On the unutilized capacity of a production-storage system

A one-product one-machine production/inventory problem in which the machine is subject to failure, is considered. The product is stored in an inventory of finite capacity. When the machine is operable, it produces at a rate α greater than the demand rate β, until the inventory becomes full and thereafter it produces at the demand rate. This stepping down of the rate of production results in the under-utilisation of the machine. The under-utilisation of the machine and the demand not met are analysed; special cases are considered. Cost analysis is also indicated.     

Optimal EOQ Models for Deteriorating Items with Time-Varying Demand

In this paper, optimal inventory lot-sizing models are developed for deteriorating items with general continuous time-varying demand over a finite planning horizon and under three replenishment policies. The deterioration rate is assumed to be a constant fraction of the on-hand inventory. Shortages are permitted and are completely backordered. The proposed solution procedures are shown to generate global minimum replenishment schedules for both general increasing and decreasing demand patterns. An extensive empirical comparison using randomly generated linear and exponential demands revealed that the replenishment policy which starts with shortages in every cycle is the least cost policy and the replenishment policy which prohibits shortages in the last cycle exhibited the best service level effectiveness. An optimal procedure for the same problem with trended inventory subject to a single constraint on the minimum service level (maximum fraction of time the inventory system is out of stock during the planning horizon) is also proposed in this paper.     

The impact of data collection on fill rate performance in the (R,s, Q) inventory model

In this paper we consider the determination of the reorder point s in an (R, s, Q) inventory model subject to a fill rate service level constraint. We assume that the underlying demand process is a compound renewal process. We then derive an approximation method to compute the reorder level such that a target service level is achieved. Restrictions on the input parameters are given, within which this method is applicable. Moreover, we will investigate the effects on the fill rate performance in case the underlying demand process is indeed a compound renewal process, while the demand process is modelled as a discrete-time demand process. That is, the time axis is divided in time units (for example, days) and demands per time unit are independent and identically distributed random variables. It will be shown that smooth and erratic behaviour of the inter-arrival times have different impacts on the performance of the fill rate when demand is modelled as a discrete-time process and in case the underlying demand process is a compound renewal process.     

On the stochastic uncapacitated dynamic single-item lotsizing problem with service level constraints

In this paper, we consider the uncapacitated single-item dynamic lotsizing problem with stochastic period demands and backordering. We present a model formulation that minimizes the setup and holding costs with respect to a constraint on the probability that the inventory at the end of any period does not become negative (α service level) and, alternatively, to a fill rate constraint (β service level). In contrast to earlier model formulations which consider the cycle α service level (α_c) and which approximate the on hand inventory by the net inventory, we include the exact on hand inventory into the model formulation. Therefore, the models are also applicable in situations with very low service levels.     

Analysis of a two-sided production policy with inventory-level-dependent production rates

In this paper we analyse a stochastic production/inventory problem with compound Poisson demand and state (i.e. inventory level) dependent production rates. Customers arrive according to a Poisson process where the amount demanded by each customer is assumed to have a general distribution. When the inventory W(t) falls below a critical level m, production is started at a rate of r[W(t)], i.e. production rate dynamically changes as a function of the inventory level. Production continues until a level M (œ w m) is reached. Excess demand is assumed to be lost. We identify a dam content process X that is a dual for the inventory level W and develop the stationary distribution for the X process. To achieve this we use tools from renewal and level crossing theories. The two-sided (m, M) policy is optimized using the expected cost obtained from the stationary density of W and a conditional (on w) expected cost function for this process. For a special case, we obtain explicit results for all the relevant expressions. Numerical examples are provided for several test problems. © 1996 John Wiley & Sons, Ltd.     

On the Effect of Product Variety in Production–Inventory Systems

In this paper, we examine the effect of product variety on inventory costs in a production–inventory system with finite capacity where products are made to stock and share the same manufacturing facility. The facility incurs a setup time whenever it switches from producing one product type to another. The production facility has a finite production rate and stochastic production times. In order to mitigate the effect of setups, products are produced in batches. In contrast to inventory systems with exogenous lead times, we show that inventory costs increase almost linearly in the number of products. More importantly, we show that the rate of increase is sensitive to system parameters including demand and process variability, demand and capacity levels, and setup times. The effect of these parameters can be counterintuitive. For example, we show that the relative increase in cost due to higher product variety is decreasing in demand and process variability. We also show that it is decreasing in expected production time. On the other hand, we find that the relative cost is increasing in expected setup time, setup time variability and aggregate demand rate. Furthermore, we show that the effect of product variety on optimal base stock levels is not monotonic. We use the model to draw several managerial insights regarding the value of variety-reducing strategies such as product consolidation and delayed differentiation.     

基于排队的库存服务系统最优控制策略

研究一个连续盘点的(s,Q)补货的库存服务系统。基于排队理论建立库存水平状态平衡方程,并推导出库存水平稳态概率分布以及作为库存控制的系统稳态性能指标。以库存成本最小化为目标,构建服务水平约束的库存控制模型。针对模型的非线性约束与整数型变量的特征,采用一种改进的遗传算法(IGA)用于决策变量的寻优。数值实验表明,当目标服务水平大于库存系统内生的服务水平时,实施服务水平约束能够降低库存控制成本。     

Optimal control of an inventory-production system with state-dependent random yield

In this paper we study a single stage, periodic-review inventory problem for a single item with stochastic demand. The inventory manager determines order sizes according to an order-up-to logic and observes a random yield due to quality problems in the production. We distinguish between two different states of the production process combined with different probabilities to produce a defective unit. In order to improve the production process, periodic inspections are conducted and in case of a failure the machine is repaired. Approximations are developed to evaluate the average cost for a given order-up-to level and a given inspection interval and we illustrate the existence of optimal policy parameters. The approximations are tested in a simulation study and reveal an excellent performance as they lead to near optimal policy parameters. Moreover, we decompose the problem and test different methods to compute the policy parameters either sequentially or separately. Our results show that a joint optimization of the inventory and maintenance policy leads to a better system performance and reduced costs.     

Optimal production inventory policy for defective items with fuzzy time period

In this paper, an optimal production inventory model with fuzzy time period and fuzzy inventory costs for defective items is formulated and solved under fuzzy space constraint. Here, the rate of production is assumed to be a function of time and considered as a control variable. Also the demand is linearly stock dependent. The defective rate is taken as random, the inventory holding cost and production cost are imprecise. The fuzzy parameters are converted to crisp ones using credibility measure theory. The different items have the different imprecise time periods and the minimization of cost for each item leads to a multi-objective optimization problem. The model is under the single management house and desired inventory level and product cost for each item are prescribed. The multi-objective problem is reduced to a single objective problem using Global Criteria Method (GCM) and solved with the help of Fuzzy Riemann Integral (FRI) method, Kuhn–Tucker condition and Generalised Reduced Gradient (GRG) technique. In optimum results including production functions and corresponding optimum costs for the different models are obtained and then are presented in tabular forms.     

服务水平约束下动态定价与库存管理

本文研究服务水平约束下的动态定价与库存管理问题。企业在有限期内销售某种产品,产品的需求为随机需求,且期望需求依赖于产品价格。在每一期期初,企业需要在满足服务水平约束的条件下同时决定订货量和产品价格。本文首先构建了动态定价和订购联合决策的随机动态规划模型,并证明了最优解的存在性。进一步,通过对最优解的结构进行刻画,将原问题的求解转化为若干子问题的求解,降低了问题求解的难度。通过对最优解的分析发现,当期初库存增大时,产品最优价格降低。通过分析目标服务水平对利润的影响,证明了服务水平与利润之间存在权衡,实现高的服务水平需要承受利润损失。数值模拟表明,相对于传统的静态定价策略,采用动态定价策略可以降低追求服务水平所带来的利润损失,验证了动态定价策略的有效性。     

Optimale Produktionsplanung bei Frischprodukten mit dem Programm FORTUNA — Eine Fallstudie

The production rate of perishable goods depends heavily on the actual stock level and the daily demand. Production planning is therefore short-term. The production of curd (cottage cheese), with which the case study deals, is a typical example. When the daily production process is started, the demand is still unknown. When planning is non-computerized, this causes considerable fluctuations in the stock level and increases the danger of perishing. It also necessitates an over capacity for production to maintain a high level of service. The computer software package FORTUNA is a result of this problem being studied. It is based on a Markovian decision process of the type of a AHM-Inventory Production model. The computer program makes forecasts of the daily demand, computes optimal decision rules for short-term tuning of the daily production rate and produces weekly or monthly labour schedules. The second part of this paper contains the application of FORTUNA in a dairy. It reports about the analysis of the demand pattern, the identification of the parameters of the cost structure, the performance criteria of non-monetary goals, the comparison with manual planning and the long term effects.     

Optimal operational service levels in vendor managed inventory contracts - an exact approach

Vendor Managed Inventory (VMI) contracts are anchored on a fill rate at which the vendor is expected to meet the end-customer demand. Violations of this contracted fill rate due to excess and insufficient inventory are both penalized, often in a linear, but asymmetric manner. To minimize these costs, the vendor needs to maintain an operational fill rate that is different from the contracted fill rate. We model, analyze and solve an optimization problem that determines this operational fill rate and the associated optimal inventory decision. We establish that, for some special, yet popular, models of demand (e.g. truncated normal, gamma, Weibull and uniform distributions), the optimal solution can be derived in closed form and computed precisely. For other demand distributions, either the optimization problem becomes ill-defined or we may need to use approximate solution methods. An extensive computational study reveals that, for realistic values of problem parameters, the operational fill rate is often larger (by as much as 20%) than the contracted service level, possibly explaining the inventory glut commonly observed in real-world VMI systems.     

Optimal pricing,production, and inventory for deteriorating items under demand uncertainty: The finite horizon case

This paper aims to investigate the joint dynamic pricing and production decisions of deteriorating items with uncertain demand over a finite selling season, where the demand is price sensitive and the potential demand is characterized by a stochastic process. The stocks deteriorate physically at a constant fraction of the on-hand inventory. A joint dynamic pricing and production problem to maximize the total expected profit is modeled as a stochastic optimal control problem. We derive the closed-form solutions, which are in time-dependent linear feedback form of the inventory level when it is either positive or negative. It is shown that the manufacturer always benefits from a reduction in the volatility of potential market demand. In addition, to highlight the effectiveness of the joint dynamic strategy, we also consider the case of optimal production with a static price. A numerical example is presented to illustrate the validity of the optimal control policy, and sensitivity analysis on major parameters is performed to provide more managerial insights into deteriorating items.     

Fuzzy pricing,marketing and service planning in a fuzzy inventory model: A geometric programming approach

In the real world markets, demand is influenced by different parameters. Recently, many researchers have been interested in integrated production and marketing planning strategies in inventory models where demand depends on different parameters such as price and/or marketing expenditure. The quality of services that are offered to customers of a product is one of the most important parameters that affects demand in the real markets and has not been considered in development of inventory models. On the other hand, the cost parameters in real inventory systems and other parameters such as price, marketing and service elasticity to demand are imprecise and uncertain in nature. So, the notion of fuzziness can be applied to cope with this uncertainty. In this paper, a new fuzzy profit maximization inventory model with shortages is proposed. The demand is considered as a power function of price, marketing expenditure and service expenditure. Furthermore, unit cost is determined as a power function of order quantity. Since the proposed model is in a fuzzy environment, a fuzzy decision should be made to meet the decision criteria, and the results should be fuzzy. Therefore, the proposed model is formulated and solved using geometric programming and fuzzy optimization techniques to derive an approximation of the results’ membership functions. The model is illustrated with a numerical example and finally a case study is provided for evaluation and validation of the results of model.     

Analysis of deteriorating inventory/production systems using a linear quadratic regulator

We consider an inventory-production system where items deteriorate at a constant rate. The objective is to develop an optimal production policy that minimizes the cost associated with inventory and production rate. The inventory problem is first modeled as a linear optimal control problem. Then linear quadratic regulator (LQR) technique is applied to the control problem in order to determine the optimal production policy. Examples are solved for three different demand functions. Sensitivity analysis is then conducted to study the effect of changing the cost parameters on the objective function.     

Dynamic inventory targets revisited

This paper is about periodic review inventory systems which are controlled by replenishing the inventory up to a target level which is set based on a demand forecast generated from past demands. It is shown that the replenishments will fluctuate more than final demand. Furthermore the effectiveness of a given safety stock is significantly reduced, indeed even with a very high target the maximum achievable service level can be quite limited. The paper is based on an actual spare parts inventory control system used in a domestic appliance company.     

Customer differentiated end-of-life inventory problem

This paper deals with the service parts end-of-life inventory problem in a circumstance that demands for service parts are differentiated. Customer differentiation might be due to criticality of the demand or based on various service contracts. In both cases, we model the problem as a finite horizon stochastic dynamic program and characterize the structure of the optimal inventory policy. We show that when customers are differentiated based on the demand criticality then the optimal structure consists of time and state dependent threshold levels for inventory rationing. In case of differentiation based on service contracts, we show that in addition to rationing thresholds we also need contract extension thresholds by which the system decides whether to offer an extension to an expiring contract or not. By numerical experiments in both cases, we identify the value of incorporating such decisions in service parts end-of-life inventory management with customer differentiation. Moreover, we show that these decisions not only result in cost efficiency but also decrease the risk of part obsolescence drastically.     

Allocation of warehouse inventory with electronic data interchange and fixed order intervals

This paper considers the problem of allocating warehouse inventory to retailers where retailer orders and the replenishment of warehouse inventory occur periodically on a fixed schedule. We assume that the warehouse and the retailers have the opportunity to exchange demand information through Electronic Data Interchange (EDI). At the warehouse level, for instance, the available information on the retailer's demand may be utilized in determining the shipment quantities needed to meet the desired service level to the retailers. Unlike similar models focusing primarily on optimizing systems wide performance measures, in this paper we focus on the service level furnished to the retailers by the warehouse. To this end, three different allocation policies are considered: static, myopic, and dynamic rules characterizing the impact of available demand information on the resulting service levels. Numerical illustrations exemplify the allocation rules considered. An interesting though counter intuitive observation is that the existence of additional demand information cannot, a prior, be assumed superior.     

The Optimality of the ‘Zero-Switch’ Rule for a Class of Economic Lot-Scheduling Problems

The economic lot-scheduling problem for the single-machine, n-item scheduling problem has received attention in a number of journals. One approach is to define a sequence (called the fundamental cycle) in which every item is made at least once, and then to determine the length of production runs consistent with the aggregate inventory level which will maximize the length of the cycle duration. The assumption that production is switched from one item to the next only when the inventory level of the latter reaches zero is often used in heuristic solutions to these models. This paper illustrates the conditions in which the ‘zero-switch’ rule is a necessary condition at the optimal solution for situations in which demand is continuous and production capacity equals aggregate demand.     

A Robust Optimization Approach to Dynamic Pricing and Inventory Control with no Backorders

In this paper, we present a robust optimization formulation for dealing with demand uncertainty in a dynamic pricing and inventory control problem for a make-to-stock manufacturing system. We consider a multi-product capacitated, dynamic setting. We introduce a demand-based fluid model where the demand is a linear function of the price, the inventory cost is linear, the production cost is an increasing strictly convex function of the production rate and all coefficients are time-dependent. A key part of the model is that no backorders are allowed. We show that the robust formulation is of the same order of complexity as the nominal problem and demonstrate how to adapt the nominal (deterministic) solution algorithm to the robust problem.