Optimisation of integrated reverse logistics networks with different product recovery routes

The awareness of importance of product recovery has grown swiftly in the past few decades. This paper focuses on a problem of inventory control and production planning optimisation of a generic type of an integrated Reverse Logistics (RL) network which consists of a traditional forward production route, two alternative recovery routes, including repair and remanufacturing and a disposal route. It is assumed that demand and return quantities are uncertain. A quality level is assigned to each of the returned products. Due to uncertainty in the return quantity, quantity of returned products of a certain quality level is uncertain too. The uncertainties are modelled using fuzzy trapezoidal numbers. Quality thresholds are used to segregate the returned products into repair, remanufacturing or disposal routes. A two phase fuzzy mixed integer optimisation algorithm is developed to provide a solution to the inventory control and production planning problem. In Phase 1, uncertainties in quantity of product returns and quality of returns are considered to calculate the quantities to be sent to different recovery routes. These outputs are inputs into Phase 2 which generates decisions on component procurement, production, repair and disassembly. Finally, numerical experiments and sensitivity analysis are carried out to better understand the effects of quality of returns and RL network parameters on the network performance. These parameters include quantity of returned products, unit repair costs, unit production cost, setup costs and unit disposal cost.     

Sensitivity analysis of the newsvendor model

Quality of decisions in inventory management models depends on the accuracy of parameter estimates used for decision making. In many situations, error in decision making is unavoidable. In such cases, sensitivity analysis is necessary for better implementation of the model. Though the newsvendor model is one of the most researched inventory models, little is known about its robustness. In this paper, we perform sensitivity analysis of the classical newsvendor model. Conditions for symmetry/skewness of cost deviation (i.e., deviation of expected demand–supply mismatch cost from its minimum) have been identified. These conditions are closely linked with symmetry/skewness of the demand density function. A lower bound of cost deviation is established for symmetric unimodal demand distributions. Based on demonstrations of the lower bound, we found the newsvendor model to be sensitive to sub-optimal ordering decisions, more sensitive than the economic order quantity model. Order quantity deviation (i.e., deviation of order quantity from its optimum) is explored briefly. We found the magnitude of order quantity deviation to be comparable with that of parameter estimation error. Mean demand is identified as the most influential parameter in deciding order quantity deviation.     

A Bayesian Approach to Estimating Decision Parameters in a Replacement Inventory System

This paper deals with the estimation of decision parameters in a special class of inventory systems in which the rate of stock depletion depends on the internal operations of the parent organization instead of market demands. Stocking decisions for this type of inventory systems are unique in that demands for the stocked items are internal demands, sporadic in some instances, infrequent in others, and almost never the direct results of conscious economic decisions. To cope with the peculiar situation, Bayesian point and interval estimation procedures are used. The estimated probability measures provide a basis on which stocking decisions pertinent to this type of inventory systems can be made or evaluated. Specific statistical postulates are made, and a numerical example is given for illustration. The possibility of applying the estimated results to one of the existing inventory models is briefly discussed at the end.     

On the impact of suboptimal decisions in the newsvendor model

We study the impact of suboptimal decisions in the newsvendor model, one of the popular inventory models. We establish a lower bound for the deviation of inventory cost from its minimum, when the order quantity is suboptimal. Demonstration of the bound shows the model to be sensitive to suboptimal decisions.     

Optimal inventory policies for profit maximizing EOQ models under various cost functions

In this paper, we establish and analyze three EOQ based inventory models under profit maximization via geometric programming (GP) techniques. Through GP, we find optimal order quantity and price for each of these models considering production (lot sizing) as well as marketing (pricing) decisions. We also investigate the effects on the changes in the optimal solutions when different parameters are changed. In addition, a comparative analysis between the profit maximization models is conducted. By investigating the error in the optimal price, order quantity, and profit of these models, several interesting economic implications and insights can be observed.     

Robust economic order quantity models

In this paper, we study the classical economic order quantity (EOQ) model under significant. In particular, the problem under consideration is the economic order quantity model with the input data of the demand rate, the order cost, and the holding cost rate being uncertain. A robustness approach based on scenario characterization of the input data is adopted to describe the uncertainties. The aim of the approach is to find an inventory policy that performs well under all realizable input data scenarios. An efficient linear time algorithm is devised to find the robust decisions. Analytical results are obtained for the case where input data are defined in continuous intervals. Comparisons on performances between the robust decisions and the stochastic optimization decisions are conducted. The results demonstrate the advantages of robustness approach.     

A stochastic model for joint spare parts inventory and planned maintenance optimisation

Spare parts demands are usually generated by the need of maintenance either preventively or at failures. These demands are difficult to predict based on historical data of past spare parts usages, and therefore, the optimal inventory control policy may be also difficult to obtain. However, it is well known that maintenance costs are related to the availability of spare parts and the penalty cost of unavailable spare parts consists of usually the cost of, for example, extended downtime for waiting the spare parts and the emergency expedition cost for acquiring the spare parts. On the other hand, proper planned maintenance intervention can reduce the number of failures and associated costs but its performance also depends on the availability of spare parts. This paper presents the joint optimisation for both the inventory control of the spare parts and the Preventive Maintenance (PM) inspection interval. The decision variables are the order interval, PM interval and order quantity. Because of the random nature of plant failures, stochastic cost models for spare parts inventory and maintenance are derived and an enumeration algorithm with stochastic dynamic programming is employed for finding the joint optimal solutions over a finite time horizon. The delay-time concept developed for inspection modelling is used to construct the probabilities of the number of failures and the number of the defective items identified at a PM epoch, which has not been used in this type of problems before. The inventory model follows a periodic review policy but with the demand governed by the need for spare parts due to maintenance. We demonstrate the developed model using a numerical example.     

Optimal inventory policies under decreasing cost functions via geometric programming

In this paper, we establish and analyze two economic order quantity (EOQ) based inventory models under total cost minimization and profit maximization via geometric programming (GP) techniques. Through GP, optimal solutions for both models are found and managerial implications on the optimal policy are determined through bounding and sensitivity analysis. We investigate the effects on the changes in the optimal order quantity and the demand per unit time according to varied parameters by studying optimality conditions. In addition, a comparative analysis between the total cost minimization model and the profit maximization model is conducted. By investigating the error in the optimal order quantity of these two models, several interesting economic implications and managerial insights can be observed.     

Cost Comparisons for Out-of-Phase Inventory Models

Inventory costs for a fixed time period have traditionally been determined by allocating total costs per cycle uniformly throughout that cycle as well as any partial cycles. This procedure for cost allocation has led to the solution of numerous inventory problems, most notable of which is the anticipated price-increase model. When comparing two out-of-phase inventory models, if costs are accounted for when they occur over a fixed planning horizon, inventory policies should be changed to reflect the impact of this different cost-allocation procedure. For the anticipated price-increase model, the ‘optimal’ order quantity as well as the implied savings in inventory costs will be different when cost models are developed based on these different cost-allocation methods. If the objective is to maximize over a fixed planning horizon the actual savings in inventory costs as they occur, the cost models presented here should be used.     

Fuzzy profit measures for a fuzzy economic order quantity model

Changing economic conditions make the selling price and demand quantity more and more uncertain in the market. The conventional inventory models determine the selling price and order quantity for a retailer’s maximal profit with exactly known parameters. This paper develops a solution method to derive the fuzzy profit of the inventory model when the demand quantity and unit cost are fuzzy numbers. Since the parameters contained in the inventory model are fuzzy, the profit value calculated from the model should be fuzzy as well. Based on the extension principle, the fuzzy inventory problem is transformed into a pair of two-level mathematical programs to derive the upper bound and lower bound of the fuzzy profit at possibility level α. According to the duality theorem of geometric programming, the pair of two-level mathematical programs is transformed into a pair of conventional geometric programs to solve. By enumerating different α values, the upper bound and lower bound of the fuzzy profit are collected to approximate the membership function. Since the profit of the inventory problem is expressed by the membership function rather than by a crisp value, more information is provided for making decisions.     

Credit Policy and Inventory Control

Credit policies are shown to be important in the basic economic order quantity inventory model. An economic order quantity model is derived which explicitly considers possible credit periods allowed by suppliers. This model is shown to be very sensitive to the length of the credit period, and to the relationship between the credit period and inventory level. It is also shown to be more sensitive to estimates of demand for inventory items and less sensitive to order costs than the basic economic order quantity model. A practical example illustrates this sensitivity, shows how inventory costs may be considerably reduced by taking the existence of a credit period into account, and demonstrates the implications for inventory and credit policies.     

Periodic capacitated arc-routing problem with inventory constraints

The purpose of this paper is to study the periodic arc-routing problem when the arcs of a network behave as customers, and sufficient material is delivered so that each achieves its desired inventory level. Therefore, routing and inventory decisions are made simultaneously. Applications include dust suppression in open-pit mines or forest roads and plant watering along sidewalks or street medians. A truck periodically sprays water along the edges of a network. The humidity reaches a desired level and is then consumed over time until water is delivered again. The quantity of water delivered can be fixed or variable; we consider both scenarios and propose a mathematical model for each. Results are reported to validate the model. The contribution of this paper is the first mathematical model that combines inventory and routing decisions in the arc-routing domain.     

Optimal production stopping time for perishable products with ramp-type quadratic demand dependent production and setup cost

A single item economic production quantity (EPQ) model is discussed to analyse the behaviour of the inventory level after it’s introduction to the market. It is assumed that demand is time dependent accelerated growth-effect of accelerated growth-steady type. Unlike the conventional EPQ models, which are restricted to general production cycle over the finite or infinite time horizon, we consider the production sale scenario of the very first production cycle for newly introduced perishable product. Shortage is not allowed. Set up cost of an order cycle depends on the total amount of inventory produced. The finite production rate is proportional to demand rate. Optimal production stopping time is determined to maximize total unit profit of the system. A numerical example is presented to illustrate the development of the model. Sensitivity analysis of the model is carried out.     

Economic order quantity models for ameliorating/deteriorating items under inflation and time discounting

The items that incur a gradual loss in quality or quantity over time while in inventory are usually called deteriorating items. In reality, there are some items whose value or utility or quantity increase with time and those items can be termed as ameliorating items. In this paper, an effort has been made to incorporate these two opposite physical characteristics of stored items into inventory model. We develop models for ameliorating/deteriorating items with time-varying demand pattern over a finite planning horizon, taking into account the effects of inflation and time value of money. Optimal solutions of the proposed models are derived and the effects of amelioration/deterioration on the inventory replenishment policies are studied with the help of numerical examples.     

Estimating the lead-time demand distribution when the daily demand is non-normal and autocorrelated Hon-Shiang LAU

This paper develops convenient formulas for estimating the probability distribution of lead time demand when the inventory item's daily demand follows a probability distribution of any arbitrary shape, and when simple univariate models can be found for the autocorrelated daily demand series. Numerical examples are presented to illustrate the use of these formulas. The numerical results also indicate that significant error may be incurred when inventory decisions are made without proper consideration of the autocorrelations or the arbitrary distribution shapes of daily demands.     

A Lagrangean heuristic algorithm for disassembly scheduling with capacity constraints

This paper considers the problem of determining the disassembly schedule (quantity and timing) of products in order to satisfy the demand of their parts or components over a finite planning horizon. The objective is to minimize the sum of set-up, disassembly operation, and inventory holding costs. As an extension of the uncapacitated versions of the problem, we consider the resource capacity restrictions over the planning horizon. An integer program is suggested to describe the problem mathematically, and to solve the problem, a heuristic is developed using a Lagrangean relaxation technique together with a method to find a good feasible solution while considering the trade-offs among different costs. The effectiveness of the algorithm is tested on a number of randomly generated problems and the test results show that the heuristic suggested in this paper can give near optimal solutions within a short amount of computation time.     

Capacitated replenishment and disposal planning for multiple products with resalable returns

We consider a replenishment and disposal planning problem (RDPP) that arises in settings where customer returns are in as-good-as-new condition. These returns can be placed into inventory to satisfy future demand or can be disposed of, in case they lead to excess inventory. Our focus is on a multi-product setting with dynamic demands and returns over a finite planning horizon with explicit replenishment and disposal capacities. The problem is to determine the timing of replenishment and disposal setups, along with the associated quantities for the products, so as to minimize the total costs of replenishment, disposal, and inventory holding throughout the planning horizon. We examine two variants of the RDPP of interest both of which are specifically motivated by a spare part kitting application. In one variant, the replenishment capacity is shared among multiple products while the disposal capacity is product specific. In the other variant, both the replenishment and disposal capacities are shared among the products. We propose a Lagrangian Relaxation approach that relies on the relaxation of the capacity constraints and develop a smoothing heuristic that uses the solution of the Lagrangian problem to obtain near-optimal solutions. Our computational results demonstrate that the proposed approach is very effective in obtaining high-quality solutions with a reasonable computational effort.     

An inventory control problem for deteriorating items with back-ordering and financial considerations

This paper investigates the effects of time value of money and inflation on the optimal ordering policy in an inventory control system. We proposed an economic order quantity model to manage a perishable item over the finite horizon planning under which back-ordering and delayed payment are assumed. The demand and deterioration rates are constant. The present value of total cost during the planning horizon in this inventory system is modeled first, then a three phases solution procedure is proposed to derive the optimal order and shortage quantities, and the number of replenishment during the planning horizon. Finally, the proposed model is illustrated through numerical examples and the sensitivity analysis is reported to find some managerial insights.     

A model of JIT make-to-stock inventory with stochastic demand

We consider a firm that manages its internal manufacturing operations according to a just-in-time (JIT) system but maintains an inventory of finished goods as a buffer against random demands from external customers. We formulate a model in which finished goods are replenished by a small fixed quantity each time period. In the interest of schedule stability, the size of the replenishment quantity must remain fixed for a predetermined interval of time periods. We analyse the single-interval problem in depth, showing how to compute a cost-minimising value of the replenishment quantity for a given interval length, and characterising the optimal cost, inventory levels and service as functions of the interval length and initial inventory. The model displays significant cost and service penalties for schedule stability. A dynamic version of the problem is also formulated, and shown to be convex in nature with relatively easily computed optima.     

Effects of imperfect products on lot sizing with work in process inventory

The economic production quantity (EPQ) is one of the most widely known inventory control models that can be regarded as the generalized form of the Economic Order Quantity. However, the model is built on an unrealistic assumption that all the produced items need to be of perfect quality. Also, the introduction of work in process, WIP, as part of the inventory has been of lesser concern in developing inventory models. This paper attempts to develop the economic production quantity considering work in process inventory and manufacturing imperfect products that may be either reworkable or non-reworkable. The non-reworkable imperfect products are sold at a reduced price. This paper introduces a new model for this problem.