An exact solution procedure for multi-item two-echelon spare parts inventory control problem with batch ordering in the central warehouse

We consider a multi-item two-echelon inventory system in which the central warehouse operates under a (Q,R) policy, and the local warehouses implement basestock policy. An exact solution procedure is proposed to find the inventory control policy parameters that minimize the system-wide inventory holding and fixed ordering cost subject to an aggregate mean response time constraint at each facility.     

On two-echelon inventory systems with Poisson demand and lost sales

We consider a two-echelon, continuous review inventory system under Poisson demand and a one-for-one replenishment policy. Demand is lost if no items are available at the local warehouse, the central depot, or in the pipeline in between. We give a simple, fast and accurate approach to approximate the service levels in this system. In contrast to other methods, we do not need an iterative analysis scheme. Our method works very well for a broad set of cases, with deviations to simulation below 0.1% on average and below 0.36% for 95% of all test instances.     

Analysis and evaluation of an Assemble-to-Order system with batch ordering policy and compound Poisson demand

We consider a multi-product and multi-component Assemble-to-Order (ATO) system where the external demand follows compound Poisson processes and component inventories are controlled by continuous-time batch ordering policies. The replenishment lead-times of components are stochastic, sequential and exogenous. Each element of the bill of material (BOM) matrix can be any non-negative integer. Components are committed to demand on a first-come-first-serve basis. We derive exact expressions for key performance metrics under either the assumption that each demand must be satisfied in full (non-split orders), or the assumption that each unit of demand can be satisfied separately (split orders). We also develop an efficient sampling method to estimate these metrics, e.g., the expected delivery lead-times and the order-based fill-rates. Based on the analysis and a numerical study of an example motivated by a real world application, we characterize the impact of the component interaction on system performance, demonstrate the efficiency of the numerical method and quantify the impact of order splitting.     

Controlling distribution inventory systems with shipment consolidation and compound Poisson demand

We consider a one-warehouse-multiple-retailer inventory system where the retailers face stochastic customer demand, modelled as compound Poisson processes. Deliveries from the central warehouse to groups of retailers are consolidated using a time based shipment consolidation policy. This means that replenishment orders have to wait until a vehicle departures, which increases the lead time for the retailers and therefore also the safety stock. Thus, a trade-off exists between expected shipment costs and holding costs. Our aim is to determine the shipment intervals and the required amount of safety stock for each retailer and the warehouse to minimize total cost, both for backorder costs and fill rate constraints. Previous work has focused on exact solutions which are computationally demanding and not applicable for larger real world problems. The focus of our present work is on the development of computationally attractive heuristics that can be applied in practice. A numerical study shows that the proposed heuristics perform well compared to the exact cost minimizing solutions. We also illustrate that the approaches are appropriate for solving real world problems using data from a large European company.     

A two-echelon base-stock inventory model with Poisson demand and the sequential processing of orders at the upper echelon

We consider a two-echelon inventory system with a number of non-identical, independent ‘retailers’ at the lower echelon and a single ‘supplier’ at the upper echelon. Each retailer experiences Poisson demand and operates a base stock policy with backorders. The supplier manufactures to order and holds no stock. Orders are produced, in first-come first-served sequence, with a fixed production time. The supplier therefore functions as an M/D/1 queue. We are interested in the performance characteristics (average inventory, average backorder level) at each retailer. By finding the distribution of order lead time and hence the distribution of demand during order lead time, we find the steady state inventory and backorder levels based on the assumption that order lead times are independent of demand during order lead time at a retailer. We also propose two alternative approximation procedures based on assumed forms for the order lead time distribution. Finally we provide a derivation of the steady state inventory and backorder levels which will be exact as long as there is no transportation time on orders between the supplier and retailers. A numerical comparison is made between the exact and approximate measures. We conclude by recommending an approach which is intuitive and computationally straightforward.     

Customer waiting times in an (R,S) inventory system with compound Poisson demand

Besides service level and mean physical stock, customer waiting time is an important performance characteristic for an inventory system. In this paper we discuss the calculation of this waiting time in case a periodic review control policy with order-up-to-levelS is used and customers arrive according to a Poisson process. For the case of Gamma distributed demand per customer, we obtain (approximate) expressions for the waiting time characteristics. The approach clearly differs from the traditional approaches. It can also be used to obtain other performance characteristics such as the mean physical stock and the service level.     

Dynamic demand fulfillment in spare parts networks with multiple customer classes

We study real-time demand fulfillment for networks consisting of multiple local warehouses, where spare parts of expensive technical systems are kept on stock for customers with different service contracts. Each service contract specifies a maximum response time in case of a failure and hourly penalty costs for contract violations. Part requests can be fulfilled from multiple local warehouses via a regular delivery, or from an external source with ample capacity via an expensive emergency delivery. The objective is to minimize delivery cost and penalty cost by smartly allocating items from the available network stock to arriving part requests. We propose a dynamic allocation rule that belongs to the class of one-step lookahead policies. To approximate the optimal relative cost, we develop an iterative calculation scheme that estimates the expected total cost over an infinite time horizon, assuming that future demands are fulfilled according to a simple static allocation rule. In a series of numerical experiments, we compare our dynamic allocation rule with the optimal allocation rule, and a simple but widely used static allocation rule. We show that the dynamic allocation rule has a small optimality gap and that it achieves an average cost reduction of 7.9% compared to the static allocation rule on a large test bed containing problem instances of real-life size.     

Periodic review lost-sales inventory models with compound Poisson demand and constant lead times of any length

In almost all literature on inventory models with lost sales and periodic reviews the lead time is assumed to be either an integer multiple of or less than the review period. In a lot of practical settings such restrictions are not satisfied. We develop new models allowing constant lead times of any length when demand is compound Poisson. Besides an optimal policy, we consider pure and restricted base-stock policies under new lead time and cost circumstances. Based on our numerical results we conclude that the latter policy, which imposes a restriction on the maximum order size, performs almost as well as the optimal policy. We also propose an approximation procedure to determine the base-stock levels for both policies with closed-form expressions.     

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.     

Confidence-based optimisation for the newsvendor problem under binomial,Poisson and exponential demand

We introduce a novel strategy to address the issue of demand estimation in single-item single-period stochastic inventory optimisation problems. Our strategy analytically combines confidence interval analysis and inventory optimisation. We assume that the decision maker is given a set of past demand samples and we employ confidence interval analysis in order to identify a range of candidate order quantities that, with prescribed confidence probability, includes the real optimal order quantity for the underlying stochastic demand process with unknown stationary parameter(s). In addition, for each candidate order quantity that is identified, our approach produces an upper and a lower bound for the associated cost. We apply this approach to three demand distributions in the exponential family: binomial, Poisson, and exponential. For two of these distributions we also discuss the extension to the case of unobserved lost sales. Numerical examples are presented in which we show how our approach complements existing frequentist—e.g. based on maximum likelihood estimators—or Bayesian strategies.     

Multi-item inventory models with price dependent demand under flexibility and reliability consideration and imprecise space constraint: A geometric programming approach

In this paper, multi-item economic production quantity (EPQ) models with selling price dependent demand, infinite production rate, stock dependent unit production and holding costs are considered. Flexibility and reliability consideration are introduced in the production process. The models are developed under two fuzzy environments–one with fuzzy goal and fuzzy restrictions on storage area and the other with unit cost as fuzzy and possibility–necessity restrictions on storage space. The objective goal and constraint goal are defined by membership functions and the presence of fuzzy parameters in the objective function is dealt with fuzzy possibility/necessity measures. The models are formed as maximization problems. The first one—the fuzzy goal programming problem is solved using Fuzzy Additive Goal Programming (FAGP) and Modified Geometric Programming (MGP) methods. The second model with fuzzy possibility/necessity measures is solved by Geometric Programming (GP) method. The models are illustrated through numerical examples. The sensitivity analyses of the profit function due to different measures of possibility and necessity are performed and presented graphically.     

Optimal ordering policies in inventory systems with random demand and random deal offerings

In this paper, we determine the optimal order policies for a firm facing random demand and random deal offerings. In a periodic review setting, a firm may first place an order at the regular price. Later in the period, if a price promotion is offered by the supplier (with a certain probability), the firm may decide to place another order. We consider two models in the paper. In the first model, the firm does not share the cost savings (due to the promotion offered by the supplier) with its own customers, i.e. its demand distribution remains fixed. In the second model, the cost savings are shared with the final customers. As a result, the demand distribution shifts to the right. For both the models, in a dynamic finite-horizon problem, the order policy structure is divided into three regions and is as follows. If the initial inventory level for the firm exceeds a certain threshold level, it is optimal not to order anything. If it is in the medium range, it is optimal to wait for the promotion and order only if it is offered. The order quantity when the promotion is offered has an ‘order up to’ policy structure. Finally, if the inventory level is below another threshold, it is optimal to place an order at the regular price, and to place a second order if the promotion is offered. The low initial inventory level makes it risky to just wait for the promotion to be offered. The sum of the order quantities in this case has an ‘order up to’ structure. Finally, we model the supplier's problem as a Stackelberg game and discuss the motivation for the supplier to offer a promotion for the case of uniform demand distribution for the firm. In the first model (when the firm does not share the cost savings with its customers), we show that it is rarely optimal for the supplier to offer a promotion. In the second model, the supplier may offer a promotion depending on the price elasticity of the product.     

Ergodic control of diffusions with compound Poisson jumps under a general structural hypothesis

We study the ergodic control problem for a class of controlled jump diffusions driven by a compound Poisson process. This extends the results of Arapostathis et al. (2019) to running costs that are not near-monotone. This generality is needed in applications such as optimal scheduling of large-scale parallel server networks.We provide a full characterizations of optimality via the Hamilton–Jacobi–Bellman (HJB) equation, for which we additionally exhibit regularity of solutions under mild hypotheses. In addition, we show that optimal stationary Markov controls are a.s. pathwise optimal. Lastly, we show that one can fix a stable control outside a compact set and obtain near-optimal solutions by solving the HJB on a sufficiently large bounded domain. This is useful for constructing asymptotically optimal scheduling policies for multiclass parallel server networks.     

A two warehouse inventory model for deteriorating items with a linear trend in demand and shortages

In this paper, we develop a deterministic inventory model with two warehouses (one is the existing storage known as own warehouse (OW) and the other is hired on rental basis known as rented warehouse (RW). The model allows different levels of item deterioration in both warehouses. The demand rate is supposed to be a linear (increasing) function of time and the replenishment rate is infinite. The stock is transferred from RW to OW in continuous release pattern and the associated transportation cost is taken into account. Shortages in OW are allowed and excess demand is backlogged. For the general model, we give the equations for the optimal policy and cost function and we discuss some special cases. A numerical example is given to illustrate the solution procedure of the model. Finally, based on this example, we conduct a sensitivity analysis of the model.     

A comparison between the order and the volume fill rate for a base-stock inventory control system under a compound renewal demand process

The order fill rate (OFR) is sometimes suggested as an alternative to the volume fill rate (VFR) (most often just denoted fill rate) as a performance measure for inventory control systems. We consider a continuous review, base-stock policy, where replenishment orders have a constant lead time and unfilled demands are backordered. For this policy, we develop exact mathematical expressions for the two fill-rate measures when demand follows a compound renewal process. We also elaborate on when the OFR can be interpreted as the (extended) ready rate. For the case when customer orders are generated by a negative binomial distribution, we show that it is the size of the shape parameter of this distribution that determines the relative magnitude of the two fill rates. In particular, we show that when customer orders are generated by a geometric distribution, the OFR and the VFR are equal.     

A new approach of forecasting intermittent demand for spare parts inventories in the process industries

Accurate demand forecasting is of vital importance in inventory management of spare parts in process industries, while the intermittent nature makes demand forecasting for spare parts especially difficult. With the wide application of information technology in enterprise management, more information and data are now available to improve forecasting accuracy. In this paper, we develop a new approach for forecasting the intermittent demand of spare parts. The described approach provides a mechanism to integrate the demand autocorrelated process and the relationship between explanatory variables and the nonzero demand of spare parts during forecasting occurrences of nonzero demands over lead times. Two types of performance measures for assessing forecast methods are also described. Using data sets of 40 kinds of spare parts from a petrochemical enterprise in China, we show that our method produces more accurate forecasts of lead time demands than do exponential smoothing, Croston's method and Markov bootstrapping method.     

Newsvendor characterizations for one-warehouse multi-retailer inventory systems with discrete demand under the balance assumption

This paper considers a one-warehouse multi-retailer inventory system that faces discrete stochastic demand of the customers. Under the so-called balance assumption (also known as the allocation assumption), base stock policies are optimal. Our main contribution is to show that the optimal base stock levels satisfy newsvendor characterizations, which are in terms of inequalities, and to extend the newsvendor equalities known for the continuous demand model. These characterizations are appealing because they (i) are easy to explain to nonmathematical oriented people like managers and MBA students, (ii) contribute to the understanding of optimal control, (iii) help intuition development by providing direct relation between cost and optimal policy parameters.