Control policies for single-stage production systems with perishable inventory and customer impatience

We consider problems of inventory and admission control for make-to-stock production systems with perishable inventory and impatient customers. Customers may balk upon arrival (refuse to place orders) and renege while waiting (withdraw delayed orders) during stockouts. Item lifetimes and customer patience times are random variables with general distributions. Processing, setup, and customer inter-arrival times are however assumed to be exponential random variables. In particular, the paper studies two models. In the first model, the system suspends its production when its stock reaches a safety level and can resume later without incurring any setup delay or cost. In the second model, the system incurs setup delays and setup costs; during stockouts, all arriving customers are informed about anticipated delays and either balk or place their orders but cannot withdraw them later. Using results from the queueing literature, we derive expressions for the system steady-state probabilities and performance measures, such as profit from sales and costs of inventory, setups, and delays in filling customer orders. We use these expressions to find optimal inventory and admission policies, and investigate the impact of product lifetimes and customer patience times on system performance.     

On the value of customer information for an independent supplier in a continuous review inventory system

We consider the inventory control problem of an independent supplier in a continuous review system. The supplier faces demand from a single customer who in turn faces Poisson demand and follows a continuous review (R, Q) policy. If no information about the inventory levels at the customer is available, reviews and ordering are usually carried out by the supplier only at points in time when a customer demand occurs. It is common to apply an installation stock reorder point policy. However, as the demand faced by the supplier is not Markovian, this policy can be improved by allowing placement of orders at any point in time. We develop a time delay policy for the supplier, wherein the supplier waits until time t after occurrence of the customer demand to place his next order. If the next customer demand occurs before this time delay, then the supplier places an order immediately. We develop an algorithm to determine the optimal time delay policy. We then evaluate the value of information about the customer’s inventory level. Our numerical study shows that if the supplier were to use the optimal time delay policy instead of the installation stock policy then the value of the customer’s inventory information is not very significant.     

A general solution for the newsboy model with random order size and possibly a cutoff transaction size

In a recent paper, Dekker et al developed a solution procedure for the newsboy problem with a cutoff transaction size (CTS), such that customers with orders larger than the cutoff value are satisfied in an alternative way, against additional cost. A compound Poisson demand with discrete order sizes is assumed, and a computational procedure developed to identify the optimal solution. In this paper, we discard all distributional assumptions, and, given that order size is random, only the first three moments of the arrival rate and the order size are specified. A general optimal solution is developed, using Shore's piece-wise linear approximations. For cases where a CTS exists, the derived optimal solution is extended to also identify the optimal CTS. The new solution approach requires minimal distributional information, and its merits relative to current approaches are discussed and numerically demonstrated. The new methodology, based on a ‘Calculus of moments’ combined with a distributional approximation, may be easily extended to other computationally intractable problems.     

Analysis of optimal opportunistic replenishment policies for inventory systems by using a (s,S) model with a maximum issue quantity restriction

The analysis of optimal inventory replenishment policies for items having lumpy demand patterns is difficult, and has not been studied extensively although these items constitute an appreciable portion of inventory populations in parts and supplies types of stockholdings. This paper studies the control of an inventory item when the demand is lumpy. A continuous review (s,S) policy with a maximum issue quantity restriction and with the possibility of opportunistic replenishment is proposed to avoid the stock of these items being depleted unduly when all the customer orders are satisfied from the available inventory and to reduce ordering cost by coordinating inventory replenishments. The nature of the customer demands is approximated by a compound Poisson distribution. When a customer order arrives, if the order size is greater than the maximum issue quantity w, the order is satisfied by placing a special replenishment order rather than from the available stock directly. In addition, if the current inventory position is equal to or below a critical level A when such an order arrives, an opportunistic replenishment order which combines the special replenishment order and the regular replenishment order will be placed, in order to satisfy the customer's demand and to bring the inventory position to S. In this paper, the properties of the cost function of such an inventory system with respect to the control parameters s, S and A are analysed in detail. An algorithm is developed to determine the global optimal values of the control parameters. Indeed, the incorporation of the maximum issue quantity and opportunistic replenishment into the (s,S) policy reduces the total operating cost of the inventory system.     

Inventory control by different service levels

This paper examines the multiple period inventory control problem of a single product with multiple (two) prices, depending on service level, in which optimal pricing and ordering decisions are made in each period. Traditional inventory and pricing models consider only single products, single prices, and single service levels. However, this research paper finds that a seller can improve inventory control and revenue by offering multiple prices depending on service level. This research considers a single product with multiple (two) pricing policies corresponding to service level as follows: if the customer is willing to delay the shipment, he/she will be offered a lower regular price. Otherwise, the customer will pay the regular price plus extra charges for express service. In this paper, I show the following: (1) there is an optimal pricing and replenishment policy that can control inventory and (2) there exists a finite threshold for inventory levels such that if the inventory level at the beginning of each period is higher than the threshold, the customer will be offered the express service at the regular price, without any extra charge.     

具有两类需求服务的随机库存系统控制策略研究

研究具有两类顾客排队需求服务的随机库存系统.系统采取(s,Q)补货策略且当库存水平下降到安全库存s时,到达的第二类顾客以概率P得到服务.首先,建立库存水平状态转移方程并通过递推算法求解获得库存水平稳态概率分布和系统稳态指标;接下来,构建库存成本函数;最后,采用数值试验的方法研究该库存系统的最优控制策略并考察系统参数的敏感性.     

具有定价和开机成本的生产-库存系统的最优(s,d,S)策略

考虑一个具有有限容量和开机成本的连续盘点生产-库存系统, 其控制策略为(s,d,S)策略. 未被满足的需求都会丢失. 当机器处于关闭状态时,库存产品可以两个不同的价格进行销售. 当机器处于开机状态时,库存只能以较高的价格进行销售. 研究了如何发现该系统下的最优(s,d,S)策略,并开发了用于计算最优控制参数的有效算法.     

Integer programming approach to reactive scheduling in make-to-order manufacturing

New algorithms based on mixed integer programming formulations are proposed for reactive scheduling in a dynamic, make-to-order manufacturing environment. The problem objective is to update a long-term production schedule subject to service level and inventory constraints, whenever the customer orders are modified or new orders arrive. Different rescheduling policies are proposed, from a total reschedule of all remaining and unmodified customer orders to a non-reschedule of all such orders. In addition, a medium restrictive policy is considered for rescheduling only a subset of remaining customer orders awaiting material supplies. Numerical examples modeled after a real-world scheduling/rescheduling of customer orders in the electronics industry are presented and some results of computational experiments are reported.     

Optimal integrated production and inventory control of an assemble-to-order system with multiple non-unitary demand classes

We study a pure assemble-to-order system subject to multiple demand classes where customer orders arrive according to a compound Poisson process. The finished product is assembled from m different components that are produced on m distinct production facilities in a make-to-stock fashion. We show that the optimal production policy of each component is a state-dependent base-stock policy and the optimal inventory allocation policy is a multi-level state-dependent rationing policy. Using numerical experimentation, we first study the system behavior as a function of order size variability and order size. We show that the optimal average cost rate is more sensitive to order size variability than to order size. We also compare the optimal policy to the first-come first-serve policy and show that there is great benefit to inventory rationing. We also propose two simple heuristics and show that these can effectively mimic the optimal policy which is generally much more difficult to determine and, especially, to implement.     

An Incomplete Information Inventory Model with Presence of Inventories or Backorders as Only Observations

In many real-life contexts, inventory levels are only incompletely observed due to non-observation of demand, discrepancies in transmitting sales data, transaction errors, spoilage, misplacement, or theft of inventory. We study a periodic review inventory system, where the demand is not observed and the unmet demand is backordered. As a result, the inventory manager cannot tell the exact quantities of inventories or backorders. However, by looking at the shelf, he knows whether the inventory is positive or nonpositive. Only with this information, the inventory manager must determine the order quantity in each period that would minimize the expected total discounted cost over an infinite-horizon. The dynamic programming formulation of this problem has an infinite-dimensional state space. We use the concept of unnormalized probability to establish the existence of an optimal feedback policy and the uniqueness of the solution of the dynamic programming equation when the periodic cost has linear growth.     

Optimal control of a finite-capacity inventory system with setup cost and lost sales

One of the most fundamental results in inventory theoryis the optimality of (s, S) policy for inventory systems withsetup cost. This result is established based on a key assumptionof infinite production/ordering capacity. Several studies haveshown that, when there is a finite production/ordering capacity,the optimal policy for the inventory system is very complicatedand indeed, only partial characterization for the optimal policyis possible. In this paper, we consider a continuous reviewinventory system with finite production/ordering capacity andsetup cost, and show that the optimal control policy for thissystem has a very simple structure. We also develop efficientalgorithms to compute the optimal control parameters.     

The effect of information sharing on supply chain stability and the bullwhip effect

This paper analyzes the bullwhip effect in multi-stage supply chains operated with linear and time-invariant inventory management policies and shared supply chain information. Such information includes past order sequences and inventory records at all supplier stages. The paper characterizes the stream of orders placed at any stage of the chain when the customer demand process is known and ergodic, and gives an exact formula for the variance of the orders placed. The paper also derives robust analytical conditions, based only on inventory management policies, to predict the presence of the bullwhip effect and bound its magnitude. These results hold independently of the customer demand. The general framework proposed in this paper allows for any inventory replenishment policies, any ways of sharing and utilizing information, and any customer demand processes. It is also shown as a special case that sharing customer demand information across the chain significantly reduces, but does not completely eliminate, the bullwhip effect.     

Optimal admission and pricing control problems in service industries with multiple servers and sideline profit

This paper deals with the problem of selecting profitable customer orders sequentially arriving at a company operating in service industries with multiple servers in which two classes of services are provided. The first class of service is designed to meet the particular needs of customers; and the company (1) makes a decision on whether to accept or to reject the order for this service (admission control) and (2) decides a price of the order and offers it to an arriving customer (pricing control). The second class of service is provided as a sideline, which prevents servers from being idle when the number of customer orders for the first class is less than the number of servers. This yields the sideline profit. A cost is paid to search for customer orders, which is called the search cost. In the context of search cost, the company has an option whether to conduct the search or not. In this paper, we discuss both admission control and pricing control problems within an identical framework as well as examine the structure of the optimal policies to maximize the total expected net profit gained over an infinite planning horizon. We show that when the sideline profit is large, the optimal policies may not be monotone in the number of customer orders in the system. Copyright © 2008 John Wiley & Sons, Ltd.     

Modeling customer impatience in a newsboy problem with time-sensitive shortages

Customers across all stages of the supply chain often respond negatively to inventory shortages. One approach to modeling customer responses to shortages in the inventory control literature is time-dependent partial backlogging. Partial backlogging refers to the case in which a customer will backorder shortages with some probability, or will otherwise solicit the supplier’s competitors to fulfill outstanding shortages. If the backorder rate (i.e., the probability that a customer elects to backorder shortages) is assumed to be dependent on the supplier’s backorder replenishment lead-time, then shortages are said to be represented as time-dependent partial backlogging. This paper explores various backorder rate functions in a single period stochastic inventory problem in an effort to characterize a diversity of customer responses to shortages. We use concepts from utility theory to formally classify customers in terms of their willingness to wait for the supplier to replenish shortages. Under mild assumptions, we verify the existence of a unique optimal solution that corresponds to each customer type. Sensitivity analysis experiments are conducted in order to compare the optimal actions associated with each customer type under a variety of conditions. Additionally, we introduce the notion of expected value of customer patience information (EVCPI), and then conduct additional sensitivity analyses to determine the most and least opportune conditions for distinguishing between customer behaviors.     

Supply chain inventory optimization with two customer classes in discrete time

In this paper we consider a single-item inventory system where two demand classes with different service requirements are satisfied from a common inventory. A critical level, reorder point, order quantity or (s, q, k) policy is in use. The time axis is divided into discrete time units, which is a common characteristic of many real-life supply-chain processes. The inventory process within the lead time of a replenishment order is modelled as a sequence of (1) an ordinary renewal process and (2) two alternating renewal processes. Approximations are developed for the demand class-specific fill rates and the probability distribution of the waiting time of low priority customer orders. This waiting time distribution is used for the inventory allocation in a two-stage supply chain.     

Multicriteria Trade-Offs in a Warehouse/Retailer System

Multiple Criteria Decision Making (MCDM) methodology is applied to a two-echelon serial inventory/distribution system, consisting of a warehouse and retailer. Different situations, such as deterministic and probabilistic demand, and whether marginal inventory costs are known, are discussed. Three non-linear multiobjective programming models and corresponding solution approaches are presented to obtain non-dominated inventory policies achieving trade-offs among objectives such as customer service, inventory investment and transportation cost. Our results are MCDM generalizations of Brown's exchange curve, Starr and Miller's optimal policy curve and Gardner and Dannenbring's optimal policy surface.     

A Stochastic Petri Net Approach for Inventory Rationing in Multi-Echelon Supply Chains

Manufacturing supply chains are considered as discrete event dynamical systems (DEDS) where coordination of material and information flows is essential to satisfy customer orders and to improve the bottomline of the constituent organizations. A critical problem that is often faced by distribution centres that hold finished good inventory is that of inventory rationing. Inventory rationing is a useful strategy to tackle the problem of conflicting objectives i.e., minimizing inventory costs (holding and backorder) on the one hand and achieving the desired customer service levels (CSLs) on the other. The focus of this paper is to formulate Generalized Stochastic Petri net models to address the inventory rationing problem in the context of multi-echelon make-to-stock distribution chains, where the goods flow through multiple echelons, typically from product manufacturers all the way up-to the retail outlets. The statistical inventory control (SIC) policies modeled by the GSPN are (R, s, S) and a variant that we propose, (R^∗, s, S). We compare the performance of the model under two rationing settings. The first setting considers a case without cooperation, where the individual local stockpoints maximize their own performance. The second setting considers a case with cooperation, where the local stockpoints cooperate with each other to maximize the overall system performance. We provide a methodology to approximately determine the optimal rational fractions with different weights assigned to expected backorder and holding cost components (b/h). We present some interesting results obtained after rigorous numerical experimentation on the model.     

Optimal pricing and ordering policy for non-instantaneous deteriorating items under inflation and customer returns

This paper deals with an economic production quantity inventory model for non-instantaneous deteriorating items under inflationary conditions considering customer returns. We adopt a price- and time-dependent demand function. Also, the customer returns are considered as a function of both price and demand. The effects of time value of money are studied using the Discounted Cash Flow approach. The main objective is to determine the optimal selling price, the optimal replenishment cycles, and the optimal production quantity simultaneously such that the present value of total profit is maximized. An efficient algorithm is presented to find the optimal solution. Finally, numerical examples are provided to solve the presented inventory model using our proposed algorithm, which is further clarified through a sensitivity analysis. The results of analysing customer returns provide important suggestions to financial managers who use price as a control to match the quantity sold to inventory while maximizing revenues. The paper ends with a conclusion and an outlook to future studies.     

Optimal production and inventory rationing policies with selective-information sharing and two demand classes

This paper studies the impact of partner selection on the value of information sharing in a distribution system with one capacitated make-to-stock manufacturer and two retailers. When the high priority retailer with a higher shortfall cost is the sole partner, in the case that the low priority one places an order, the manufacturer allocates inventory more accurately according to more predictable orders from the high priority retailer. When only the low priority retailer shares information, the manufacturer is better informed about orders from this retailer, which shall trigger rationing decisions. Such intriguing differences in utilizing information from two prioritized retailers further induce different interactions between production and rationing policies and form two distinctive but closely related selective-information sharing systems. We characterize the manufacturer’s optimal production and rationing policies under both systems. Through a numerical study, we emphasize the effectiveness of partnering with the high priority retailer. When the manufacturer can establish information sharing links with only one retailer, such a choice usually brings more benefits despite differences in order sizes and/or demand rates of the two retailers. When a selective-information sharing system is the pilot run to full-information sharing, we find that the value of information throughout the implementation process often exhibits second-mover advantage and such a choice also helps the manufacturer create a more balanced return pattern. Finally, we illustrate that the cost-effectiveness of inventory rationing can be significant and optimally rationing inventory is the prerequisite for the superior of the selective-information sharing system with the high priority retailer.     

A Sequential Algorithm for an Inventory Selection Problem

Assume that we have m finished products in an inventory. Eachfinished product is characterized by two measurements P andQ. A customer specifies a purchase order by the requirementsof characteristics P and Q. A product is qualified to satisfya purchase order if and only if it possesses better measurementsof both P and Q than the customer requires. For a given batchof n purchase orders, the inventory selection problem is tochoose n finished products from the inventory to satisfy allpurchase orders with a minimum cost. This problem can be formulatedas a large-scale transportation problem. When the cost functionof selecting a product to satisfy an order exhibits certainstructure, we develop a fast sequential algorithm to solve thisproblem. Possible extensions and related problems are also discussedin this paper.