On the equivalence of strong formulations for capacitated multi-level lot sizing problems with setup times

Several mixed integer programming formulations have been proposed for modeling capacitated multi-level lot sizing problems with setup times. These formulations include the so-called facility location formulation, the shortest route formulation, and the inventory and lot sizing formulation with (?, S) inequalities. In this paper, we demonstrate the equivalence of these formulations when the integrality requirement is relaxed for any subset of binary setup decision variables. This equivalence has significant implications for decomposition-based methods since same optimal solution values are obtained no matter which formulation is used. In particular, we discuss the relax-and-fix method, a decomposition-based heuristic used for the efficient solution of hard lot sizing problems. Computational tests allow us to compare the effectiveness of different formulations using benchmark problems. The choice of formulation directly affects the required computational effort, and our results therefore provide guidelines on choosing an effective formulation during the development of heuristic-based solution procedures.     

Facets and algorithms for capacitated lot sizing

The dynamic economic lot sizing model, which lies at the core of numerous production planning applications, is one of the most highly studied models in all of operations research. And yet, capacitated multi-item versions of this problem remain computationally elusive. We study the polyhedral structure of an integer programming formulation of a single-item capacitated version of this problem, and use these results to develop solution methods for multi-item applications. In particular, we introduce a set of valid inequalities for the problem and show that they define facets of the underlying integer programming polyhedron. Computational results on several single and multiple product examples show that these inequalities can be used quite effectively to develop an efficient cutting plane/branch and bound procedure. Moreover, our results show that in many instances adding certain of these inequalities a priori to the problem formulation, and avoiding the generation of cutting planes, can be equally effective.Supported by Grant #ECS-8316224 from the Systems Theory and Operations Research Program of the National Science Foundation.     

GRASP heuristic with path-relinking for the multi-plant capacitated lot sizing problem

This paper addresses the independent multi-plant, multi-period, and multi-item capacitated lot sizing problem where transfers between the plants are allowed. This is an NP-hard combinatorial optimization problem and few solution methods have been proposed to solve it. We develop a GRASP (Greedy Randomized Adaptive Search Procedure) heuristic as well as a path-relinking intensification procedure to find cost-effective solutions for this problem. In addition, the proposed heuristics is used to solve some instances of the capacitated lot sizing problem with parallel machines. The results of the computational tests show that the proposed heuristics outperform other heuristics previously described in the literature. The results are confirmed by statistical tests.     

Hybrid heuristics for the multi-stage capacitated lot sizing and loading problem

The multi-stage capacitated lot sizing and loading problem (MCLSLP) deals with the issue of determining the lot sizes of product items in serially-arranged manufacturing stages and loading them on parallel facilities in each stage to satisfy dynamic demand over a given planning horizon. It is assumed that regular time capacity decisions have already been made in the tactical level and allocated to the stages, but it is still an important decision problem whether to augment regular time capacity by overtime capacity. Each item may be processed on a technologically feasible subset of existing facilities with different process and setup times on each facility. Since the solution of the MCLSLP requires the design of a powerful algorithm, simulated annealing (SA) and genetic algorithms (GA) are integrated to enhance their individual performances. Furthermore, these global optimisation methods are incorporated into a Lagrangean relaxation scheme, hence creating a hybrid solution methodology. Numerical results obtained using these methods confirm the mutual benefits of integrating different solution techniques.     

Improved lower bounds for the capacitated lot sizing problem with setup times

We present new lower bounds for the capacitated lot sizing problem, applying decomposition to the network reformulation. The demand constraints are the linking constraints and the problem decomposes into subproblems per period containing the capacity and setup constraints. Computational results and a comparison to other lower bounds are presented.     

A dynamic lot sizing model with exponential machine breakdowns

This paper addresses the dynamic lot sizing model with the assumption that the equipment is subject to stochastic breakdowns. We consider two different situations. First we assume that after a machine breakdown the setup is totally lost and new setup cost is incurred. Second we consider the situation in which the cost of resuming the production run after a failure might be substantially lower than the production setup cost. We show that under the first assumption the cost penalty for ignoring machine failures will be noticeably higher than in the classical lot sizing case with static demand. For the second case, two lot sizes per period are required, an ordinary lot size and a specific second (or resumption) lot size. If during the production of a future period demand the production quantity exceeds the second lot size, the production run will be resumed after a breakdown and terminated if the amount produced is less than this lot size. Considering the results of the static lot sizing case, one would expect a different policy. To find an optimum lot sizing decision for both cases a stochastic dynamic programming model is suggested.     

Economic lot sizing: The capacity reservation model

Capacity reservation contracts allow a consumer to purchase up to a certain capacity at a unit price lower than that of the spot market, while the consumer’s excess orders are realized at the spot price. In this paper, we consider a lot sizing problem where the consumer places orders following a capacity reservation contract. In particular, we study the general problem and the polynomial time solvable special cases of the problem and propose corresponding algorithms for them.     

Inventory replenishment model: lot sizing versus just-in-time delivery

Motivated by a practical industrial problem where a manufacturer stipulates a minimum order from each buyer but where a local dealer promises the buyer a just-in-time delivery with a slightly higher unit cost, this paper uses a dynamic lot-sizing model with a stepwise cargo cost function and a minimum order amount constraint to help the buyer select the supplier with minimum total cost.     

Hybrid heuristics for the capacitated lot sizing and loading problem with setup times and overtime decisions

The capacitated lot sizing and loading problem (CLSLP) deals with the issue of determining the lot sizes of product families/end items and loading them on parallel facilities to satisfy dynamic demand over a given planning horizon. The capacity restrictions in the CLSLP are imposed by constraints specific to the production environment considered. When a lot size is positive in a specific period, it is loaded on a facility without exceeding the sum of the regular and overtime capacity limits. Each family may have a different process time on each facility and furthermore, it may be technologically feasible to load a family only on a subset of existing facilities. So, in the most general case, the loading problem may involve unrelated parallel facilities of different classes. Once loaded on a facility, a family may consume capacity during setup time. Inventory holding and overtime costs are minimized in the objective function. Setup costs can be included if setups incur costs other than lost production capacity. The CLSLP is relevant in many industrial applications and may be generalized to multi-stage production planning and loading models. The CLSLP is a synthesis of three different planning and loading problems, i.e., the capacitated lot sizing problem (CLSP) with overtime decisions and setup times, minimizing total tardiness on unrelated parallel processors, and, the class scheduling problem, each of which is NP in the feasibility and optimality problems. Consequently, we develop hybrid heuristics involving powerful search techniques such as simulated annealing (SA), tabu search (TS) and genetic algorithms (GA) to deal with the CLSLP. Results are compared with optimal solutions for 108 randomly generated small test problems. The procedures developed here are also compared against each other in 36 larger size problems.     

A joint optimal pricing,rebate value,and lot sizing model

Delayed incentives in the form of mail-in cash rebates are very popular among manufacturers, and more recently, among retailers. One of the main advantages of rebates is that while they increase demand, a small proportion of consumers redeem them. In this paper, we formulate and solve models for jointly determining the optimal price, rebate face value, and the optimal order quantity for a price and rebate sensitive deterministic demand. The models show that under realistic conditions, offering rebates can have significant pricing and inventory policy implications and can lead to a significant increase in profit.     

A polynomial time algorithm to solve the single-item capacitated lot sizing problem with minimum order quantities and concave costs

This paper deals with the single-item capacitated lot sizing problem with concave production and storage costs, and minimum order quantity (CLSP-MOQ). In this problem, a demand must be satisfied at each period t over a planning horizon of T periods. This demand can be satisfied from the stock or by a production at the same period. When a production is made at period t, the produced quantity must be greater to than a minimum order quantity (L) and lesser than the production capacity (U). To solve this problem optimally, a polynomial time algorithm in O(T⁵) is proposed and it is computationally tested on various instances.     

A new dynamic programming algorithm for the single item capacitated dynamic lot size model

We develop a new dynamic programming method for the single item capacitated dynamic lot size model with non-negative demands and no backlogging. This approach builds the Optimal value function in piecewise linear segments. It works very well on the test problems, requiring less than 0.3 seconds to solve problems with 48 periods on a VAX 8600. Problems with the time horizon up to 768 periods are solved. Empirically, the computing effort increases only at a quadratic rate relative to the number of periods in the time horizon.This research was supported in part by NSF grants DDM-8814075 and DMC-8504786.     

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.     

An integrated model for lot sizing with supplier selection and quantity discounts

Good inventory management is essential for a firm to be cost competitive and to acquire decent profit in the market, and how to achieve an outstanding inventory management has been a popular topic in both the academic field and in real practice for decades. As the production environment getting increasingly complex, various kinds of mathematical models have been developed, such as linear programming, nonlinear programming, mixed integer programming, geometric programming, gradient-based nonlinear programming and dynamic programming, to name a few. However, when the problem becomes NP-hard, heuristics tools may be necessary to solve the problem. In this paper, a mixed integer programming (MIP) model is constructed first to solve the lot-sizing problem with multiple suppliers, multiple periods and quantity discounts. An efficient Genetic Algorithm (GA) is proposed next to tackle the problem when it becomes too complicated. The objectives are to minimize total costs, where the costs include ordering cost, holding cost, purchase cost and transportation cost, under the requirement that no inventory shortage is allowed in the system, and to determine an appropriate inventory level for each planning period. The results demonstrate that the proposed GA model is an effective and accurate tool for determining the replenishment for a manufacturer for multi-periods.     

An O(T) algorithm for the capacitated lot sizing problem with minimum order quantities

This paper explores a single-item capacitated lot sizing problem with minimum order quantity, which plays the role of minor set-up cost. We work out the necessary and sufficient solvability conditions and apply the general dynamic programming technique to develop an O(T³) exact algorithm that is based on the concept of minimal sub-problems. An investigation of the properties of the optimal solution structure allows us to construct explicit solutions to the obtained sub-problems and prove their optimality. In this way, we reduce the complexity of the algorithm considerably and confirm its efficiency in an extensive computational study.     

Economic lot sizing problem with inventory bounds

This paper studies a economic lot sizing (ELS) problem with both upper and lower inventory bounds. Bounded ELS models address inventory control problems with time-varying inventory capacity and safety stock constraints. An O(n²) algorithm is found by using net cumulative demand (NCD) to measure the amount of replenishment requested to fulfill the cumulative demand till the end of the planning horizon. An O(n) algorithm is found for the special case, the bounded ELS problem with non-increasing marginal production cost.     

Optimal lot sizing with unreliable production system

The classical lot sizing model deals with economic lot sizing for production in a deterministic framework. In real life, various forms of uncertainty affect the production. These include machine breakdown, quality variations, and so on. This paper develops a model with unreliable production systems and under alternative repair option strategies.     

Worst case performance for lot sizing heuristics

We are considering the dynamic lot size problem without backlogging. The worst case performance of three heuristics is analyzed. There is no bound for the worst case behaviour of the Silver-Meal algorithm. The other two algorithms considered are both in the worst possible case giving a cost which is twice the optimal one.