Optimal FCFS allocation rules for periodic‐review assemble‐to‐order systems

In Assemble‐To‐Order (ATO) systems, situations may arise in which customer demand must be backlogged due to a shortage of some components, leaving available stock of other components unused. Such unused component stock is called remnant stock. Remnant stock is a consequence of both component ordering decisions and decisions regarding allocation of components to end‐product demand. In this article, we examine periodic‐review ATO systems under linear holding and backlogging costs with a component installation stock policy and a First‐Come‐First‐Served (FCFS) allocation policy. We show that the FCFS allocation policy decouples the problem of optimal component allocation over time into deterministic period‐by‐period optimal component allocation problems. We denote the optimal allocation of components to end‐product demand as multimatching. We solve the multi‐matching problem by an iterative algorithm. In addition, an approximation scheme for the joint replenishment and allocation optimization problem with both upper and lower bounds is proposed. Numerical experiments for base‐stock component replenishment policies show that under optimal base‐stock policies and optimal allocation, remnant stock holding costs must be taken into account. Finally, joint optimization incorporating optimal FCFS component allocation is valuable because it provides a benchmark against which heuristic methods can be compared. © 2015 Wiley Periodicals, Inc. Naval Research Logistics 62: 158–169, 2015     

Optimal joint preventive maintenance and production policies

We study joint preventive maintenance (PM) and production policies for an unreliable production‐inventory system in which maintenance/repair times are non‐negligible and stochastic. A joint policy decides (a) whether or not to perform PM and (b) if PM is not performed, then how much to produce. We consider a discrete‐time system, formulating the problem as a Markov decision process (MDP) model. The focus of the work is on the structural properties of optimal joint policies, given the system state comprised of the system's age and the inventory level. Although our analysis indicates that the structure of optimal joint policies is very complex in general, we are able to characterize several properties regarding PM and production, including optimal production/maintenance actions under backlogging and high inventory levels, and conditions under which the PM portion of the joint policy has a control‐limit structure. In further special cases, such as when PM set‐up costs are negligible compared to PM times, we are able to establish some additional structural properties. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Selecting T for a periodic review inventory model with staggered deliveries

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 a JIT setting). Every T periods, one audits the current stock level and decides on deliveries for the next T periods, thus incurring a fixed audit cost and—when one schedules deliveries—a fixed order cost. The problem is to find a review period T and an ordering policy that satisfy the average cost criterion. The current article extends an earlier treatment of this problem, which assumed that the fixed order cost is automatically incurred once every T periods. We characterize an optimal ordering policy when T is fixed, prove that an optimal review period T** exists, and develop a global search algorithm for its computation. We also study the behavior of four approximations to T** based on the assumption that the fixed order cost is incurred during every cycle. Analytic results from a companion article (where μ/σ is large) and extensive computational experiments with normal and gamma demand test problems suggest these approximations and associated heuristic policies perform well when μ/σ ≥ 2. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 329–352, 2000     

A two product dynamic economic lot size production model with either-or production constraints

This paper considers the production of two products with known demands over a finite set of periods. The production and inventory carrying costs for each product are assumed to be concave. We seek the minimum cost production schedule meeting all demands, without backlogging, assuming that at most one of the two products can be produced in any period. The optimization problem is first stated as a nonlinear programming problem, which allows the proof of a result permitting the search for the optimal policy to be restricted to those which produce a product only when its inventory level is zero. A dynamic programming formulation is given and the model is then formulated as a shortest route problem in a specially constructed network.     

A dynamic,nonstationary inventory problem for a price/quantity setting firm

A dynamic and nonstationary model is formulated for a firm which attempts to minimize total expected costs over a finite planning horizon. The control variables are price and production. The price p and the demand ζ are linked through the relationship ζ = g(p) + η, where g(p) is the riskless demand curve and η is a random variable. The general model allows for proportional ordering costs, convex holding and stockout costs, downward sloping riskless demand curve, backlogging, partial backlogging, lost sales, partial spoilage of inventory, and two modes of collecting revenue. Sufficient conditions are developed for this problem to have an optimal policy which resembles the single critical number policy known from stochastic inventory theory. It is also shown what set of parameters will satisfy these sufficiency conditions.     

Periodic-review inventory models with inventory-level-dependent demand

Demand for some items can depend on the inventory level on display, a phenomenon often exploited by marketing researchers and practitioners. The implications of this phenomenon have received scant attention in the context of periodic-review inventory control models. We develop an approach to model periodic-review production/inventory problems where the demand in any period depends randomly, in a very general form, on the starting inventory level. We first obtain a complete analytical solution for a single-period model. We then investigate two multiperiod models, one with lost sales and the other with backlogging, whose optimal policies turn out to be myopic. Some extensions are also discussed. © 1994 John Wiley & Sons, Inc.     

Markov decision processes with restricted observations: Finite horizon case

In this article we consider a Markov decision process subject to the constraints that result from some observability restrictions. We assume that the state of the Markov process under consideration is unobservable. The states are grouped so that the group that a state belongs to is observable. So, we want to find an optimal decision rule depending on the observable groups instead of the states. This means that the same decision applies to all the states in the same group. We prove that a deterministic optimal policy exists for the finite horizon. An algorithm is developed to compute policies minimizing the total expected discounted cost over a finite horizon. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44 : 439–456, 1997     

Assessment of hazardous-inspection policies

Inspection procedures may at times pose a hazard to the system being monitored. In this article, a simple hazardous-inspection model is considered. The character of the optimal ongoing inspection policy (for inspections subsequent to the first) is reviewed, and the possible forms of the optimal initiation policy are established. Efficient computational procedures are developed for calculating optimal policies. Some discussion is included of the counterintuitive nature of some of the results.     

Dynamic inventory management with cash flow constraints

In this article, we consider a classic dynamic inventory control problem of a self‐financing retailer who periodically replenishes its stock from a supplier and sells it to the market. The replenishment decisions of the retailer are constrained by cash flow, which is updated periodically following purchasing and sales in each period. Excess demand in each period is lost when insufficient inventory is in stock. The retailer's objective is to maximize its expected terminal wealth at the end of the planning horizon. We characterize the optimal inventory control policy and present a simple algorithm for computing the optimal policies for each period. Conditions are identified under which the optimal control policies are identical across periods. We also present comparative statics results on the optimal control policy. © 2008 Wiley Periodicals, Inc. Naval Research Logistics 2008     

An asymptotically optimal inspection policy

An inspection model in life testing situations is discussed. The system under study is assumed to consist on n independent components all of which fail independently in an exponential fashion. Failures can be discovered only through inspection. The experimenter is assumed to lack the knowledge of the parameter of the exponential distribution. A stochastic sequential inspection policy is suggested which uses the data collected through experimentation to estimate the unknown parameter. It is shown that this policy is asymptotically optimal. Some numerical demonstrations are included.     

Technical note: A computationally efficient algorithm for undiscounted Markov decision processes with restricted observations

We present a computationally efficient procedure to determine control policies for an infinite horizon Markov Decision process with restricted observations. The optimal policy for the system with restricted observations is a function of the observation process and not the unobservable states of the system. Thus, the policy is stationary with respect to the partitioned state space. The algorithm we propose addresses the undiscounted average cost case. The algorithm combines a local search with a modified version of Howard's (Dynamic programming and Markov processes, MIT Press, Cambridge, MA, 1960) policy iteration method. We demonstrate empirically that the algorithm finds the optimal deterministic policy for over 96% of the problem instances generated. For large scale problem instances, we demonstrate that the average cost associated with the local optimal policy is lower than the average cost associated with an integer rounded policy produced by the algorithm of Serin and Kulkarni Math Methods Oper Res 61 (2005) 311–328. © 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Optimal replacement policies for multistate deteriorating systems

We consider state-age-dependent replacement policies for a multistate deteriorating system. We assume that operating cost rates and replacement costs are both functions of the underlying states. Replacement times and sojourn times in different states are all state-dependent random variables. The optimization criterion is to minimize the expected long-run cost rate. A policy-improvement algorithm to derive the optimal policy is presented. We show that under reasonable assumptions, the optimal replacement policies have monotonic properties. In particular, when the failure-rate functions are nonincreasing, or when all the replacement costs and the expected replacement times are independent of state, we show that the optimal policies are only state dependent. Examples are given to illustrate the structure of the optimal policies in the special case when the sojourntime distributions are Weibull. © 1994 John Wiley & Sons, Inc.     

A dynamic inventory system with recycling

This paper deals with a periodic review inventory system in which a constant proportion of stock issued to meet demand each period feeds back into the inventory after a fixed number of periods. Various applications of the model are discussed, including blood bank management and the control of reparable item inventories. We assume that on hand inventory is subject to proportional decay. Demands in successive periods are assumed to be independent identically distributed random variables. The functional equation defining an optimal policy is formulated and a myopic base stock approximation is developed. This myopic policy is shown to be optimal for the case where the feedback delay is equal to one period. Both cost and ordering decision comparisons for optimal and myopic policies are carried out numerically for a delay time of two periods over a wide range of input parameter values.     

Sensitivity of the (Q,R) inventory model to penalty cost parameter

This paper treats an approximate continuous review inventory model with backlogging of excess demand and stochastic leadtime. The major result derived is that the behavior of the optimal order size with respect to the shortage cost parameter is determined solely by the “conditional mean residual life” function corresponding to the leadtime demand distribution. Some minor results and illustrative examples are also included.     

Algorithms and heuristics for variable-yield lot sizing

We consider the multiperiod lot-sizing problem in which the production yield (the proportion of usable goods) is variable according to a known probability distribution. We review two economic order quantity (EOQ) models for the stationary demand continuous-time problem and derive an EOQ model when the production yield follows a binomial distribution and backlogging of demand is permitted. A dynamic programming algorithm for an arbitrary sequence of demand requirements is presented. Heuristics based on both the EOQ model and appropriate modification of the underlying perfect-yield lot-sizing policies are discussed, and extensive computational evaluation of these heuristics is presented. Two of these heuristics are then modified to include the notion of supply safety stock. The modified heuristics consistently produce near-optimal lot-sizing policies for problems with stationary and time-varying demands.     

Supply management in assembly systems

We consider the case when n components are needed to assemble a given product. Components are provided by suppliers, and the period between the order time and the time a component is available (i.e., the lead time) is a random variable with a known distribution. The due date for the assembled product is also known. The costs to be taken into account are the inventory costs of the components and the backlogging cost of the assembled product. We propose an iterative algorithm which leads to the optimal order instants of the components. © 1993 John Wiley & Sons, Inc.     

Approximation algorithms for capacitated stochastic inventory systems with setup costs

We develop the first approximation algorithm with worst‐case performance guarantee for capacitated stochastic periodic‐review inventory systems with setup costs. The structure of the optimal control policy for such systems is extremely complicated, and indeed, only some partial characterization is available. Thus, finding provably near‐optimal control policies has been an open challenge. In this article, we construct computationally efficient approximate optimal policies for these systems whose demands can be nonstationary and/or correlated over time, and show that these policies have a worst‐case performance guarantee of 4. We demonstrate through extensive numerical studies that the policies empirically perform well, and they are significantly better than the theoretical worst‐case guarantees. We also extend the analyses and results to the case with batch ordering constraints, where the order size has to be an integer multiple of a base load. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 304–319, 2014     

Inventory policies with quantized ordering

This article studies (nQ, r) inventory policies, under which the order quantity is restricted to be an integer multiple of a base lot size Q. Both Q and r are decision variables. Assuming the one-period expected holding and backorder cost function is unimodal, we develop an efficient algorithm to compute the optimal Q and r. The algorithm is facilitated by simple observations about the cost function and by tight upper bounds on the optimal Q. The total number of elementary operations required by the algorithm is linear in these upper bounds. By using the algorithm, we compare the performance of the optimal (nQ, r) policy with that of the optimal (s, S) policy through a numerical study, and our results show that the difference between them is small. Further analysis of the model shows that the cost performance of an (nQ, r) policy is insensitive to the choice of Q. These results establish that (nQ, r) models are potentially useful in many settings where quantized ordering is beneficial.     

Optimal inventory policy when stockouts alter demand

An inventory model in which future demand is affected by stockouts has been considered recently by B. L. Schwartz. Some generalizations of Schwartz's model are presented in this paper and properties of the optimal policies are determined. In the case of deterministic demand, a set-up cost is included and a mixture of backlogged and nonbacklogged orders is allowed during stockout. It is proved that the optimal policy entails either no stockout or continual stockout, depending on the values of three parameters. For stochastic demand, the effect of stockouts on demand density is postulated, the resulting optimal inventory policy is discussed, and an example involving an exponential density function is then analyzed in detail.     

Dynamic learning,pricing, and ordering by a censored newsvendor

We address the problem of determining optimal ordering and pricing policies in a finite‐horizon newsvendor model with unobservable lost sales. The demand distribution is price‐dependent and involves unknown parameters. We consider both the cases of perishable and nonperishable inventory. A very general class of demand functions is studied in this paper. We derive the optimal ordering and pricing policies as unique functions of the stocking factor (which is a linear transformation of the safety factor). An important expression is obtained for the marginal expected value of information. As a consequence, we show when lost sales are unobservable, with perishable inventory the optimal stocking factor is always at least as large as the one given by the single‐period model; however, if inventory is nonperishable, this result holds only under a strong condition. This expression also helps to explain why the optimal stocking factor of a period may not increase with the length of the problem. We compare this behavior with that of a full information model. We further examine the implications of the results to the special cases when demand uncertainty is described by additive and multiplicative models. For the additive case, we show that if demand is censored, the optimal policy is to order more as well as charge higher retail prices when compared to the policies in the single‐period model and the full information model. We also compare the optimal and myopic policies for the additive and multiplicative models. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007