Service differentiation in spare parts inventory management

The contemporary after-sales market is of increasing importance. One of the features required by the market is to provide differentiated service levels to different groups of customers. We use critical levels as a means to offer differentiation. Critical level policies aim to exploit the differences in target service levels by inventory rationing. In our multi-item single-location spare parts inventory model, we aim to minimize the spare parts provisioning cost, that is inventory holding and transportation cost, under the condition that aggregate mean waiting time constraints for all customer groups are met. In a computational experiment and a case study with data from a company in the semiconductor supplier industry, we show that significant cost reductions can be obtained when critical level policies are used instead of base stock policies (ie policies without critical levels).     

Inventory rationing for the News-Vendor problem with a drop-shipping option

We consider a single-period inventory model for a bricks-and-clicks business. Store inventory can be used to fulfill both store demand and internet demand. Drop-shipping is used as an additional option for internet sale. We analyze two rationing policies for store inventory: a threshold policy and a fixed-portion policy. We formulate the expected profit for both and prove concavity. There exists an optimal order quantity for store inventory and an optimal stock rationing level below which the manager starts to use drop-shipping for internet demand. Numerical examples show that considering the rationing problem for the single-period inventory model, which is ignored in some earlier works, can result in remarkable differences.     

Managing an integrated production inventory system with information on the production and demand status and multiple non-unitary demand classes

In this paper, we study a system consisting of a manufacturer or supplier serving several retailers or clients. The manufacturer produces a standard product in a make-to-stock fashion in anticipation of orders emanating from n retailers with different contractual agreements hence ranked/prioritized according to their importance. Orders from the retailers are non-unitary and have sizes that follow a discrete distribution. The total production time is assumed to follow a k₀-Erlang distribution. Order inter-arrival time for class l demand is assumed to follow a k_l-Erlang distribution. Work-in-process as well as the finished product incur a, per unit per unit of time, carrying cost. Unsatisfied units from an order from a particular demand class are assumed lost and incur a class specific lost sale cost. The objective is to determine the optimal production and inventory allocation policies so as to minimize the expected total (discounted or average) cost. We formulate the problem as a Markov decision process and show that the optimal production policy is of the base-stock type with base-stock levels non-decreasing in the demand stages. We also show that the optimal inventory allocation policy is a rationing policy with rationing levels non-decreasing in the demand stages. We also study several important special cases and provide, through numerical experiments, managerial insights including the effect of the different sources of variability on the operating cost and the benefits of such contracts as Vendor Managed Inventory or Collaborative Planning, Forecasting, and Replenishment. Also, we show that a heuristic that ignores the dependence of the base-stock and rationing levels on the demands stages can perform very poorly compared to the optimal policy.     

Joint management of capacity and inventory in make-to-stock production systems with multi-class demand

We evaluate the benefits of coordinating capacity and inventory decisions in a make-to-stock production environment. We consider a firm that faces multi-class demand and has additional capacity options that are temporary and randomly available. We formulate the model as a Markov decision process (MDP) and prove that a solution to the optimal joint control problem exists. For several special cases we characterize the structure of the optimal policy. For the general case, however, we show that the optimal policy is state-dependent, and in many instances non-monotone and difficult to implement. Therefore, we consider three pragmatic heuristic policies and assess their performance. We show that the majority of the savings originate from the ability to dynamically adjust capacity, and that a simple heuristic that can adjust production capacity (based on workload fluctuation) but uses a static production/rationing policy can result in significant savings.     

Inventory rationing in an (<Emphasis Type="Italic">s,Q</Emphasis>) inventory model with lost sales and two demand classes

Whenever demand for a single item can be categorised into classes of different priority, an inventory rationing policy should be considered. In this paper we analyse a continuous review (s, Q) model with lost sales and two demand classes. A so-called critical level policy is applied to ration the inventory among the two demand classes. With this policy, low-priority demand is rejected in anticipation of future high-priority demand whenever the inventory level is at or below a prespecified critical level. For Poisson demand and deterministic lead times, we present an exact formulation of the average inventory cost. A simple optimisation procedure is presented, and in a numerical study we compare the optimal rationing policy with a policy where no distinction between the demand classes is made. The benefit of the rationing policy is investigated for various cases and the results show that significant cost reductions can be obtained.     

Optimal production and rationing policies of a make-to-stock production system with batch demand and backordering

In this paper, we consider the stock rationing problem of a single-item make-to-stock production/inventory system with multiple demand classes. Demand arrives as a Poisson process with a randomly distributed batch size. It is assumed that the batch demand can be partially satisfied. The facility can produce a batch up to a certain capacity at the same time. Production time follows an exponential distribution. We show that the optimal policy is characterized by multiple rationing levels.     

Optimizing product service system by franchise fee contracts under information asymmetry

This paper studies the problem of how to effectively provide product service system (PSS) in a service-oriented manufacturing supply chain under asymmetric private demand information. The PSS in the supply chain is operated heterogeneously and complementarily, in which the manufacturer provides the product while the retailer who possesses private demand information is responsible for adding the necessary value-added service on the basic product. We address the issue of how different contracts affect the decisions and profitability of the supply chain members. Three types of contracts are developed to help supply chain partners to make decisions and enhance the supply chain’s efficiency. The first is the franchise fee (FF) contract, under which the manufacturer provides a two-part tariff contract (wholesale price and franchise fee) to influence the retailer’s decision and to detect her private demand information. The second is the franchise fee with service requirement (FFS) contract, under which the manufacturer specifies the service level required in addition to the two-part tariff contract terms. The third is the franchise fee with centralized service requirement (FFCS) contract, which is similar to the FFS contract but that the service level specified by the manufacturer is the system optimal solution. Our analytical results show that all three contracts enable the manufacturer to detect the retailer’s private demand information, with the FFCS contract achieving the greatest channel profit. Finally, numerical examples are presented, and sensitivity analysis of service level and profit are conducted to compare the performance of the three contracts under different settings. The paper provides managerial guidelines for the manufacturer in contract offering under different conditions.     

Dynamic inventory rationing strategies for inventory systems with two demand classes,Poisson demand and backordering

We study inventory systems with two demand classes (critical and non-critical), Poisson demand and backordering. We analyze dynamic rationing strategies where the number of items reserved for critical demand depends on the remaining time until the next order arrives. Different from results in the literature, we do not discretize demand but derive a set of formulae that determine the optimal rationing level for any possible value of the remaining time. Moreover, we show that the cost parameters can be captured in a single relevant dimension, which allows us to present the optimal rationing levels in charts and lookup tables that are easy to implement. Numerical examples illustrate that the optimal dynamic rationing strategy outperforms all static strategies with fixed rationing levels.     

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.     

Inventory sharing in integrated network design and inventory optimization with low-demand parts

Service Parts Logistics (SPL) problems induce strong interaction between network design and inventory stocking due to high costs and low demands of parts and response time based service requirements. These pressures motivate the inventory sharing practice among stocking facilities. We incorporate inventory sharing effects within a simplified version of the integrated SPL problem, capturing the sharing fill rates in 2-facility inventory sharing pools. The problem decides which facilities in which pools should be stocked and how the demand should be allocated to stocked facilities, given full inventory sharing between the facilities within each pool so as to minimize the total facility, inventory and transportation costs subject to a time-based service level constraint. Our analysis for the single pool problem leads us to model this otherwise non-linear integer optimization problem as a modified version of the binary knapsack problem. Our numerical results show that a greedy heuristic for a network of 100 facilities is on average within 0.12% of the optimal solution. Furthermore, we observe that a greater degree of sharing occurs when a large amount of customer demands are located in the area overlapping the time windows of both facilities in 2-facility pools.     

价格和服务双因素影响的供应链协调决策模型研究

以单个制造商和存在竞争的两个零售商组成的供应链结构模型为研究对象,建立价格和服务两个重要因素影响的市场需求函数,研究供应链协调决策模型。以销售价格、服务质量和制造商批发价格作为三个决策变量,分析集中决策和分散决策两种情景的最优策略,研究收益共享、服务成本分担、收益共享成本分担等三种不同契约的供应链协调问题,并使用数值仿真方法,分析了相关参数变化对系统协调的影响。仿真结果表明:收益共享契约和成本分担契约需满足一定条件才能达到供应链协调,但其效果不一定实现帕累托最优;收益共享和成本分担契约可实现供应链协调,但收入共享系数需在合理区间取值;改进的收益共享成本分担契约能够避免共享系数的盲区,更加有效地达到供应链协调,保持供应链良好运行。     

Analysis of supply contracts with quantity flexibility

This paper explores a class of supply contracts under which a buyer receives discounts for committing to purchases in advance. The further in advance the commitment is made, the larger the discount. As time rolls forward, the buyer can increase the order quantities for future periods of the rolling horizon based on updated demand forecast information and inventory status. However, the buyer pays a higher per-unit cost for the incremental units. Such contracts are used by automobile and contract manufacturers, and are quite common in fuel oil and natural gas delivery markets. We develop a finite-horizon dynamic programming model to characterize the structure of the optimal replenishment strategy for the buyer. We present heuristic approaches to calculate the order volume in each period of the rolling horizon. Finally, we numerically evaluate the heuristic approaches and draw some managerial insights based on the findings.     

Call,put and bidirectional option contracts in agricultural supply chains with sales effort

This paper develops option contracts in a supplier-retailer agricultural supply chain where the market demand depends on sales effort. First, we examine a benchmark case of integrated supply chain with the loss rate. Second, we introduce three coordinating option contracts led by the supplier to reduce the retailer's risk, where the call option contract can reduce the shortage risk, the put option contract can reduce the inventory risk and the bidirectional option contract can reduce the bilateral risk. We find that both the optimal initial order quantity and the optimal option quantity increase with the sales effort and the option price will balance the influence of the loss rate on supply chain coordination. Furthermore, the bidirectional option price is the highest while its option quantity is the least, and the put option initial order quantity is the highest. Third, we also consider an option contract led by the retailer to reduce the supplier's wholesale risk. Among the above four option contracts, we find that the option quantity led by the retailer is the highest. Finally, the numerical examples present the impact of the parameters on the optimal decisions, and provide practical managerial insights to reduce the different risk in the agricultural supply chain.     

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.     

Consignment contracts with retail competition

Consignment contracts have been widely employed in many industries. Under such contracts, items are sold at a retailer’s but the supplier retains the full ownership of the inventory until purchased by consumers; the supplier collects payment from the retailer based on actual units sold. We investigate how competition among retailers influences the supply chain decisions and profits under different consignment arrangements, namely a consignment price contract and a consignment contract with revenue share. First, we investigate how these two consignment contracts and a price only contract compare from the perspective of each supply chain partner. We find that the retailers benefit more from a consignment price contract than from a consignment contract with revenue share or a price only contract, regardless of the level of retailer differentiation. The supplier’s most beneficial contact, however, critically depends upon the level of retailer differentiation: a consignment contract with revenue share is preferable for the supplier if retailer differentiation is strong; otherwise a consignment price contract is preferable. Second, we study how retailer differentiation affects the profits of all supply chain partners. We find that less retailer differentiation improves the supplier’s profit for both types of consignment contract. Moreover, less retailer differentiation improves profits of the retailers in a consignment price contract, but not necessarily in a consignment contract with revenue share.     

Optimal lateral transshipment policies for a two location inventory problem with multiple demand classes

We consider an inventory model for spare parts with two stockpoints, providing repairable parts for a critical component of advanced technical systems. As downtime costs for these systems are expensive, ready–for–use spare parts are kept in stock to be able to quickly respond to a breakdown of a system. We allow for lateral transshipments of parts between the stockpoints upon a demand arrival. Each stockpoint faces demands from multiple demand classes. We are interested in the optimal lateral transshipment policy. There are three ways in which a demand can by satisfied: from own stock, via a lateral transshipment, or via an emergency procedure. Using stochastic dynamic programming, we characterize and prove the structure of the optimal policy, that is, the policy for satisfying the demands which minimizes the average operating costs of the system. This optimal policy is a threshold type policy, with state-dependent thresholds at each stockpoint for every demand class. We show a partial ordering in these thresholds in the demand classes. In addition, we derive conditions under which the so-called hold back and complete pooling policies are optimal, two policies that are often assumed in the literature. Furthermore, we study several model extensions which fit in the same modeling framework.     

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.     

A two-stage heuristic for disassembly scheduling with assembly product structure

Disassembly scheduling, one of the important operational problems in disassembly systems, is the problem of determining the ordering and disassembly schedules of used or end-of-life products while satisfying the demand of their parts or components over a certain planning horizon. This paper considers products with assembly structure for the objective of minimizing the sum of purchase, set up, inventory holding, and disassembly operation costs, and suggests a two-stage heuristic, in which an initial solution is obtained in the form of the minimal latest ordering and disassembly schedule, and then improved iteratively considering trade-offs among different cost factors. To show the performance of the heuristic, computational experiments were done on the example obtained from the literature and a number of randomly generated test problems, and the results show that the heuristic can give optimal or very near-optimal solutions within very short computation times.     

Pooling through lateral transshipments in service parts systems

We study the inventory management problem of a service center operating in a decentralized service parts network. The service centers collaborate through inventory and service pooling, and through sharing information on the inventory status. Upon demand arrival, a service center may request a part from the other center, in which case a payment is made. Under this competitive and collaborative environment, we first characterize the optimal operating policy of an individual service center. Through computational analysis we identify the conditions under which pooling is most beneficial to the service center, and make an assessment of different pooling strategies which are commonly adopted in practice and in the literature. Finally, we analyze the effect of interaction between the centers on the benefit of pooling.     

Optimal shared-savings contracts in supply chains: Linear contracts and double moral hazard

In many supply chains consumption of indirect materials, sold by a supplier to a customer for use in her production process, can be reduced by efforts exerted by either party. Since traditional supply contracts provide no incentive for the supplier to exert such effort, shared-savings contracts have been proposed as a way to improve incentives in the channel, leading to more efficient effort choices by the two parties. Such shared-savings contracts typically combine a fixed service fee with a variable component based on consumption volume. We formalize this situation using the double moral hazard framework, in which both parties decide how much effort to exert by trading off the cost of their effort against the benefits that they will obtain from reduced consumption. We also extend the double moral hazard framework to analyze a broader class of cost-of-effort functions than considered so far, including the linear cost-of-effort functions commonly found in practice. We show that the supplier can still always induce the optimal second-best equilibrium with a linear shared-savings contract. Under this broader class of functions, however, the behavior of the optimal contract as a function of the problem parameters becomes more complex. We illustrate how small changes in the problem parameters can turn profits from being a well-behaved to a poorly-behaved function of the contract, and provide some theoretical characterization of this phenomenon. The practical significance of this is that simple (linear) contracts are sufficient in many double moral hazard contexts, even for the broader class of functions we consider, but care must be taken in selecting the optimal contract parameters.