Capacitated lot‐sizing and scheduling with parallel machines,back‐orders,and setup carry‐over

We address the capacitated lot‐sizing and scheduling problem with setup times, setup carry‐over, back‐orders, and parallel machines as it appears in a semiconductor assembly facility. The problem can be formulated as an extension of the capacitated lot‐sizing problem with linked lot‐sizes (CLSPL). We present a mixed integer (MIP) formulation of the problem and a new solution procedure. The solution procedure is based on a novel “aggregate model,” which uses integer instead of binary variables. The model is embedded in a period‐by‐period heuristic and is solved to optimality or near‐optimality in each iteration using standard procedures (CPLEX). A subsequent scheduling routine loads and sequences the products on the parallel machines. Six variants of the heuristic are presented and tested in an extensive computational study. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Strong turnpike policies in the single-item capacitated lot-sizing problem with periodical dynamic parameter

This article considers optimization problems in a discrete capacitated lot sizing model for a single product with limited backlogging. The demand as well as the holding and backlogging costs are assumed to be periodical in time. Nothing is assumed about types of the cost functions. It is shown that there exists an optimal infinite inverse policy and a strong turnpike policy. A forward algorithm for computing optimal policies relative to the class of batch ordering type policies is derived. Some backward procedure is adopted to determine a strong turnpike policy. The algorithm is simple, and it terminates after the a number of steps equal to the turnpike horizon. Some remarks on the existence of rolling horizontal plans and forecast horizons are also given. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 775–790, 1997     

Multi‐item capacitated lot‐sizing problems with setup times and pricing decisions

We study a multi‐item capacitated lot‐sizing problem with setup times and pricing (CLSTP) over a finite and discrete planning horizon. In this class of problems, the demand for each independent item in each time period is affected by pricing decisions. The corresponding demands are then satisfied through production in a single capacitated facility or from inventory, and the goal is to set prices and determine a production plan that maximizes total profit. In contrast with many traditional lot‐sizing problems with fixed demands, we cannot, without loss of generality, restrict ourselves to instances without initial inventories, which greatly complicates the analysis of the CLSTP. We develop two alternative Dantzig–Wolfe decomposition formulations of the problem, and propose to solve their relaxations using column generation and the overall problem using branch‐and‐price. The associated pricing problem is studied under both dynamic and static pricing strategies. Through a computational study, we analyze both the efficacy of our algorithms and the benefits of allowing item prices to vary over time. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Competition under time‐varying demands and dynamic lot sizing costs

We develop a competitive pricing model which combines the complexity of time‐varying demand and cost functions and that of scale economies arising from dynamic lot sizing costs. Each firm can replenish inventory in each of the T periods into which the planning horizon is partitioned. Fixed as well as variable procurement costs are incurred for each procurement order, along with inventory carrying costs. Each firm adopts, at the beginning of the planning horizon, a (single) price to be employed throughout the horizon. On the basis of each period's system of demand equations, these prices determine a time series of demands for each firm, which needs to service them with an optimal corresponding dynamic lot sizing plan. We establish the existence of a price equilibrium and associated optimal dynamic lotsizing plans, under mild conditions. We also design efficient procedures to compute the equilibrium prices and dynamic lotsizing plans.© 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Formulations for dynamic lot sizing with service levels

In this article, we study deterministic dynamic lot‐sizing problems with a service‐level constraint on the total number of periods in which backlogs can occur over a finite planning horizon. We give a natural mixed integer programming formulation for the single item problem (LS‐SL‐I) and study the structure of its solution. We show that an optimal solution to this problem can be found in \begin{align*}\mathcal O(n^2\kappa)\end{align*} time, where n is the planning horizon and \begin{align*}\kappa=\mathcal O(n)\end{align*} is the maximum number of periods in which demand can be backlogged. Using the proposed shortest path algorithms, we develop alternative tight extended formulations for LS‐SL‐I and one of its relaxations, which we refer to as uncapacitated lot sizing with setups for stocks and backlogs. {We show that this relaxation also appears as a substructure in a lot‐sizing problem which limits the total amount of a period's demand met from a later period, across all periods.} We report computational results that compare the natural and extended formulations on multi‐item service‐level constrained instances. © 2013 Wiley Periodicals, Inc. Naval Research Logistics, 2013     

Machine scheduling with pickup and delivery

The coordination of production, supply, and distribution is an important issue in logistics and operations management. This paper develops and analyzes a single‐machine scheduling model that incorporates the scheduling of jobs and the pickup and delivery arrangements of the materials and finished jobs. In this model, there is a capacitated pickup and delivery vehicle that travels between the machine and the storage area, and the objective is to minimize the makespan of the schedule. The problem is strongly NP‐hard in general but is solvable in polynomial time when the job processing sequence is predetermined. An efficient heuristic is developed for the general problem. The effectiveness of the heuristic is studied both analytically and computationally. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Multiple-facility loading under capacity-based economies of scope

Multiple-facility loading (MFL) involves the allocation of products among a set of finite-capacity facilities. Applications of MFL arise naturally in a variety of production scheduling environments. MFL models typically assume that capacity is consumed as a linear function of products assigned to a facility. Product similarities and differences, however, result in capacity-based economies or diseconomies of scope, and thus the effective capacity of the facility is often a (nonlinear) function of the set of tasks assigned to the facility. This article addresses the multiple-facility loading problem under capacity-based economies (and diseconomies) of scope (MFLS). We formulate MFLS as a nonlinear 0–1 mixed-integer programming problem, and we discuss some useful properties. MFLS generalizes many well-known combinatorial optimization problems, such as the capacitated facility location problem and the generalized assignment problem. We also define a tabu-search heuristic and a branch-and-bound algorithm for MFLS. The tabu-search heuristic alternates between two search phases, a regional search and a diversification search, and offers a novel approach to solution diversification. We also report computational experience with the procedures. In addition to demonstrating MFLS problem tractability, the computational results indicate that the heuristic is an effective tool for obtaining high-quality solutions to MFLS. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 229–256, 1997     

The dynamic transshipment problem

We investigate the strategy of transshipments in a dynamic deterministic demand environment over a finite planning horizon. This is the first time that transshipments are examined in a dynamic or deterministic setting. We consider a system of two locations which replenish their stock from a single supplier, and where transshipments between the locations are possible. Our model includes fixed (possibly joint) and variable replenishment costs, fixed and variable transshipment costs, as well as holding costs for each location and transshipment costs between locations. The problem is to determine how much to replenish and how much to transship each period; thus this work can be viewed as a synthesis of transshipment problems in a static stochastic setting and multilocation dynamic deterministic lot sizing problems. We provide interesting structural properties of optimal policies which enhance our understanding of the important issues which motivate transshipments and allow us to develop an efficient polynomial time algorithm for obtaining the optimal strategy. By exploring the reasons for using transshipments, we enable practitioners to envision the sources of savings from using this strategy and therefore motivate them to incorporate it into their replenishment strategies. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48:386–408, 2001     

Transshipment through crossdocks with inventory and time windows

A major challenge in making supply meet demand is to coordinate transshipments across the supply chain to reduce costs and increase service levels in the face of demand fluctuations, short lead times, warehouse limitations, and transportation and inventory costs. In particular, transshipment through crossdocks, where just‐in‐time objectives prevail, requires precise scheduling between suppliers, crossdocks, and customers. In this work, we study the transshipment problem with supplier and customer time windows where flow is constrained by transportation schedules and warehouse capacities. Transportation is provided by fixed or flexible schedules and lot‐sizing is dealt with through multiple shipments. We develop polynomial‐time algorithms or, otherwise, provide the complexity of the problems studied. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Computational complexity of finding Pareto efficient outcomes for biobjective lot‐sizing models

In this article, we study a biobjective economic lot‐sizing problem with applications, among others, in green logistics. The first objective aims to minimize the total lot‐sizing costs including production and inventory holding costs, whereas the second one minimizes the maximum production and inventory block expenditure. We derive (almost) tight complexity results for the Pareto efficient outcome problem under nonspeculative lot‐sizing costs. First, we identify nontrivial problem classes for which this problem is polynomially solvable. Second, if we relax any of the parameter assumptions, we show that (except for one case) finding a single Pareto efficient outcome is an ‐hard task in general. Finally, we shed some light on the task of describing the Pareto frontier. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 386–402, 2014     

A nonlinear continuous time optimal control model of dynamic pricing and inventory control with no backorders

In this paper, we present a continuous time optimal control model for studying a dynamic pricing and inventory control problem for a make‐to‐stock manufacturing system. We consider a multiproduct capacitated, dynamic setting. We introduce a demand‐based model where the demand is a linear function of the price, the inventory cost is linear, the production cost is an increasing strictly convex function of the production rate, and all coefficients are time‐dependent. A key part of the model is that no backorders are allowed. We introduce and study an algorithm that computes the optimal production and pricing policy as a function of the time on a finite time horizon, and discuss some insights. Our results illustrate the role of capacity and the effects of the dynamic nature of demand in the model. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Labor staffing and scheduling models for controlling service levels

The problems of labor staffing and scheduling have received substantial attention in the literature. We introduce two new models of the labor staffing and scheduling problems that avoid the limitations of existing models. Collectively, the models have five important attributes. First, both models ensure the delivery of a minimally acceptable level of service in all periods. Second, one model can identify the least expensive way of delivering a specified aggregate level of customer service (the labor staffing problem and a form of labor scheduling problem). Third, the other model can identify the highest level of service attainable with a fixed amount of labor (the other form of the labor scheduling problem). Fourth, the models enable managers to identify the pareto relationship between labor costs and customer service. Fifth, the models allow a degree of control over service levels that is unattainable with existing models. Because of these attributes, which existing models largely do not possess, we expect these models to have broad applicability in a wide range of organizations operating in both competitive and noncompetitive environments. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 719–740, 1997     

Yield randomness,cost tradeoffs,and diversification in the EOQ model

Existing production/inventory models with random (variable) yield take the yield distribution as given. This work takes a step towards selecting the optimal yield randomness, jointly with lot sizing decisions. First, we analyze an EOQ model where yield variance and lot size are to be selected simultaneously. Two different cost structures are considered. Secondly, we consider source diversification (‘second sourcing’) as a means of reducing effective yield randomness, and trade its benefits against its costs. Conditions for the superiority of diversification between two sources with distinct yield distributions over a single source are derived. The optimal number of identical sources is also analyzed. Some comments on the congruence of the results with recent JIT practices are provided.     

Economic lot sizing with constant capacities and concave inventory costs

This article studies the classical single‐item economic lot‐sizing problem with constant capacities, fixed‐plus‐linear order costs, and concave inventory costs, where backlogging is allowed. We propose an O(T³) optimal algorithm for the problem, which improves upon the O(T⁴) running time of the famous algorithm developed by Florian and Klein (Manage Sci18 (1971) 12–20). Instead of using the standard dynamic programming approach by predetermining the minimal cost for every possible subplan, we develop a backward dynamic programming algorithm to obtain a more efficient implementation. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2012     

Lot sizing with learning and forgetting in setups: Analytical results and insights

This article considers the dynamic lot sizing problem when there is learning and forgetting in setups. Learning in setups takes place with repetition when additional setups are made and forgetting takes place when there is a break between two successive setups. We allow the amount forgotten over a break to depend both on the length of the break and the amount of learning at the beginning of the break. The learning and forgetting functions we use are realistic. We present several analytical results and use these in developing computationally efficient algorithms for solving the problem. Some decision/forecast horizon results are also developed, and finally we present managerial insights based on our computational results. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 93–108, 2016     

An optimal procedure for the coordinated replenishment dynamic lot‐sizing problem with quantity discounts

We consider in this paper the coordinated replenishment dynamic lot‐sizing problem when quantity discounts are offered. In addition to the coordination required due to the presence of major and minor setup costs, a separate element of coordination made possible by the offer of quantity discounts needs to be considered as well. The mathematical programming formulation for the incremental discount version of the extended problem and a tighter reformulation of the problem based on variable redefinition are provided. These then serve as the basis for the development of a primal‐dual based approach that yields a strong lower bound for our problem. This lower bound is then used in a branch and bound scheme to find an optimal solution to the problem. Computational results for this optimal solution procedure are reported in the paper. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 686–695, 2000     

Dynamic lot‐sizing model with production time windows

We consider a dynamic lot‐sizing model with production time windows where each of n demands has earliest and latest production due dates and it must be satisfied during the given time window. For the case of nonspeculative cost structure, an O(nlogn) time procedure is developed and it is shown to run in O(n) when demands come in the order of latest production due dates. When the cost structure is somewhat general fixed plus linear that allows speculative motive, an optimal procedure with O(T⁴) is proposed where T is the length of a planning horizon. Finally, for the most general concave production cost structure, an optimal procedure with O(T⁵) is designed. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Minimal forecast horizon procedures for dynamic lot size models

This article presents new results which should be useful in finding production decisions while solving the dynamic lot sizing problem of Wagner–Whitin on a rolling horizon basis. In a rolling horizon environment, managers obtain decisions for the first period (or the first few periods) by looking at the forecasts for several periods. This article develops procedures to find optimal decisions for any specified number of initial periods (called planning horizon in the article) by using the forecast data for the minimum possible number of future periods. Computational results comparing these procedures with the other procedures reported in the literature are very encouraging.     

The one‐warehouse multiretailer problem with an order‐up‐to level inventory policy

We consider a two‐level system in which a warehouse manages the inventories of multiple retailers. Each retailer employs an order‐up‐to level inventory policy over T periods and faces an external demand which is dynamic and known. A retailer's inventory should be raised to its maximum limit when replenished. The problem is to jointly decide on replenishment times and quantities of warehouse and retailers so as to minimize the total costs in the system. Unlike the case in the single level lot‐sizing problem, we cannot assume that the initial inventory will be zero without loss of generality. We propose a strong mixed integer program formulation for the problem with zero and nonzero initial inventories at the warehouse. The strong formulation for the zero initial inventory case has only T binary variables and represents the convex hull of the feasible region of the problem when there is only one retailer. Computational results with a state‐of‐the art solver reveal that our formulations are very effective in solving large‐size instances to optimality. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010