding cost of products, a dynamic production policy is adopted. If there is no customer waiting in the system, instead of shutting down, the system operates at a low production rate until a certain threshold of inventory is reached. If the inventory is empty and a new customer emerges, the system switches to a high production rate where the switching time is assumed to be exponentially distributed. Potential customers arrive according to the Poisson process. They are strategic in the sense that they make decisions on whether to stay for product or leave without purchase on the basis of on their utility value and the system information on whether the number of products is observable to customers or not. The strategic behavior is explored, and a Stackelberg game between production manager and customers is formulated where the former is the game leader. We find that the optimal inventory threshold minimizing the cost function can be obtained by a search algorithm. Numerical results demonstrate that the expected cost function in an observable case is not greater than that in an unobservable case. If a customer's delay sensitivity is relatively small, these two cases are entirely identical. With increasing of delay sensitivity, the optimal inventory threshold might be positive or zero, and hence, a demarcation line is depicted to determine when a make‐to‐stock policy is advantageous to the manager.     

Comparative studies on dynamic programming and integer programming approaches for concave cost production/inventory control problems

This paper is concerned with classical concave cost multi-echelon production/inventory control problems studied by W. Zangwill and others. It is well known that the problem with m production steps and n time periods can be solved by a dynamic programming algorithm in O(n ⁴ m) steps, which is considered as the fastest algorithm for solving this class of problems. In this paper, we will show that an alternative 0–1 integer programming approach can solve the same problem much faster particularly when n is large and the number of 0–1 integer variables is relatively few. This class of problems include, among others problem with set-up cost function and piecewise linear cost function with fewer linear pieces. The new approach can solve problems with mixed concave/convex cost functions, which cannot be solved by dynamic programming algorithms.     

A dynamic production planning and scheduling algorithm for two products processed on one line

This paper presents a dynamic production planning and scheduling algorithm for two products processed on one line over a fixed time horizon. Production rates are assumed fixed, and restrictions are placed or inventory levels and production run lengths. The resulting problem is a nonlinear binary program, which is solved using an implicit enumeration strategy. The algorithm focuses on the run changeover period while developing tighter bounds on the length of the upcoming run to improve computational efficiency. About 99% pf 297 randomly generated problems with varying demand patterns are solved in less than 15 seconds of CPU time on a CDC Cyber 172 Computer. A mixed integer programming formulation of the generalized multi-product case under no-backlogging of demand is also given.     

A Robust Optimization Approach to Dynamic Pricing and Inventory Control with no Backorders

In this paper, we present a robust optimization formulation for dealing with demand uncertainty in a dynamic pricing and inventory control problem for a make-to-stock manufacturing system. We consider a multi-product capacitated, dynamic setting. We introduce a demand-based fluid model where the demand is a linear function of the price, the inventory cost is linear, the production cost is an increasing strictly convex function of the production rate and all coefficients are time-dependent. A key part of the model is that no backorders are allowed. We show that the robust formulation is of the same order of complexity as the nominal problem and demonstrate how to adapt the nominal (deterministic) solution algorithm to the robust problem.     

Modelling for a dynamic inventory-production control system

The modelling of an inventory control production scheduling system is discussed. The model uses a Dynamic Programming formulation, incorporating the characteristics of the system, so that it can be used interactively by busy managers. This was achieved by a modified Wagner-Whitin algorithm and an interactive safety stock method. The microcomputer implementation of this model was tested, showing practically useful features, and resulted in substantial cost savings and increased customer service.     

考虑机器调整次数和产品质量的卷烟批量计划和柔性流水车间调度集成问题

针对卷烟企业生产中的批量计划和柔性流水车间调度集成问题,构建了整数规划模型,目标函数由卷烟生产时间、生产线调整次数、卷烟质量、库存成本四部分组成。鉴于该问题的NP-hard性,设计遗传算法进行求解,通过合理设计遗传算子,避免不可行解出现。应用某卷烟企业数据得到优化排产结果,与该企业之前依照经验排产方案进行对比,发现优化排程结果在减少品牌转换次数,提高生产的连续性方面具有明显优势。该算法已作为某卷烟企业排产人员的排产参考,应用于排产决策中,取得了良好的效果,对卷烟企业制定排产计划具有一定的实际指导意义。     

A forward algorithm and planning horizon procedure for the production smoothing problem without inventory

We develop a forward algorithm for solving and finding planning horizons for the infinite horizon version of the deterministic production smoothing problem without inventory. This model approximates the real world situation for highly obsolescent or perishable commodities such as newspapers and fresh produce. Computational results show that the algorithm is linear in problem length while linear programming is at least quadratic.     

Strong planning and forecast horizons for a model with simultaneous price and production decisions

In this paper, we have solved a general inventory model with simultaneous price and production decisions. Both linear and non-linear (strictly convex) production cost cases are treated. Upper and lower bounds are imposed on state as well as control variables. The problem is solved by using the Lagrangian form of the maximum principle. Strong planning and strong forecast horizons are obtained. These arise when the state variable reaches its upper or lower bound. The existence of these horizons permits the decomposition of the whole problem into a set of smaller problems, which can be solved separately, and their solutions put together to form a complete solution to the problem. Finally, we derive a forward branch and bound algorithm to solve the problem. The algorithm is illustrated with a simple example.     

A linear programming embedded genetic algorithm for an integrated cell formation and lot sizing considering product quality

Production lot sizing models are often used to decide the best lot size to minimize operation cost, inventory cost, and setup cost. Cellular manufacturing analyses mainly address how machines should be grouped and parts be produced. In this paper, a mathematical programming model is developed following an integrated approach for cell configuration and lot sizing in a dynamic manufacturing environment. The model development also considers the impact of lot sizes on product quality. Solution of the mathematical model is to minimize both production and quality related costs. The proposed model, with nonlinear terms and integer variables, cannot be solved for real size problems efficiently due to its NP-complexity. To solve the model for practical purposes, a linear programming embedded genetic algorithm was developed. The algorithm searches over the integer variables and for each integer solution visited the corresponding values of the continuous variables are determined by solving a linear programming subproblem using the simplex algorithm. Numerical examples showed that the proposed method is efficient and effective in searching for near optimal solutions.     

A Chebyshev approximation for solving the optimal production inventory problem of deteriorating multi-item

In this paper, some realistic multi-period production–inventory models are formulated for deteriorating items with known dynamic demands for optimal productions. Here, the rates of production are time dependent (quadratic/linear) or constant expressed by a Chebyshev polynomial and considered as a control variable. The models are solved using Chebyshev spectral approximations, the El-Hawary technique and a genetic algorithm (GA). The models have been illustrated by numerical data. The optimum results for different production functions are presented in both tabular and graphical forms.     

Analysis of deteriorating inventory/production systems using a linear quadratic regulator

We consider an inventory-production system where items deteriorate at a constant rate. The objective is to develop an optimal production policy that minimizes the cost associated with inventory and production rate. The inventory problem is first modeled as a linear optimal control problem. Then linear quadratic regulator (LQR) technique is applied to the control problem in order to determine the optimal production policy. Examples are solved for three different demand functions. Sensitivity analysis is then conducted to study the effect of changing the cost parameters on the objective function.     

A hybrid optimization approach for multi-level capacitated lot-sizing problems

Solving multi-level capacitated lot-sizing problems is still a challenging task, in spite of increasing computational power and faster algorithms. In this paper a new approach combining an ant-based algorithm with an exact solver for (mixed-integer) linear programs is presented. A MAX–MIN ant system is developed to determine the principal production decisions, a LP/MIP solver is used to calculate the corresponding production quantities and inventory levels. Two different local search methods and an improvement strategy based on reduced mixed-integer problems are developed and integrated into the ant algorithm. This hybrid approach provides superior results for small and medium-sized problems in comparison to the existing approaches in the literature. For large-scale problems the performance of this method is among the best.     

上升线性需求条件下考虑资金时间价值的变质性物品生产库存模型

变质性物品生产库存系统的研究具有重要实际意义.本文研究了变质性物品生产库存系统在上升趋势线性需求条件下,考虑资金的时间价值,在有限计划时间水平内,如何确定最优生产周期,各周期最优生产率,以及最优库存安排策略.通过本文的研究,得到了一些有用的结论.     

基于随机动态规划的有限库存ATO系统优化控制

本文研究n维组件单一产品,有限库存的ATO系统。通过建立马尔可夫决策过程模型(MDP),构造优化算法,研究组件生产与库存的最优控制策略。最优策路可以表示为状态依赖型库存阈值,系统内任一组件的控制策略受其它组件库存状态的影响。利用最优控制理论动态规划方法和数值计算方法对最优控制策略的存在性、最优值的数值计算进行研究,建立更符合实际生产的ATO系统决策模型,进行相应的理论和实验验证,研究系统参数对最优策略的影响。     

成品油调和配方优化研究

成品油调和是石油炼制过程中的重要环节,直接影响炼油企业的经济效益。本文以石化行业为背景,针对成品油调和配方优化问题进行了研究,在满足成品油质量指标约束的条件下,以最小化企业生产成本为目标,建立了混合整数规划模型,提出了基于遗传算法的有效求解策略,并根据某炼油厂的实际生产数据进行了仿真实验,计算结果反映了库存成本与启动成本之间的平衡关系,即:当单位库存成本不变,单位启动成本逐渐变大时,库存总成本随之增大,启动次数随之减少。反之,当单位启动成本不变,单位库存成本逐渐变大时,启动次数随之增大,库存总成本随之减少。     

Direct shipping and the dynamic single-depot/multi-retailer inventory system

In this paper we study a single-depot/multi-retailer system with independent stochastic stationary demands, linear inventory costs, and backlogging at the retailers over an infinite horizon. In addition, we also consider the transportation cost between the depot and the retailers. Orders are placed each period by the depot. The orders arrive at the depot and are allocated and delivered to the retailers. No inventory is held at the depot. We consider a specific policy of direct shipments. That is, a lower bound on the long run average cost per period for the system over all order/delivery strategies is developed. The simulated long term average cost per period of the delivery strategy of direct shipping with fully loaded trucks is examined via comparison to the derived lower bound. Simulation studies demonstrate that very good results can be achieved by a direct shipping policy.     

An interactive method for inventory control with fuzzy lead-time and dynamic demand

Normally, the real-world inventory control problems are imprecisely defined and human interventions are often required to solve these decision-making problems. In this paper, a realistic inventory model with imprecise demand, lead-time and inventory costs have been formulated and an inventory policy is proposed to minimize the cost using man–machine interaction. Here, demand increases with time at a decreasing rate. The imprecise parameters of lead-time, inventory costs and demand are expressed through linear/non-linear membership functions. These are represented by different types of membership functions, linear or quadratic, depending upon the prevailing supply condition and marketing environment. The imprecise parameters are first transformed into corresponding interval numbers and then following the interval mathematics, the objective function for average cost is changed into respective multi-objective functions. These functions are minimized and solved for a Pareto-optimum solution by interactive fuzzy decision-making procedure. This process leads to man–machine interaction for optimum and appropriate decision acceptable to the decision maker’s firm. The model is illustrated numerically and the results are presented in tabular forms.     

A dynamic inventory model with supplier selection in a serial supply chain structure

Considering the inherent connection between supplier selection and inventory management in supply chain networks, this article presents a multi-period inventory lot-sizing model for a single product in a serial supply chain, where raw materials are purchased from multiple suppliers at the first stage and external demand occurs at the last stage. The demand is known and may change from period to period. The stages of this production–distribution serial structure correspond to inventory locations. The first two stages stand for storage areas for raw materials and finished products in a manufacturing facility, and the remaining stages symbolize distribution centers or warehouses that take the product closer to customers. The problem is modeled as a time-expanded transshipment network, which is defined by the nodes and arcs that can be reached by feasible material flows. A mixed integer nonlinear programming model is developed to determine an optimal inventory policy that coordinates the transfer of materials between consecutive stages of the supply chain from period to period while properly placing purchasing orders to selected suppliers and satisfying customer demand on time. The proposed model minimizes the total variable cost, including purchasing, production, inventory, and transportation costs. The model can be linearized for certain types of cost structures. In addition, two continuous and concave approximations of the transportation cost function are provided to simplify the model and reduce its computational time.