Dynamic setup reduction in production lot sizing with nonconstant deterministic demand

We examine three production policies under nonconstant, deterministic demand and dynamic setup cost reduction, where a decision to invest in setup reduction is made at the beginning of each period of a planning horizon. The three production policies are the reorder point, order quantity (s, Q) policy; the fixed production cycle, variable order quantity (t, Q_i) policy; and the variable production cycle, variable order quantity (t_i, Q_i). We study the behavior of the total relevant cost and develop a lot sizing and an investment solution procedure. Numerical examples are provided and dynamic setup cost reduction is compared with static setup cost reduction, where the decision to invest in setup reduction is made only at the initial setup.     

Capacitated lot-sizing with extensions: a review

The capacitated lot-sizing problem (CLSP) is a standard formulation for big bucket lot-sizing problems with a discrete period segmentation and deterministic demands. We present a literature review on problems that incorporate one of the following extensions in the CLSP: back-orders, setup carry-over, sequencing, and parallel machines. We illustrate model formulations for each of the extensions and also mention the inclusion of setup times, multi-level product structures and overtime in a study. For practitioners, this overview allows to check the availability of successful solution procedures for a specific problem. For scientists, it identifies areas that are open for future research.      

Dynamic lot-sizing with setup cost reduction

One of the fundamental tenets of the Just-in-Time (JIT) manufacturing philosophy is that reduction or even elimination of inventory conserves valuable resources and reduces wasteful spending. In many cases, to achieve inventory reductions requires investment in reduction of setup costs. For this reason, certain proposals for incorporating means for reducing setup costs into classical production-inventory models have been offered in recent years. This article considers a dynamic lot-sizing model M where the values of the setup costs can be reduced by various amounts depending upon the level of funds R committed to this reduction. We show that for each fixed value of R, the model can be represented as a shortest path problem. By minimizing the optimal value function V(R) of the shortest path problem over R, model M can, in theory, be solved. In practice, the viability of this approach depends crucially upon the properties of the function V. Since these properties depend upon the nature of the setup cost function K used in model M, we analyze how V varies as K varies. This allows us to propose two exact, finite algorithms for solving model M, one for the case when K is a concave function, the other for the case when K is convex. Computational results for the convex case are presented. The problems solved demonstrate that, in practice, setup cost reductions chosen according to model M have the potential to significantly reduce both inventory levels and total costs.     

Competitive online scheduling of perfectly malleable jobs with setup times

We study how to efficiently schedule online perfectly malleable parallel jobs with arbitrary arrival times on m ? 2 processors. We take into account both the linear speedup of such jobs and their setup time, i.e., the time to create, dispatch, and destroy multiple processes. Specifically, we define the execution time of a job with length p_j running on k_j processors to be p_j/k_j + (k_j − 1)c, where c > 0 is a constant setup time associated with each processor that is used to parallelize the computation. This formulation accurately models data parallelism in scientific computations and realistically asserts a relationship between job length and the maximum useful degree of parallelism. When the goal is to minimize makespan, we show that the online algorithm that simply assigns k_j so that the execution time of each job is minimized and starts jobs as early as possible has competitive ratio 4(m − 1)/m for even m ? 2 and 4m/(m + 1) for odd m ? 3. This algorithm is much simpler than previous offline algorithms for scheduling malleable jobs that require more than a constant number of passes through the job list.     

The multi-item capacitated lot-sizing problem with setup times and shortage costs

We address a multi-item capacitated lot-sizing problem with setup times and shortage costs that arises in real-world production planning problems. Demand cannot be backlogged, but can be totally or partially lost. The problem is NP-hard. A mixed integer mathematical formulation is presented. Our approach in this paper is to propose some classes of valid inequalities based on a generalization of Miller et al. [A.J. Miller, G.L. Nemhauser, M.W.P. Savelsbergh, On the polyhedral structure of a multi-item production planning model with setup times, Mathematical Programming 94 (2003) 375–405] and Marchand and Wolsey [H. Marchand, L.A. Wolsey, The 0–1 knapsack problem with a single continuous variable, Mathematical Programming 85 (1999) 15–33] results. We also describe fast combinatorial separation algorithms for these new inequalities. We use them in a branch-and-cut framework to solve the problem. Some experimental results showing the effectiveness of the approach are reported.     

Single-machine scheduling problems with past-sequence-dependent setup times

This paper studies single-machine scheduling problems with setup times which are proportionate to the length of the already scheduled jobs, that is, with past-sequence-dependent or p-s-d setup times. The following objective functions are considered: the maximum completion time (makespan), the total completion time, the total absolute differences in completion times and a bicriteria combination of the last two objective functions. It is shown that the standard single-machine scheduling problem with p-s-d setup times and any of the above objective functions can be solved in O(nlog n) time (where n is the number of jobs) by a sorting procedure. It is also shown that all of our results extend to a “learning” environment in which the p-s-d setup times are no longer linear functions of the already elapsed processing time due to learning effects.     

Single machine scheduling with a general exponential learning effect

In this paper we consider the scheduling problem with a general exponential learning effect and past-sequence-dependent (p-s-d) setup times. By the general exponential learning effect, we mean that the processing time of a job is defined by an exponent function of the total weighted normal processing time of the already processed jobs and its position in a sequence, where the weight is a position-dependent weight. The setup times are proportional to the length of the already processed jobs. We consider the following objective functions: the makespan, the total completion time, the sum of the δ ? 0th power of completion times, the total weighted completion time and the maximum lateness. We show that the makespan minimization problem, the total completion time minimization problem and the sum of the quadratic job completion times minimization problem can be solved by the smallest (normal) processing time first (SPT) rule, respectively. We also show that the total weighted completion time minimization problem and the maximum lateness minimization problem can be solved in polynomial time under certain conditions.     

A hybrid two-stage transportation and batch scheduling problem

We study the coordinated scheduling problem of hybrid batch production on a single batching machine and two-stage transportation connecting the production, where there is a crane available in the first-stage transportation that transports jobs from the warehouse to the machine and there is a vehicle available in the second-stage transportation to deliver jobs from the machine to the customer. As the job to be carried out is big and heavy in the steel industry, it is reasonable assumed that both the crane and the vehicle have unit capacity. The batching machine processes a batch of jobs simultaneously. Each batch occur a setup cost. The objective is to minimize the sum of the makespan and the total setup cost. We prove that this problem is strongly NP-hard. A polynomial time algorithm is proposed for a case where the job transportation times are identical on the crane or the vehicle. An efficient heuristic algorithm for the general problem is constructed and its tight worst-case bound is analyzed. In order to further verify the performance of the proposed heuristics, we develop a lower bound on the optimal objective function. Computational experiments show that the heuristic algorithm performs well on randomly generated problem instances.     

Inventory control in multi-channel retail

In recent years multi-channel retail systems have received increasing interest. Partly due to growing online business that serves as a second sales channel for many firms, offering channel specific prices has become a common form of revenue management. We analyze conditions for known inventory control policies to be optimal in presence of two different sales channels. We propose a single item lost sales model with a lead time of zero, periodic review and nonlinear non-stationary cost components without rationing to realistically represent a typical web-based retail scenario. We analyze three variants of the model with different arrival processes: demand not following any particular distribution, Poisson distributed demand and a batch arrival process where demand follows a Pòlya frequency type distribution. We show that without further assumptions on the arrival process, relatively strict conditions must be imposed on the penalty cost in order to achieve optimality of the base stock policy. We also show that for a Poisson arrival process with fixed ordering costs the model with two sales channels can be transformed into the well known model with a single channel where mild conditions yield optimality of an (s, S) policy. Conditions for optimality of the base stock and (s, S) policy for the batch arrival process with and without fixed ordering costs, respectively, are presented together with a proof that the batch arrival process provides valid upper and lower bounds for the optimal value function.     

Multiple lot-sizing decisions in a two-stage production with an interrupted geometric yield and non-rigid demand

In a production system with random yield, it may be more cost effective to release lots multiple times towards fulfilling a customer order. Such a decision, called the multiple lot-sizing problem, has been investigated in various contexts. This paper proposes an efficient algorithm for solving a new multiple lot-sizing problem defined in the context of a two-stage production system with non-rigid demand when its process yields are governed by interrupted geometric distributions. We formulate this problem as a dynamic program (DP) and develop lemmas to solve it. However, solving such a DP may be computationally extensive, particularly for large-scale cases with a high yield. Therefore, this study proposes an efficient algorithm for resolving computational issues. This algorithm is designed to reduce the DP network into a much simpler algorithm by combining a group of DP branches into a single one. Extensive experiments were carried out. Results indicate that the proposed reduction algorithm is quite helpful for practitioners dealing with large-scale cases characterized by high-yield.     

A bicriteria parallel machine scheduling with a learning effect of setup and removal times

In studies on scheduling problems, generally setup times and removal times of jobs have been neglected or by including those into processing times. However, in some production systems, setup times and removal times are very important such that they should be considered independent from processing times. Since, in general jobs are done according to automatic machine processes in production systems processing times do not differ according to process sequence. But, since human factor becomes influential when setup times and removal times are taken into consideration, setup times will be decreasing by repeating setup processes frequently. This fact is defined with learning effect in scheduling literature. In this study, a bicriteria m-identical parallel machines scheduling problem with a learning effect of setup times and removal times is considered. The objective function of the problem is minimization of the weighted sum of total completion time and total tardiness. A mathematical programming model is developed for the problem which belongs to NP-hard class. Results of computational tests show that the proposed model is effective in solving problems with up to 15 jobs and five machines. We also proposed three heuristic approaches for solving large jobs problems. According to the best of our knowledge, no work exists on the minimization of the weighted sum of total completion time and total tardiness with a learning effect of setup times and removal times.     

Eigenvalues and the One-Dimensional p-Laplacian

We consider the boundary value problem (?_p(u′))′ + λF(t, u) = 0, with p > 1, t ∈ (0, 1), u(0) = u(1) = 0, and with λ > 0. The value of λ is chosen so that the boundary value problem has a positive solution. In addition, we derive an explicit interval for λ such that, for any λ in this interval, the existence of a positive solution to the boundary value problem is guaranteed. In addition, the existence of two positive solutions for λ in an appropriate interval is also discussed.     

A finite difference solution to a two-dimensional parabolic inverse problem

In this paper, we consider the problem of finding u = u(x, y, t) and p = p(t) which satisfy u_t = u_xx + u_yy + p(t)u + ? in R × [0, T], u(x, y, 0) = f(x, y), (x, y) ∈ R = [0, 1] × [0, 1], u is known on the boundary of R and u(x^∗, y^∗, t) = E(t), 0 < t ? T, where E(t) is known and (x^∗, y^∗) is a given point of R. Through a function transformation, the nonlinear two-dimensional diffusion problem is transformed into a linear problem, and a backward Euler scheme is constructed. It is proved by the maximum principle that the scheme is uniquely solvable, unconditionally stable and convergent in L_∞ norm. The convergence orders of u and p are of O(τ + h²). The impact of initial data errors on the numerical solution is also considered. Numerical experiments are presented to illustrate the validity of the theoretical results.     

An efficient approach for solving the lot-sizing problem with time-varying storage capacities

We address the dynamic lot size problem assuming time-varying storage capacities. The planning horizon is divided into T periods and stockouts are not allowed. Moreover, for each period, we consider a setup cost, a holding unit cost and a production/ordering unit cost, which can vary through the planning horizon. Although this model can be solved using O(T³) algorithms already introduced in the specialized literature, we show that under this cost structure an optimal solution can be obtained in O(T log T) time. In addition, we show that when production/ordering unit costs are assumed to be constant (i.e., the Wagner–Whitin case), there exists an optimal plan satisfying the Zero Inventory Ordering (ZIO) property.     

An FPTAS for a single-item capacitated economic lot-sizing problem with monotone cost structure

We present a fully polynomial time approximation scheme (FPTAS) for a capacitated economic lot-sizing problem with a monotone cost structure. An FPTAS delivers a solution with a given relative error ɛ in time polynomial in the problem size and in 1/ɛ. Such a scheme was developed by van Hoesel and Wagelmans [8] for a capacitated economic lot-sizing problem with monotone concave (convex) production and backlogging cost functions. We omit concavity and convexity restrictions. Furthermore, we take advantage of a straightforward dynamic programming algorithm applied to a rounded problem.     

Time-varying minimum cost flow problems

In this paper, we study a minimum cost flow problem on a time-varying network. Let N(V,A,l,b,c_r,c_w) be a network with an arc set A and a vertex set V. Each a∈A is associated with three integer parameters: a positive transit time b(a,t), an arbitrary transit cost c_r(a,t), and a positive capacity limit l(a,t). Each x∈V is associated with two integer parameters: a waiting cost c_w(x,t) and a vertex capacity l(x,t). All these parameters are functions of the discrete time t=0,1,2,… The objective is to find an optimal schedule to send a flow from the origin (the source vertex) to its destination (the sink vertex) with the minimum cost, subject to the constraint that the flow must arrive at the destination before a deadline T. Three versions of the problem are examined, which are classified depending on whether waiting at the intermediate vertices of the network is strictly prohibited, arbitrarily allowed, or bounded. Three algorithms with pseudopolynomial time complexity are proposed, which can find optimal solutions to the three versions of the problem, respectively.     

Lot-sizing on a tree

For the problem of lot-sizing on a tree with constant capacities, or stochastic lot-sizing with a scenario tree, we present various reformulations based on mixing sets. We also show how earlier results for uncapacitated problems involving (Q,S_Q) inequalities can be simplified and extended. Finally some limited computational results are presented.     

Fix-and-optimize heuristics for capacitated lot-sizing with sequence-dependent setups and substitutions

In this paper, we consider a capacitated single-level dynamic lot-sizing problem with sequence-dependent setup costs and times that includes product substitution options. The model is motivated from a real-world production planning problem of a manufacturer of plastic sheets used as an interlayer in car windshields. We develop a mixed-integer programming (MIP) formulation of the problem and devise MIP-based Relax&Fix and Fix&Optimize heuristics. Unlike existing literature, we combine Fix&Optimize with a time decomposition. Also, we develop a specialized substitute decomposition and devise a computation budget allocation scheme for ensuring a uniform, efficient usage of computation time by decompositions and their subproblems. Computational experiments were performed on generated instances whose structure follows that of the considered practical application and which have rather tight production capacities. We found that a Fix&Optimize algorithm with an overlapping time decomposition yielded the best solutions. It outperformed the state-of-the-art approach Relax&Fix and all other tested algorithm variants on the considered class of instances, and returned feasible solutions with neither overtime nor backlogging for all instances. It returned solutions that were on average only 5% worse than those returned by a standard MIP solver after 4 hours and 19% better than those of Relax&Fix.     

On alternative mixed integer programming formulations and LP-based heuristics for lot-sizing with setup times

We address the multi-item, capacitated lot-sizing problem (CLSP) encountered in environments where demand is dynamic and to be met on time. Items compete for a limited capacity resource, which requires a setup for each lot of items to be produced causing unproductive time but no direct costs. The problem belongs to a class of problems that are difficult to solve. Even the feasibility problem becomes combinatorial when setup times are considered. This difficulty in reaching optimality and the practical relevance of CLSP make it important to design and analyse heuristics to find good solutions that can be implemented in practice. We consider certain mixed integer programming formulations of the problem and develop heuristics including a curtailed branch and bound, for rounding the setup variables in the LP solution of the tighter formulations. We report our computational results for a class of instances taken from literature.