Production strategies for a stochastic lot-sizing problem with constant capacity

This paper presents a single item capacitated stochastic lot-sizing problem motibated by a Dutch company operating in a Make-To-Order environment. Due to a highly fluctuating and unpredictable demand, it is not possible to keep any finished goods inventory. In response to a customer's order, a fixed delivery date is quoted by the company. The objective is to determine in each period of the planning horizon the optimal size of production lots so that delivery dates are met as closely as possible at the expense of minimal average costs. These include set-up costs, holding costs for orders that are finished before their promised delivery date and penalty costs for orders that are not satisfied on time and are therefore backordered. Given that the optimal production policy is likely to be too complex in this situation, attention is focused on the development of heuristic procedures. In this paper two heuristics are proposed. The first one is an extension of a simple production strategy derived by Dellaert [5] for the uncapacitated version of the problem. The second heuristic is based on the well-known Silver-Meal algorithm for the case of deterministic time-varying demand. Experimental results suggest that the first heuristic gives low average costs especially when the demand variability is low and there are large differences in the cost parameters. The Silver-Meal approach is usually outperformed by the first heuristic in situations where the available production capacity is tight and the demand variability is low.     

Production-inventory control policy under warm/cold state-dependent fixed costs and stochastic demand: partial characterization and heuristics

The motivation for our study comes from some production and inventory systems in which ordering/producing quantities that exceed certain thresholds in a given period might eliminate some setup activities in the next period. Many examples of such systems have been discussed in prior research but the analysis has been limited to production settings under deterministic demand. In this paper, we consider a periodic-review production-inventory model under stochastic demand and incorporate the following fixed-cost structure into our analysis. When the order quantity in a given period exceeds a specified threshold value, the system is assumed to be in a “warm” state and no fixed cost is incurred in the next period regardless of the order quantity; otherwise the system state is considered “cold” and a positive fixed cost is required to place an order. Assuming that the unsatisfied demand is lost, we develop a dynamic programming formulation of the problem and utilize the concepts of quasi-K-convexity and non-K-decreasing to show some structural results on the optimal cost-to-go functions. This analysis enables us to derive a partial characterization of the optimal policy under the assumption that the demands follow a Pólya or uniform distribution. The optimal policy is defined over multiple decision regions for each system state. We develop heuristic policies that are aimed to address the partially characterized decisions, simplify the ordering policy, and save computational efforts in implementation. The numerical experiments conducted on a large set of test instances including uniform, normal and Poisson demand distributions show that a heuristic policy that is inspired by the optimal policy is able to find the optimal solution in almost all instances, and that a so-called generalized base-stock policy provides quite satisfactory results under reasonable computational efforts. We use our numerical examples to generate insights on the impact of problem parameters. Finally, we extend our analysis into the infinite horizon setting and show that the structure of the optimal policy remains similar.     

A Two-Echelon Inventory Optimization Model with Demand Time Window Considerations

This paper studies a two-echelon dynamic lot-sizing model with demand time windows and early and late delivery penalties. The problem is motivated by third-party logistics and vendor managed inventory applications in the computer industry where delivery time windows are typically specified under a time definite delivery contract. Studying the optimality properties of the problem, the paper provides polynomial time algorithms that require O(T ³) computational complexity if backlogging is not allowed and O(T ⁵) computational complexity if backlogging is allowed.     

Capacitated dynamic lot-sizing problem with delivery/production time windows

In this paper we generalize the classical dynamic lot-sizing problem by considering production capacity constraints as well as delivery and/or production time windows. Utilizing an untraditional decomposition principle, we develop a polynomial-time algorithm for computing an optimal solution for the problem under the assumption of non-speculative costs. The proposed solution methodology is based on a dynamic programming algorithm that runs in O(nT⁴) time, where n is the number of demands and T is the length of the planning horizon.     

考虑顾客退货和固定成本的联合补货与定价策略

为了吸引更多顾客,许多电子商务零售商允许顾客在一定时间内退货,导致其利润明显减少。同时,在补货时不仅产生依赖补货量的变动成本,而且会产生与补货量无关的固定成本。基于此,以最大化电子商务零售商的利润为目标,建立考虑顾客退货和固定成本的联合补货与定价模型,其中顾客的退货量与满足的需求呈正比。在一般需求情形下,部分刻画多期问题的最优策略;在特殊需求情形下,证明(s,S,p)策略对单期问题最优,并对多期问题的最优策略进行严格刻画。根据已有刻画为多期问题构造启发式策略。数值结果表明启发式策略近似最优;当初始库存水平足够高/低时,最优补货水平和定价随退货率与固定成本单调变化。关键词:联合补货与定价模型;顾客退货;固定成本;随机动态规划;最优策略     

A simple heuristic for echelon policies in serial supply chains

This paper proposes a simple heuristic that generates a solution for echelon (r,nQ,T) policies by sequentially solving a deterministic demand problem, a subproblem with fixed reorder intervals, and a subproblem with fixed batch sizes. For each of these problems, we further simplify the computation by solving a series of single-stage systems whose parameters are obtained directly from the original problem data. In a numerical study, we find that this heuristic outperforms an existing one in the literature.     

A Lagrangian-based heuristic for the capacitated lot-sizing problem in parallel machines

This paper addresses the capacitated lot-sizing problem involving the production of multiple items on unrelated parallel machines. A production plan should be determined in order to meet the forecast demand for the items, without exceeding the capacity of the machines and minimize the sum of production, setup and inventory costs. A heuristic based on the Lagrangian relaxation of the capacity constraints and subgradient optimization is proposed. Initially, the heuristic is tested on instances of the single machine problem and results are compared with heuristics from the literature. For parallel machines and small problems the heuristic performance is tested against optimal solutions, and for larger problems it is compared with the lower bound provided by the Lagrangian relaxation.     

The single-item lot-sizing problem with two production modes,inventory bounds,and periodic carbon emissions capacity

We consider the single-item lot-sizing problem with inventory bounds under a carbon emissions constraint with two options for producing items: regular or green. We wish to find the optimal production plan so that the total carbon emissions from production cannot exceed the carbon emissions capacity in each period. Extending a problem without fixed carbon emissions and inventory bounds, we show that the extended problem is polynomially solvable by a dynamic programming algorithm.     

Optimal production mix

This paper deals with a production plant in which two different products can be produced. The plant consists of three subsystemsS _i . Before or after a phase of separate processing in subsystemsS ₁ andS ₂, the two products have to be processed in subsystemS ₃. Each of these subsystems has a limited capacity.In the first part, we assume empty stocks at the beginning; at a fixed timeT in the future, certain quantitiesX _i of the two products have to be delivered to the customers. Facing linear holding costs, convex production costs, and stringent capacity constraints, the problem is to decide when to produce which product at what rate.It is shown that the optimal solution consists of up to six different regimes and that the time paths of the production rates need not be monotonic. These results, which can be obtained analytically, are also illustrated in several numerical examples.Finally, the case is considered where the terminal demand at timeT is replaced by a continuous and seasonally fluctuating demand rate. It is demonstrated that the optimal production rates show an interesting and nontrivial behavior. In particular, it may happen that, on intervals where the demand for the one product increases, the optimal production rate decreases. This is also demonstrated by computer plots in some numerical examples.The first author gratefully acknowledges support from the Austrian Science Foundation under Grant S3204 and the second author from Stiftung Volkswagenwerk. An earlier version of this paper was presented at the DGOR-NSOR Joint Conference, Eindhoven, Holland, September 23–25, 1987.     

Scheduling policies in the <Emphasis Type="Italic">M</Emphasis>/<Emphasis Type="Italic">G</Emphasis>/1 make-to-stock queue

In this paper, we analyse a production/inventory system modelled as an M/G/1 make-to-stock queue producing different products requiring different and general production times. We study different scheduling policies including the static first-come-first-served, preemptive and non-preemptive priority disciplines. For each static policy, we exploit the distributional Little's law to obtain the steady-state distribution of the number of customers in the system and then find the optimal inventory control policy and the cost. We additionally provide the conditions under which it is optimal to produce a product according to a make-to-order policy. We further extend the application area of a well-known dynamic scheduling heuristic, Myopic(T), for systems with non-exponential service times by permitting preemption. We compare the performance of the preemptive-Myopic(T) heuristic alongside that of the static preemptive-bμ rule against the optimal solution. The numerical study we have conducted demonstrates that the preemptive-Myopic(T) policy is superior between the two and yields costs very close to the optimal.     

An effective heuristic for the review period in an inventory model with staggered deliveries and normal demands

Consider a single-item, periodic review, infinite-horizon, undiscounted, inventory model with stochastic demands, proportional holding and shortage costs, and full backlogging. Orders can arrive in every period, and the cost of receiving them is negligible (as in JIT). Every T periods, one audits the stocks and chooses a delivery schedule for each of the next T periods, thus incurring a fixed audit cost and—when one schedules actual deliveries—a fixed order cost. The problem is to find a review period T and an ordering policy minimizing the average cost. An earlier article developed an algorithm for computing an optimal T, and undertook a numerical study to evaluate various approximations. Assuming normal demands, we characterize the asymptotic behavior (for large μ/σ) of the optimal T and establish the asymptotic optimality of a heuristic, calculable on a spreadsheet. A numerical study indicates that patterns established here for large μ/σ hold for σ/μ above 2.     

Stochastic lot-sizing with backlogging: computational complexity analysis

For a multi-stage stochastic programming problem, one approach is to explore a scenario tree based formulation for the problem and solve the formulation efficiently. There has been significant research progress on how to generate scenario trees in the literature. However, there is limited work on analyzing the computational complexity of the scenario-tree based formulation that considers the number of tree nodes as the input size. In this paper, we use stochastic lot-sizing problems as examples to study the computational complexity issues for the scenario-tree based formulations. We develop production path properties and a general dynamic programming framework based on these properties. The dynamic programming framework allows us to show that the optimal value function is piecewise linear and continuous, which enables us to develop polynomial time algorithms for several different problems, including those with backlogging and varying capacities under certain conditions. As special cases, we develop polynomial time algorithms that run in O(n²){\mathcal{O}(n^2)} and O(n²T log n){\mathcal{O}(n^2T\,{\rm log}\,n)} times, respectively for stochastic uncapacitated and constant capacitated lot-sizing problems with backlogging, regardless of the scenario tree structure.     

Dynamic lot-sizing model with demand time windows and speculative cost structure

We consider a deterministic lot-sizing problem with demand time windows, where speculative motive is allowed. Utilizing an untraditional decomposition principle, we provide an optimal algorithm that runs in O(nT³) time, where n is the number of demands and T is the length of the planning horizon.     

Multi-item two-echelon spare parts inventory control problem with batch ordering in the central warehouse under compound Poisson demand

We consider a multi-item two-echelon spare part inventory system in which the central warehouse operates under an (nQ,?R) policy and the local warehouses implement order-up-to S policy, each facing a compound Poisson demand. The objective is to find the policy parameters minimizing expected system-wide inventory holding and fixed ordering costs subject to an aggregate mean response time constraint at each warehouse. In this paper, we propose four alternative approximations for the steady state performance of the system; and extend a heuristic and a lower bound proposed under Poisson demand assumption to the compound Poisson setting. In a computational study, we show that the performances of the approximations, the heuristic, and the lower bound are quite satisfactory; and the relative cost saving of setting an aggregate service level rather than individually for each part is quite high.     

An Efficient Procedure for Dynamic Lot-sizing Model with Demand Time Windows

We consider a dynamic lot-sizing model with demand time windows where n demands need to be scheduled in T production periods. For the case of backlogging allowed, an O(T ³) algorithm exists under the non-speculative cost structure. For the same model with somewhat general cost structure, we propose an efficient algorithm with O(max {T ², nT}) time complexity.     

A two-echelon inventory system with transportation capacity constraint

Consider a one-warehouse multi-retailer system under constant and deterministic demand, which is subjected to transportation capacity for every delivery period. To search for the best stationary zero inventory ordering (ZIO) policy, or the best power-of-two policy, or the best nested policy, the problem is formulated as a 0–1 integer linear program in which the objective function comprises of a fixed transportation cost whenever a delivery is made and the inventory costs for both the warehouse and retailers. To overcome the transportation capacity limitation, we extend the policies to allow for staggering deliveries. It is shown that with transportation capacity constraint the non-staggering policy can have its effectiveness close to 0% from the best staggering policy and the power-of-two policy with staggering allowed can have its effectiveness close to 0% from the optimal policy. Nevertheless in general, the power-of-two policy fairs well on a number of randomly generated problems. To solve the large distribution network problem, an efficient heuristic based on the power-of-two policy with staggering of deliveries is suggested.     

Supply chain models for an assembly system with preprocessing of raw materials

In this paper, we investigate the material procurement and delivery policy in a production system where raw materials enter into the assembly line from two different flow channels. The system encompasses batch production process in which the finished product demand is approximately constant for an infinite planning horizon. Two distinct types of raw materials are passed through the assembly line before to convert them into the finished product. Of the two types of raw materials, one type requires preprocessing inside the facility before the assembly operation and other group is fed straightway in the assembly line. The conversion factors are assigned to raw materials to quantify the raw material batch size required. To analyze such a system, we formulate a nonlinear cost function to aggregate all the costs of the inventories, ordering, shipping and deliveries. An algorithm using the branch and bound concept is provided to find the best integer values of the optimal solutions. The result shows that the optimal procurement and delivery policy minimizes the expected total cost of the model. Using a test problem, the inventory requirements at each stage of production and their corresponding costs are calculated. From the analysis, it is shown that the rate and direction change of total cost is turned to positive when delivery rates per batch reaches close to the optimal value and the minimum cost is achieved at the optimal delivery rate. Also, it is shown that total incremental cost is monotonically increasing, if the finished product batch size is increased, and if, inventory cost rates are increased. We examine a set of numerical examples that reveal the insights into the procurement-delivery policy and the performance of such an assembly type inventory model.     

Dynamic demand lot-sizing rules for incremental quantity discounts

Numerous studies have developed and compared lot-sizing procedures for finite-horizon dynamic demand, material requirements planning (MRP), environments when either no purchase discounts exist or for the case of all-units quantity discounts. This paper examines lot-sizing rules when product price schedules follow incremental quantity discounts. The optimal (non-discount) procedure and some traditional heuristic procedures are modified to incorporate incremental quantity discounts. We further modify two heuristics with a ‘look-ahead enhancement’ that performs very well under experimentation. Numerical tests revealed the overall best-performing heuristic in this study to be a modified ‘least-unit cost’ method with a look-ahead enhancement. That procedure produced an average cost penalty vs optimal of 0.26%.     

A zero-inventory production and distribution problem with a fixed customer sequence

In this paper, we study the zero-inventory production and distribution problem with a single transporter and a fixed sequence of customers. The production facility has a limited production rate, and the delivery truck has non-negligible traveling times between locations. The order in which customers may receive deliveries is fixed. Each customer requests a delivery quantity and a time window for receiving the delivery. The lifespan of the product starts as soon as the production for a customer’s order is finished, which makes the product expire in a constant time. Since the production facility and the shipping truck are limited resources, not all the customers may receive the delivery within their specified time windows and/or within product lifespan. The problem is then to choose a subset of customers from the given sequence to receive the deliveries to maximize the total demand satisfied, without violating the product lifespan, the production/distribution capacity, and the delivery time window constraints. We analyze several fundamental properties of the problem and show that these properties can lead to a fast branch and bound search procedure for practical problems. A heuristic lower bound on the optimal solution is developed to accelerate the search. Empirical studies on the computational effort required by the proposed search procedure comparing to that required by CPLEX on randomly generated test cases are reported.