Lot sizing for a single product recovery system with variable setup numbers

Inventory systems for joint remanufacturing and manufacturing have recently received considerable attention. In such systems, used products are collected from customers and are kept at the recoverable inventory warehouse for future remanufacturing. In this paper a production–remanufacturing inventory system is considered, where the demand can be satisfied by production and remanufacturing. The cost structure consists of the EOQ-type setup costs, holding costs and shortage costs. The model with no shortage case in serviceable inventory is first studied. The serviceable inventory shortage case is discussed next. Both models are considered for the case of variable setup numbers of equal sized batches for production and remanufacturing processes. For these two models sufficient conditions for the optimal type of policy, referring to the parameters of the models, are proposed.     

A survey of deterministic models for the EOQ and EPQ with partial backordering

Models for the basic deterministic EOQ or EPQ problem with partial backordering or backlogging make all the assumptions of the classic EOQ or EPQ model with full backordering except that only a fraction of the demand during the stockout period is backordered. In this survey we review deterministic models that have been developed over the past 40 years that address the basic models and extensions that add other considerations, such as pricing, perishable or deteriorating inventory, time-varying or stock-dependent demand, quantity discounts, or multiple-warehouses.     

Managing inventory in a network: Performance bounds for simple policies

We consider the joint optimization of rebalancing/sourcing inventory on a graph. We focus on the lost-sales setting with customer induced relocations. Through a coupling analysis, we provide worst-case performance bounds, with tight instances, for policies commonly used in practice. We provide further insights on the performance of these policies and discuss cost regimes where they are effective.     

Inventory control with product returns: The impact of imperfect information

Product returns are characterized by considerable uncertainty on time and quantity. In the literature on inventory management for product return environments best forecasts of future returns are associated with methods that use the most information regarding product return history. In practice, however, data is often scarce and unreliable, while forecasts based on historical data, reliable or not, are never perfect. In this paper we therefore investigate the impact of imperfect information with respect to the return process on inventory management performance. We show that in the case of imperfect information the most informed method does not necessarily lead to best performance. The results have relevant implications regarding investments in product return information systems.     

Optimal policy and holding cost stability regions in a periodic review inventory system with manufacturing and remanufacturing options

In this paper a periodic review inventory model with finite horizon and remanufacturing, manufacturing options is studied. It is assumed that demand and cost parameters are constant and a sufficiently large quantity of used products is available at the beginning of the horizon. The model is studied within the class of policies with given remanufacturing and manufacturing set up and the optimal policy is obtained within this class. The policy specifies the period of switching from remanufacturing to manufacturing (switching period), the periods where remanufacturing and manufacturing activities take place and the corresponding lot sizes. An explicit formula for the cost function and some of its properties are established. Based on these, an algorithm which partitions the set of holding cost parameters into subsets, computes the optimal policy and constructs its corresponding stability regions on every such subset is proposed.     

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.     

On the optimal control of manufacturing and remanufacturing activities with a single shared server

We consider a single-product make-to-stock manufacturing–remanufacturing system. Returned products require remanufacturing before they can be sold. The manufacturing and remanufacturing operations are executed by the same single server, where switching from one activity to another does not involve time or cost and can be done at an arbitrary moment in time. Customer demand can be fulfilled by either newly manufactured or remanufactured products. The times for manufacturing and remanufacturing a product are exponentially distributed. Demand and used products arrive via mutually independent Poisson processes. Disposal of products is not allowed and all used products that are returned have to be accepted. Using Markov decision processes, we investigate the optimal manufacture–remanufacture policy that minimizes holding, backorder, manufacturing and remanufacturing costs per unit of time over an infinite horizon. For a subset of system parameter values we are able to completely characterize the optimal continuous-review dynamic preemptive policy. We provide an efficient algorithm based on quasi-birth–death processes to compute the optimal policy parameter values. For other sets of system parameter values, we present some structural properties and insights related to the optimal policy and the performance of some simple threshold policies.     

Channel coordination using product returns for a supply chain with stochastic salvage capacity

We examine returns policy in a Newsboy framework. Unlike the prior literature, however, we assume that both supplier and retailer have limited and stochastic salvage capacities. We first analyze the case of integrated supply chain in which the agents’ decisions are fully coordinated for the joint profits. The result prescribes a partial returns policy, in which the retailer returns a part of the leftovers to the supplier and liquidates the remainder through its clearance sale. In a decentralized system, the supplier should motivate the retailer to duplicate the outcome of the integrated system in choosing order and returns quantities. We propose three coordination contracts, of which each uses two benefit transfer schemes as an incentive to the retailer, instead of using a single benefit scheme as in the prior literature. All three effectively coordinate the supply chain. The supplier, as a Stakelberg leader, chooses the most profitable one since each contract yields the different shares of the agents’ profits.     

Heuristics for the multi-depot petrol station replenishment problem with time windows

In the multi-depot petrol station replenishment problem with time windows (MPSRPTW), the delivery of petroleum products stored in a number of different petroleum depots to a set of petrol distribution stations has to be optimized. Each depot has its own fleet of heterogeneous and compartmented tank trucks. Stations specify their demand by indicating the minimum and maximum quantities to be delivered for each ordered product and require the delivery within a predetermined time window. Several inter-related decisions must be made simultaneously in order to solve the problem. For this problem, the set of feasible routes to deliver all the demands, the departure depot for each route, the quantities of each product to be delivered, the assignment of these routes to trucks, the time schedule for each trip, and the loading of the ordered products to different tanks of the trucks used need to be determined. In this paper, we propose a mathematical model that selects, among a set of feasible trips, the subset that allows the delivery of all the demands while maximizing the overall daily net revenue. If this model is provided with all possible feasible trips, it determines the optimal solution for the corresponding MPSRPTW. However, since the number of such trips is often huge, we developed a procedure to generate a restricted set of promising feasible trips. Using this restricted set, the model produces a good but not necessarily optimal solution. Thus the proposed solution process can be seen as a heuristic. We report the results of the extensive numerical tests carried out to assess the performance of the proposed heuristic. In addition, we show that, for the special case of only one depot, the proposed heuristic outperforms a previously published solution method.     

A heuristic methodology for sizing a large-scale system of constrained, reusable resources

This paper proposes a methodology for sizing certain large-scale systems of reusable, capacity-constrained resources engaged in tasks of varying duration. A heuristic program schedules resources throughout a finite planning horizon using two decision variables: varying resource capacity for meeting demand and varying task duration. A model of the problem and heuristic scheduling program are presented. A sequential, iterative sizing procedure determines the number of system resources to meet demand at each stage of the problem. Results compare the methodology with heuristics used in practice to schedule resources and size a real-world, large-scale training system.     

Real-time production planning and control system for job-shop manufacturing: A system dynamics analysis

Much attention has been paid to production planning and control (PPC) in job-shop manufacturing systems. However, there is a remaining gap between theory and practice, in the ability of PPC systems to capture the dynamic disturbances in manufacturing process. Since most job-shop manufacturing systems operate in a stochastic environment, the need for sound PPC systems has emerged, to identify the discrepancy between planned and actual activities in real-time and also to provide corrective measures. By integrating production ordering and batch sizing control mechanisms into a dynamic model, we propose a comprehensive real-time PPC system for arbitrary capacitated job-shop manufacturing. We adopt a system dynamics (SD) approach which is proved to be appropriate for studying the dynamic behavior of complex manufacturing systems. We study the system’s response, under different arrival patterns for customer orders and the existence of various types real-time events related to customer orders and machine failures. We determine the near-optimal values of control variables, which improve the shop performance in terms of average backlogged orders, work in process inventories and tardy jobs. The results of extensive numerical investigation are statistically examined by using analysis of variance (ANOVA). The examination reveals an insensitivity of near-optimal values to real-time events and to arrival pattern and variability of customer orders. In addition, it reveals a positive impact of the proposed real-time PPC system on the shop performance. The efficiency of PPC system is further examined by implementing data from a real-world manufacturer.     

Optimal acquisition and production policy in a hybrid manufacturing/remanufacturing system with core acquisition at different quality levels

We study the acquisition and production planning problem for a hybrid manufacturing/remanufacturing system with core acquisition at two (high and low) quality conditions. We model the problem as a stochastic dynamic programming, derive the optimal dynamic acquisition pricing and production policy, and analyze the influences of system parameters on the acquisition prices and production quantities. The production cost differences among remanufacturing high- and low-quality cores and manufacturing new products are found to be critical for the optimal production and acquisition pricing policy: the acquisition price of high-quality cores is increasing in manufacturing and remanufacturing cost differences, while the acquisition price of low-quality cores is decreasing in the remanufacturing cost difference between high- and low-quality cores and increasing in manufacturing and remanufacturing cost differences; the optimal remanufacturing/manufacturing policy follows a base-on-stock pattern, which is characterized by some crucial parameters dependent on these cost differences.     

Lower bounds for the earliness–tardiness scheduling problem on parallel machines with distinct due dates

This paper addresses the parallel machine scheduling problem in which the jobs have distinct due dates with earliness and tardiness costs. New lower bounds are proposed for the problem, they can be classed into two families. First, two assignment-based lower bounds for the one-machine problem are generalized for the parallel machine case. Second, a time-indexed formulation of the problem is investigated in order to derive efficient lower bounds throught column generation or Lagrangean relaxation. A simple local search algorithm is also presented in order to derive an upper bound. Computational experiments compare these bounds for both the one machine and parallel machine problems and show that the gap between upper and lower bounds is about 1.5%.     

Regularity and derivative bounds for a convection-diffusion problem with a Neumann outflow condition

A convection-diffusion problem is considered on the unit square. The convective direction is parallel to two of the square's sides. A Neumann condition is imposed on the outflow boundary, with Dirichlet conditions on the other three sides. The precise relationship between the regularity of the solution and the global smoothness and corner compatibility of the data is elucidated. Pointwise bounds on derivatives of the solution are obtained; their dependence on the data regularity and compatibility and on the small diffusion parameter is made explicit. The analysis uses Fourier transforms and Mikhlin multipliers to sharpen regularity results previously published for certain subproblems in a decomposition of the solution.     

A heuristic solution technique to attain the minimal total cost bounds of transporting a homogeneous product with varying demands and supplies

Transportation of a product from multi-source to multi-destination with minimal total transportation cost plays an important role in logistics and supply chain management. Researchers have given considerable attention in minimizing this cost with fixed supply and demand quantities. However, these quantities may vary within a certain range in a period due to the variation of the global economy. So, the concerned parties might be more interested in finding the lower and the upper bounds of the minimal total costs with varying supplies and demands within their respective ranges for proper decision making. This type of transportation problem has received attention of only one researcher, who formulated the problem and solved it by LINGO. We demonstrate that this method fails to obtain the correct upper bound solution always. Then we extend this model to include the inventory costs during transportation and at destinations, as they are interrelated factors. The number of choices of supplies and demands within their respective ranges increases enormously as the number of suppliers and buyers increases. In such a situation, although the lower bound solution can be obtained methodologically, determination of the upper bound solution becomes an NP hard problem. Here we carry out theoretical analyses on developing the lower and the upper bound heuristic solution techniques to the extended model. A comparative study on solutions of small size numerical problems shows promising performance of the current upper bound technique. Another comparative study on results of numerical problems demonstrates the effect of inclusion of the inventory costs.     

Designing a quantity discount scheme for a newsvendor-type product with numerous heterogeneous retailers

This paper presents a practical approach for designing a quantity-discount (“qd”) scheme for a manufacturer who supplies a newsvendor-type product to a large number of heterogeneous retailers. The main components of our approach are: (i) an information structure for handling a large number of heterogeneous retailers with changing identities; and (ii) expected-profit expressions for any given qd scheme. We show that these expected-profit expressions can be easily optimized to produce attractive qd schemes; also, these schemes are shown to be quite robust against errors in parameter estimation.     

Predicting performance measures for Markovian type of manufacturing systems with product failures

Optoelectronic products are typically assembled and tested in a flow shop environment with multiple processors at each stage. The first few stages are dedicated for assembly and the later stages are dedicated for calibration and testing. Whenever a product (or job) fails at a stage, it is routed back to one of the downstream stages or to the same stage (depending upon the nature of the failure). Consequently, the product could circulate several times between the current stage and the preceding stage(s) before moving to the next stage. Estimating the performance measures (such as WIP and flow time) of such manufacturing systems is not trivial. This paper presents analytical approximations to estimate the performance measures of a manufacturing system with multiple product classes, job circulations due to failures, and some resources being shared among different product classes. The analytical approximations were verified using simulation on several problem instances. The experimental study indicates that these approximations can be used by operations managers to estimate the performance measures of a manufacturing system with product failures.     

Optimal control of a one product recovery system with backlogging

In this paper a product recovery system for one product is investigated.The system contains one inventory for returned and recoverableitems and one for serviceable items. Demands are satisfied fromserviceable inventory where backlogging of demands is allowed.In addition, there is the possibility of disposal for the returnedproducts. We assume deterministic but dynamic return and demandrates and a linear cost structure. The Pontryagin maximum principleis used to determine the optimal production, remanufacturingand disposal policy.