Performance evaluation of distribution strategies for the inventory routing problem

Direct shipping strategy is an easy-to-implement distribution strategy frequently used in industrial distribution systems. In this paper, an analytic method is developed for performance evaluation of the strategy for the infinite horizon inventory routing problem with delivery frequency constraint. With the method, the effectiveness of direct shipping strategy can be represented as a function of some system parameters. We demonstrate that the effectiveness of direct shipping is at least the square root of the smallest utilization ratio of vehicle capacity. This implies that the effectiveness of the strategy can reach 100% (respectively, 94.86%) whenever the demand rate of each retailer is 100% (respectively, 90%) of the vehicle capacity multiplied by the upper bound of the delivery frequency. This insight can help a firm answer questions such as: under what conditions direct shipping strategy is effective and why, and how effective the strategy is under a specific condition? In case direct shipping strategy is proven ineffective, a more general Fixed Partition Policy (FPP) that combines direct shipping strategy and multiple-stop shipping strategy must be used. An analytic method is also developed for performance evaluation of general FPPs. We demonstrate that the effectiveness of an FPP depends on the total demand rate of the retailers in each partition (each retailer set) and their closeness level. This insight provides a useful guideline to the design of effective FPPs. The analytic methods make the performance improvement of a distribution system possible through adjusting its system parameters.     

A partition approach to the inventory/routing problem

In this study we focus on the integration of inventory control and vehicle routing schedules for a distribution system in which the warehouse is responsible for the replenishment of a single item to the retailers with demands occurring at a specific constant (but retailer-dependent) rate, combining deliveries into efficient routes. This research proposes a fixed partition policy for this type of problem, in which the replenishment interval of each of the retailers’ partition region as well as the warehouse is accorded the power of two (POT) principle. A lower bound of the long-run average cost of any feasible strategy for the considered distribution system is drawn. And a tabu search algorithm is designed to find the retailers’ optimal partition regions under the fixed partition policy proposed. Computational results reveal the effectiveness of the policy as well as of the algorithm.     

A new model and hybrid approach for large scale inventory routing problems

This paper studies an inventory routing problem (IRP) with split delivery and vehicle fleet size constraint. Due to the complexity of the IRP, it is very difficult to develop an exact algorithm that can solve large scale problems in a reasonable computation time. As an alternative, an approximate approach that can quickly and near-optimally solve the problem is developed based on an approximate model of the problem and Lagrangian relaxation. In the approach, the model is solved by using a Lagrangian relaxation method in which the relaxed problem is decomposed into an inventory problem and a routing problem that are solved by a linear programming algorithm and a minimum cost flow algorithm, respectively, and the dual problem is solved by using the surrogate subgradient method. The solution of the model obtained by the Lagrangian relaxation method is used to construct a near-optimal solution of the IRP by solving a series of assignment problems. Numerical experiments show that the proposed hybrid approach can find a high quality near-optimal solution for the IRP with up to 200 customers in a reasonable computation time.     

A practical solution approach for the cyclic inventory routing problem

Vendor managed inventory (VMI) is an example of effective cooperation and partnering practices between up- and downstream stages in a supply chain. In VMI, the supplier takes the responsibility for replenishing his customers’ inventories based on their consumption data, with the aim of optimizing the over all distribution and inventory costs throughout the supply chain. This paper discusses the challenging optimization problem that arises in this context, known as the inventory routing problem (IRP). The objective of this IRP problem is to determine a distribution plan that minimizes average distribution and inventory costs without causing any stock-out at the customers. Deterministic constant customer demand rates are assumed and therefore, a long-term cyclical approach is adopted, integrating fleet sizing, vehicle routing, and inventory management. Further, realistic side-constraints such as limited storage capacities, driving time restrictions and constant replenishment intervals are taken into account. A heuristic solution approach is proposed, analyzed and evaluated against a comparable state-of-the-art heuristic.     

A sample-path approach to the optimality of echelon order-up-to policies in serial inventory systems

We present a new proof of the optimality of echelon order-up-to policies in serial inventory systems, first proved by Clark and Scarf. Our proof is based on a sample-path analysis as opposed to the original proof based on dynamic programming induction.     

Hybrid heuristics for a short sea inventory routing problem

We consider a short sea fuel oil distribution problem where an oil company is responsible for the routing and scheduling of ships between ports such that the demand for various fuel oil products is satisfied during the planning horizon. The inventory management has to be considered at the demand side only, and the consumption rates are given and assumed to be constant within the planning horizon. The objective is to determine distribution policies that minimize the routing and operating costs, while the inventory levels are maintained within their limits. We propose an arc-load flow formulation for the problem which is tightened with valid inequalities. In order to obtain good feasible solutions for planning horizons of several months, we compare different hybridization strategies. Computational results are reported for real small-size instances.     

CLOVES: A cluster-and-search heuristic to solve the vehicle routing problem with delivery and pick-up

This paper addresses the vehicle routing problem with sequence-constrained delivery and pick-up (VRPDP). We propose a multi-phase constructive heuristic that clusters nodes based on proximity, orients them along a route using shrink-wrap algorithm and allots vehicles using generalized assignment procedure. We employ genetic algorithm for an intensive final search. Trials on a large number of test-problems have yielded encouraging results.     

A simulation optimization approach for a two-echelon inventory system with service level constraints

In this paper, we present a simulation optimization algorithm for solving the two-echelon constrained inventory problem. The goal is to determine the optimal setting of stocking levels to minimize the total inventory investment costs while satisfying the expected response time targets for each field depot. The proposed algorithm is more adaptive than ordinary optimization algorithms, and can be applied to any multi-item multi-echelon inventory system, where the cost structure and service level function resemble what we assume. Empirical studies are performed to compare the efficiency of the proposed algorithms with other existing simulation algorithms.     

New models and algorithms for the cyclic inventory routing problem

This is a summary of the author’s PhD thesis supervised by El-Houssaine Aghezzaf and defended on 4 December 2006 at the Universiteit Gent. The thesis is written in English and is electronically available from http://ir18.ugent.be/birger.raa/. This work studies the problem of finding optimal three-way cost trade-offs between vehicle fleet costs, distribution costs and holding costs in the cyclic replenishment of a set of customers with constant demand rates from a single depot.      

An integrated guaranteed- and stochastic-service approach to inventory optimization in supply chains

Multi-echelon inventory optimization literature distinguishes stochastic- (SS) and guaranteed-service (GS) approaches as mutually exclusive frameworks. While the GS approach considers flexibility measures at the stages to deal with stockouts, the SS approach only relies on safety stock. Within a supply chain, flexibility levels might differ between stages rendering them appropriate candidates for one approach or the other. The existing approaches, however, require the selection of a single framework for the entire supply chain instead of a stage-wise choice. We develop an integrated hybrid-service (HS) approach which endogenously determines the overall cost-optimal approach for each stage and computes the required inventory levels. We present a dynamic programming optimization algorithm for serial supply chains that partitions the entire system into subchains of different types. From a numerical study we find that, besides implicitly choosing the better of the two pure frameworks, whose cost differences can be considerable, the HS approach enables additional pipeline and on-hand stock cost savings. We further identify drivers for the preferability of the HS approach.     

A queuing approach for inventory planning with batch ordering in multi-echelon supply chains

This paper presents stylized models for conducting performance analysis of the manufacturing supply chain network (SCN) in a stochastic setting for batch ordering. We use queueing models to capture the behavior of SCN. The analysis is clubbed with an inventory optimization model, which can be used for designing inventory policies . In the first case, we model one manufacturer with one warehouse, which supplies to various retailers. We determine the optimal inventory level at the warehouse that minimizes total expected cost of carrying inventory, back order cost associated with serving orders in the backlog queue, and ordering cost. In the second model we impose service level constraint in terms of fill rate (probability an order is filled from stock at warehouse), assuming that customers do not balk from the system. We present several numerical examples to illustrate the model and to illustrate its various features. In the third case, we extend the model to a three-echelon inventory model which explicitly considers the logistics process.     

A memetic algorithm with dynamic population management for an integrated production–distribution problem

This paper studies an NP-hard multi-period production–distribution problem to minimize the sum of three costs: production setups, inventories and distribution. This problem is solved by a very recent form of metaheuristic called memetic algorithm with population management (MA∣PM). Contrary to classical two-phase methods (production planning, then distribution planning), the algorithm simultaneously tackles production and distribution decisions. Several versions with different population management strategies are evaluated and compared with a two-phase heuristic and a Greedy Randomized Adaptive Search Procedure (GRASP), on 90 randomly generated instances with 20 periods and 50, 100 or 200 customers. The significant savings obtained compared to the two other methods confirm both the interest of integrating production and distribution decisions and of using the MA∣PM template.     

An iterated local search algorithm for the single-vehicle cyclic inventory routing problem

The Single-Vehicle Cyclic Inventory Routing Problem (SV-CIRP) belongs to the class of Inventory Routing Problems (IRP) in which the supplier optimises both the distribution costs and the inventory costs at the customers. The goal of the SV-CIRP is to minimise both kinds of costs and to maximise the collected rewards, by selecting a subset of customers from a given set and determining the quantity to be delivered to each customer and the vehicle routes, while avoiding stockouts. A cyclic distribution plan should be developed for a single vehicle.     

Stochastic leadtimes in a one-warehouse,N-retailer inventory system with the warehouse not carrying stock

This study extends upon a multi-echelon inventory model developed by Graves, introducing in the one-warehouse, N-retailer case—as Graves suggested—stochastic leadtimes between the warehouse and the retail sites in place of the original deterministic leadtimes. Effects of stochastic leadtimes on required base stock levels at the retail sites in the case where the warehouse carries no stock (e.g., serves as a cross-dock point) were investigated analytically. Two alternative treatments of stochastic leadtime distributions were considered. Using as a baseline Graves’ computational study under deterministic leadtimes, results of the current study suggest that it may be better to use the deterministic model with an accurately estimated mean leadtime than a stochastic model with a poorly estimated mean leadtime.     

Efficient computation of time-based customer service levels in a multi-item, multi-echelon supply chain: A practical approach for inventory optimization

Time-based item fill rates, or “channel” fill rates, are the building blocks needed to evaluate steady-state compliance with time-based customer service agreements. Exact computation of channel fill rates is both difficult and time-consuming, yet their accurate assessment is essential for system-wide inventory optimization. We describe and validate a practical method for computing channel fill rates in a multi-item, multi-echelon service parts distribution system. A simulation study is presented which shows that, in a three-echelon setting, our estimation errors are very small over a wide range of base stock level vectors. A more accurate, though less efficient, approximation method is also evaluated for comparison.     

A computational comparison of algorithms for the inventory routing problem

The inventory routing problem is a distribution problem in which each customer maintains a local inventory of a product such as heating oil and consumes a certain amount of that product each day. Each day a fleet of trucks is dispatched over a set of routes to resupply a subset of the customers. In this paper, we describe and compare algorithms for this problem defined over a short planning period, e.g. one week. These algorithms define the set of customers to be serviced each day and produce routes for a fleet of vehicles to service those customers. Two algorithms are compared in detail, one which first allocates deliveries to days and then solves a vehicle routing problem and a second which treats the multi-day problem as a modified vehicle routing problem. The comparison is based on a set of real data obtained from a propane distribution firm in Pennsylvania. The solutions obtained by both procedures compare quite favorably with those in use by the firm.Part of this work was performed while this author was visiting the University of Waterloo.     

Improved approximation for the capacitated inventory access point problem

The Inventory Access Point (IAP) is the single-item lot-sizing problem where a single customer faces demands in a discrete planning horizon, and the goal is to find a replenishment policy that minimizes the total inventory and ordering costs. While the uncapacitated version is polynomial, only a 3-approximation is known for the capacitated case. We improve this factor to 2.619 and, as a byproduct, we also improve the best factor for SIRPFL, which is a variant with multiple depots and customers.     

An exact static solution approach for the service parts end-of-life inventory problem

This paper studies the spare parts end-of-life inventory problem that happens after the discontinuation of part production. A final ordering quantity is set such that the service process is sustained until all service obligations expire. Also, the price erosion of substitutable or new generation products over time makes it economically justifiable to consider switching to an alternative service policy for repair such as swapping the old product with a new one. This requires the joint optimization of the final order quantity and the time to switch from repair to an alternative service policy. To the best of our knowledge, the problem has not been optimally solved yet either in its static or dynamic formulation. In the current paper, we solve its static version as a bi-level optimization problem. We investigate the convexity of the objective function and give a computationally efficient algorithm to find an exact optimal solution up to any given numerical error level ??>?0. We illustrate our approach on some numerical examples and compare our results with earlier works on this problem.     

Analysis of a two-echelon inventory system with two supply modes

In this paper, we consider a serial two-echelon periodic review inventory system with two supply modes at the most upstream stock point. As control policy for this system, we propose a natural extension of the dual-index policy, which has three base-stock levels. We consider the minimization of long run average inventory holding, backlogging, and both per unit and fixed emergency ordering costs. We provide nested newsboy characterizations for two of the three base-stock levels involved and show a separability result for the difference with the remaining base-stock level. We extend results for the single-echelon system to efficiently approximate the distributions of random variables involved in the newsboy equations and find an asymptotically correct approximation for both the per unit and fixed emergency ordering costs. Based on these results, we provide an algorithm for setting base-stock levels in a computationally efficient manner. In a numerical study, we investigate the value of dual-sourcing in supply chains and illustrate that dual-sourcing can lead to significant cost savings in cases with high demand uncertainty, high backlogging cost or long lead times.     

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.