Capacitated dynamic lot sizing problems in closed-loop supply chain

In this paper, we address the capacitated dynamic lot sizing problem arising in closed-loop supply chain where returned products are collected from customers. These returned products can either be disposed or be remanufactured to be sold as new ones again; hence the market demands can be satisfied by either newly produced products or remanufactured ones. The capacities of production, disposal and remanufacturing are limited, and backlogging is not allowed. A general model of this problem is formulated, and several useful properties of the problem are characterized when cost functions are concave. Moreover, this problem is analyzed and solved to optimality using dynamic programming algorithms under different scenarios. It is shown that the problem with only disposal or remanufacturing can be converted into a traditional capacitated lot sizing problem and be solved by a polynomial algorithm if the capacities are constant. A pseudo-polynomial algorithm is proposed for the problem with both capacitated disposal and remanufacturing. The problem with capacitated production and remanufacturing and the problem with uncapacitated production and capacitated remanufacturing are also analyzed and solved. Through numerical experiments we show that the proposed algorithms perform well when solving problems of practical sizes. From the experimental results also indicates that it is worthwhile to expand the remanufacturing capacity only when returned products exist in a relatively long planning horizon, and production capacities have little effect on the remanufacturing plan when the demand is mainly satisfied by the production.     

A reformulation for the stochastic lot sizing problem with service-level constraints

We study the stochastic lot-sizing problem with service level constraints and propose an efficient mixed integer reformulation thereof. We use the formulation of the problem present in the literature as a benchmark, and prove that the reformulation has a stronger linear relaxation. Also, we numerically illustrate that it yields a superior computational performance. The results of our numerical study reveals that the reformulation can optimally solve problem instances with planning horizons over 200 periods in less than a minute.     

Planning for demand failure: A dynamic lot size model for clinical trial supply chains

This paper examines the optimal production lot size decisions for clinical trial supply chains. One unique aspect of clinical trial supply chains is the risk of failure, meaning that the investigational drug is proven unsafe or ineffective during human testing and the trial is halted. Upon failure, any unused inventory is essentially wasted and needs to be destroyed. To avoid waste, manufacturers could produce small lot sizes. However, high production setup costs lead manufacturers to opt for large lot sizes and few setups. To optimally balance this tradeoff of waste and destruction versus production inefficiency, this paper generalizes the Wagner-Whitin model (W-W model) to incorporate the risk of failure. We show that this stochastic model, referred to as the failure-risk model, is equivalent to the deterministic W-W model if one adjusts the cost parameters properly to reflect failure and destruction costs. We find that increasing failure rates lead to reduced lot sizes and that properly incorporating the risk of failure into clinical trial drug production can lead to substantial cost savings as compared to the W-W model without the properly adjusted parameters.     

Dynamic cost allocation for economic lot sizing games

We consider a cooperative game defined by an economic lot sizing problem with concave ordering costs over a finite time horizon, in which each player faces demand for a single product in each period and coalitions can pool orders. We show how to compute a dynamic cost allocation in the strong sequential core of this game, i.e. an allocation over time that exactly distributes costs and is stable against coalitional defections at every period of the time horizon.     

A new approach towards integrated cell formation and inventory lot sizing in an unreliable cellular manufacturing system

This paper presents a comprehensive mathematical model for integrated cell formation and inventory lot sizing problem. The proposed model seeks to minimize cell formation costs as well as the costs associated with production, while dynamic conditions, alternative routings, machine capacity limitation, operations sequences, cell size constraints, process deterioration, and machine breakdowns are also taken into account. The total cost consists of machine procurement, cell reconfiguration, preventive and corrective repairs, material handling (intra-cell and inter-cell), machine operation, part subcontracting, finished and unfinished parts inventory cost, and defective parts replacement costs. With respect to the multiple products, multiple process plans for each product and multiple routing alternatives for each process plan which are assumed in the proposed model, the model is combinatorial. Moreover, unreliability conditions are considered, because moving from “in-control” state to “out-of-control” state (process deterioration) and machine breakdowns make the model more practical and applicable. To conquer the breakdowns, preventive and corrective actions are adopted. Finally, a Particle Swarm Optimization (PSO)-based meta-heuristic is developed to overcome NP-completeness of the proposed model.     

An O(T) algorithm for the capacitated lot sizing problem with minimum order quantities

This paper explores a single-item capacitated lot sizing problem with minimum order quantity, which plays the role of minor set-up cost. We work out the necessary and sufficient solvability conditions and apply the general dynamic programming technique to develop an O(T³) exact algorithm that is based on the concept of minimal sub-problems. An investigation of the properties of the optimal solution structure allows us to construct explicit solutions to the obtained sub-problems and prove their optimality. In this way, we reduce the complexity of the algorithm considerably and confirm its efficiency in an extensive computational study.     

Economic lot sizing problem with inventory bounds

This paper studies a economic lot sizing (ELS) problem with both upper and lower inventory bounds. Bounded ELS models address inventory control problems with time-varying inventory capacity and safety stock constraints. An O(n²) algorithm is found by using net cumulative demand (NCD) to measure the amount of replenishment requested to fulfill the cumulative demand till the end of the planning horizon. An O(n) algorithm is found for the special case, the bounded ELS problem with non-increasing marginal production cost.     

Production lot sizing with process deterioration and machine breakdown

The paper presents a generalized economic manufacturing quantity model for an unreliable production system in which the production facility may shift from an ‘in-control’ state to an ‘out-of-control’ state at any random time (when it starts producing defective items) and may ultimately break down afterwards. If a machine breakdown occurs during a production run, then corrective repair is done; otherwise, preventive repair is performed at the end of the production run to enhance the system reliability. The proposed model is formulated assuming that the time to machine breakdown, corrective and preventive repair times follow arbitrary probability distributions. However, the criteria for the existence and uniqueness of the optimal production time are derived under general breakdown and uniform repair time (corrective and preventive) distributions. The optimal production run time is determined numerically and the joint effect of process deterioration, machine breakdowns and repairs (corrective and preventive) on the optimal decisions is investigated for a numerical example.     

A new dynamic programming algorithm for the single item capacitated dynamic lot size model

We develop a new dynamic programming method for the single item capacitated dynamic lot size model with non-negative demands and no backlogging. This approach builds the Optimal value function in piecewise linear segments. It works very well on the test problems, requiring less than 0.3 seconds to solve problems with 48 periods on a VAX 8600. Problems with the time horizon up to 768 periods are solved. Empirically, the computing effort increases only at a quadratic rate relative to the number of periods in the time horizon.This research was supported in part by NSF grants DDM-8814075 and DMC-8504786.     

Augmenting the lot sizing order quantity when demand is probabilistic

In this paper we consider a single item, discrete time, lot sizing situation where demand is random and its parameters (e.g., mean and standard deviation) can change with time. For the appealing criterion of minimizing expected total relevant costs per unit time until the moment of the next replenishment we develop two heuristic ways of selecting an appropriate augmentation quantity beyond the expected total demand through to the planned (deterministic) time of the next replenishment. The results of a set of numerical experiments show that augmentation is important, particularly when orders occur frequently (i.e., the fixed cost of a replenishment is low relative to the costs of carrying one period of demand in stock) and the coefficient of variability of demand is relatively low, but also under other specified circumstances. The heuristic procedures are also shown to perform very favourably against a hindsight, baseline (s, S) policy, especially for larger levels of non-stationarity.     

Dynamic uncapacitated lot sizing with random demand under a fillrate constraint

This paper deals with the single-item dynamic uncapacitated lot sizing problem with random demand. We propose a model based on the “static uncertainty” strategy of Bookbinder and Tan (1988). In contrast to these authors, we use exact expressions for the inventory costs and we apply a fillrate constraint. We present an exact solution method and modify several well-known dynamic lot sizing heuristics such that they can be applied for the case of dynamic stochastic demands. A numerical experiment shows that there are significant differences in the performance of the heuristics whereat the ranking of the heuristics is different from that reported for the case of deterministic demand.     

Multi-level lot sizing and job shop scheduling with compressible process times: A cutting plane approach

This paper proposes an integer linear programming formulation for a simultaneous lot sizing and scheduling problem in a job shop environment. Among others, one of our realistic assumptions is dealing with flexible machines which enable the production manager to change their working speeds. Then, a number of valid inequalities are developed based on problem structures. As the valid inequalities can help in reducing the non-optimal parts of the solution space, they are dealt with as some cutting planes. The proposed cutting planes are used to solve the problem in (i) cut-and-branch, and (ii) branch-and-cut approaches. The performance of each cutting plane is investigated with CPLEX 12.2 on a set of randomly-generated test data. Then, some performance criteria are identified and the proposed cutting planes are ranked by TOPSIS method.     

A dynamic programming approach for batch sizing in a multi-stage production process with random yields

This paper proposes a dynamic programming approach to modeling and determining batch sizes in a single period, multi-stage production process with random yields for each stage. To improve the computational performance of the proposed approach, a statistical bound is developed. A key decision incorporated into the model is whether to continue onto the next stage of processing or to scrap the entire current batch of product. This decision is based on the expected total profit from the remaining items for processing following the removal of all defectives. The decisions involving the locations of test stations after stages are also incorporated into the modeling approach.     

Improved lower bounds for the capacitated lot sizing problem with setup times

We present new lower bounds for the capacitated lot sizing problem, applying decomposition to the network reformulation. The demand constraints are the linking constraints and the problem decomposes into subproblems per period containing the capacity and setup constraints. Computational results and a comparison to other lower bounds are presented.     

The stochastic economic lot scheduling problem: A survey

The present literature survey focuses on the stochastic economic lot scheduling problem (SELSP). The SELSP deals with the make-to-stock production of multiple standardized products on a single machine with limited capacity under random demands, possibly random setup times and possibly random production times. The main task of a production manager in this setting is the construction of a production plan for the machine. Based on the critical elements of such a production plan, we present a classification and extensive overview of the research on the SELSP together with an indication of open research areas. By doing so, we intend to stimulate the discussion on the important problems concerning the SELSP both from a theoretical and a practical point of view.     

The deterministic multi-item dynamic lot size problem with joint business volume discount

This paper considers the multi-item dynamic lot size model where joint business volume discount is applied for all items purchased whenever the total dollar value of an order reaches a certain level. Multi-item discounts are prevalent in practical applications, yet the literature has only considered limited instances of single-item models. We establish the mathematical formulation and design an effective dynamic programming based heuristic. Computational results disclose our approach obtains high quality solutions that dominate the best known heuristic for the simplified one-item case, and that proves vastly superior to the state-of-the-art CPLEX MIP code for the multi-item case (for which no alternative heuristics have been devised). We obtained significantly better solutions than CPLEX for the more complex problems, while running from 4800 to over 100,000 times faster. Enhanced variants of our method improve these outcomes further. This revised version was published online in June 2006 with corrections to the Cover Date.     

Production planning and pricing policy in a make-to-stock system with uncertain demand subject to machine breakdowns

We consider a make-to-stock system served by an unreliable machine that produces one type of product, which is sold to customers at one of two possible prices depending on the inventory level at the time when a customer arrives (i.e., the decision point). The system manager must determine the production level and selling price at each decision point. We first show that the optimal production and pricing policy is a threshold control, which is characterized by three threshold parameters under both the long-run discounted profit and long-run average profit criteria. We then establish the structural relationships among the three threshold parameters that production is off when inventory is above the threshold, and that the optimal selling price should be low when inventory is above the threshold under the scenario where the machine is down or up. Finally we provide some numerical examples to illustrate the analytical results and gain additional insights.     

Lot sizing with carbon emission constraints

This paper introduces new environmental constraints, namely carbon emission constraints, in multi-sourcing lot-sizing problems. These constraints aim at limiting the carbon emission per unit of product supplied with different modes. A mode corresponds to the combination of a production facility and a transportation mode and is characterized by its economical costs and its unitary carbon emission. Four types of constraints are proposed and analyzed in the single-item uncapacitated lot-sizing problem. The periodic case is shown to be polynomially solvable, while the cumulative, global and rolling cases are NP-hard. Perspectives to extend this work are discussed.     

Polynomial cases of the economic lot sizing problem with cost discounts

In this paper we study the economic lot sizing problem with cost discounts. In the economic lot sizing problem a facility faces known demands over a discrete finite horizon. At each period, the ordering cost function and the holding cost function are given and they can be different from period to period. There are no constraints on the quantity ordered in each period and backlogging is not allowed. The objective is to decide when and how much to order so as to minimize the total ordering and holding costs over the finite horizon without any shortages. We study two different cost discount functions. The modified all-unit discount cost function alternates increasing and flat sections, starting with a flat section that indicates a minimum charge for small quantities. While in general the economic lot sizing problem with modified all-unit discount cost function is known to be NP-hard, we assume that the cost functions do not vary from period to period and identify a polynomial case. Then we study the incremental discount cost function which is an increasing piecewise linear function with no flat sections. The efficiency of the solution algorithms follows from properties of the optimal solution. We computationally test the polynomial algorithms against the use of CPLEX.