Bayes adaptive control of two-echelon inventory systems i: development for a special case of one-station lower echelon and monte carlo evaluation

Bayes adaptive control policies are developed in the present paper for the special case of a one-station lower echelon: a Poisson distribution of demand, whose mean is assumed to have a prior gamma distribution. The cost structure is of a common type. The ordering policy for the upper echelon, which minimizes expected cost, is replaced by a new type of policy, called Bayes prediction policy. This policy does not require tedious computations, of the sort required by dynamic programming solutions. The characteristics of the policies are studied by Monte Carlo simulation, and supplemented by further theoretical development.     

An analysis of single item inventory systems with returns

Inventory systems with returns are systems in which there are units returned in a repairable state, as well as demands for units in a serviceable state, where the return and demand processes are independent. We begin by examining the control of a single item at a single location in which the stationary return rate is less than the stationary demand rate. This necessitates an occasional procurement of units from an outside source. We present a cost model of this system, which we assume is managed under a continuous review procurement policy, and develop a solution method for finding the policy parameter values. The key to the analysis is the use of a normally distributed random variable to approximate the steady-state distribution of net inventory. Next, we study a single item, two echelon system in which a warehouse (the upper echelon) supports N(N ? 1) retailers (the lower echelon). In this case, customers return units in a repairable state as well as demand units in a serviceable state at the retailer level only. We assume the constant system return rate is less than the constant system demand rate so that a procurement is required at certain times from an outside supplier. We develop a cost model of this two echelon system assuming that each location follows a continuous review procurement policy. We also present an algorithm for finding the policy parameter values at each location that is based on the method used to solve the single location problem.     

Newsvendor bounds and heuristics for serial supply chains with regular and expedited shipping

We study an infinite‐horizon, N‐stage, serial production/inventory system with two transportation modes between stages: regular shipping and expedited shipping. The optimal inventory policy for this system is a top–down echelon base‐stock policy, which can be computed through minimizing 2N nested convex functions recursively (Lawson and Porteus, Oper Res 48 (2000), 878–893). In this article, we first present some structural properties and comparative statics for the parameters of the optimal inventory policies, we then derive simple, newsvendor‐type lower and upper bounds for the optimal control parameters. These results are used to develop near optimal heuristic solutions for the echelon base‐stock policies. Numerical studies show that the heuristic performs well. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

The stochastic joint replenishment problem: A new policy,analysis, and insights

In this study, we propose a new parsimonious policy for the stochastic joint replenishment problem in a single‐location, N‐item setting. The replenishment decisions are based on both group reorder point‐group order quantity and the time since the last decision epoch. We derive the expressions for the key operating characteristics of the inventory system for both unit and compound Poisson demands. In a comprehensive numerical study, we compare the performance of the proposed policy with that of existing ones over a standard test bed. Our numerical results indicate that the proposed policy dominates the existing ones in 100 of 139 instances with comparably significant savings for unit demands. With batch demands, the savings increase as the stochasticity of demand size gets larger. We also observe that it performs well in environments with low demand diversity across items. The inventory system herein also models a two‐echelon setting with a single item, multiple retailers, and cross docking at the upper echelon. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Optimal stocking policies for low usage items in multi-echelon inventory systems

Multi-echelon logistic systems are essential parts of the service support function of high technology firms. The combination of technological developments and competitive pressures has led to the development of services systems with a unique set of characteristics. These characteristics include (1) low demand probabilities: (2) high cost items; (3) complex echelon structures; (4) existence of pooling mechanisms among stocking locations at the same echelon level; (5) high priority for service, which is often expressed in terms of response time service levels for product groups of items: (6) scrapping of failed parts; and (7) recycling of issued stock due to diagnostic use. This article develops a comprehensive model of a stochastic, multi-echelon inventory system that takes account of the above characteristics. Solutions to the constrained optimization problem are found using a branch and bound procedure. The results of applying this procedure to a spare parts inventory system for a computer manufacturer have led to a number of important policy conclusions.     

Centralized inventory control in a two‐level distribution system with Poisson demand

This paper introduces a new replenishment policy for inventory control in a two‐level distribution system consisting of one central warehouse and an arbitrary number of nonidentical retailers. The new policy is designed to control the replenishment process at the central warehouse, using centralized information regarding the inventory positions and demand processes of all installations in the system. The retailers on the other hand are assumed to use continuous review (R, Q) policies. A technique for exact evaluation of the expected inventory holding and backorder costs for the system is presented. Numerical results indicate that there are cases when considerable savings can be made by using the new (α₀, Q₀) policy instead of a traditional echelon‐ or installation‐stock (R, Q) policy. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 798–822, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10040     

A two-echelon inventory model with purchases,dispositions, shipments,returns and transshipments

This paper presents a one-period two-echelon inventory model with one warehouse in the first echelon and n warehouses in the second echelon. At the beginning of the period the stock levels at all facilities are adjusted by purchasing or disposing of items at the first echelon, returning or shipping items between the echelons and transshipping items within the second echelon. During the period, demands (which may be negative) are placed on all warehouses in the second echelon and an attempt is made to satisfy shortages either by an expedited shipment from the first echelon to the second echelon or an expedited transshipment within the second echelon. The decision problem is to choose an initial stock level at the first echelon (by a purchase or a disposition) and an initial allocation so as to minimize the initial stock movement costs during the period plus inventory carrying costs and system shortage costs at the end of the period. It is shown that the objective function takes on one of four forms, depending on the relative magnitudes of the various shipping costs. All four forms of the objective function are derived and proven to be convex. Several applications of this general model are considered. We also consider multi-period extensions of the general model and an important special case is solved explicitly.     

Optimal burn‐in procedure for periodically inspected systems

Burn‐in is a widely used method to improve the quality of products or systems after they have been produced. In this paper, we study burn‐in procedure for a system that is maintained under periodic inspection and perfect repair policy. Assuming that the underlying lifetime distribution of a system has an initially decreasing and/or eventually increasing failure rate function, we derive upper and lower bounds for the optimal burn‐in time, which maximizes the system availability. Furthermore, adopting an age replacement policy, we derive upper and lower bounds for the optimal age parameter of the replacement policy for each fixed burn‐in time and a uniform upper bound for the optimal burn‐in time given the age replacement policy. These results can be used to reduce the numerical work for determining both optimal burn‐in time and optimal replacement policy. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

A simple approximation for a multistage capacitated production-inventory system

We develop a simple approximation for multistage production-inventory systems with limited production capacity and variable demands. Each production stage follows a base-stock policy for echelon inventory, constrained by production capacity and the availability of upstream inventory. Our objective is to find base-stock levels that approximately minimize holding and backorder costs. The key step in our procedure approximates the distribution of echelon inventory by a sum of exponentials; the parameters of the exponentials are chosen to match asymptotically exact expressions. The computational requirements of the method are minimal. In a test bed of 72 problems, each with five production stages, the average relative error for our approximate optimization procedure is 1.9%. © 1996 John Wiley & Sons, Inc.     

On the first come–first served rule in multi‐echelon inventory control

A two‐echelon distribution inventory system with a central warehouse and a number of retailers is considered. The retailers face stochastic demand and replenish from the warehouse, which, in turn, replenishes from an outside supplier. The system is reviewed continuously and demands that cannot be met directly are backordered. Standard holding and backorder costs are considered. In the literature on multi‐echelon inventory control it is standard to assume that backorders at the warehouse are served according to a first come–first served policy (FCFS). This allocation rule simplifies the analysis but is normally not optimal. It is shown that the FCFS rule can, in the worst case, lead to an asymptotically unbounded relative cost increase as the number of retailers approaches infinity. We also provide a new heuristic that will always give a reduction of the expected costs. A numerical study indicates that the average cost reduction when using the heuristic is about two percent. The suggested heuristic is also compared with two existing heuristics. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Evaluation of base-stock policies in multiechelon inventory systems with state-dependent demands part I: State-independent policies

This article analyzes a model of a multiechelon inventory system. The exogenous demands form Markov-modulated Poisson processes. That is, the demand rates are functions of an underlying Markov chain. Each location follows a base-stock policy which is independent of the state of the underlying Markov chain. We employ the exogenous transit mechanism introduced by Zipkin [7] and Svoronos and Zipkin [6]. The transit times between locations have phase-type distributions. An exact procedure to compute steady-state performance measures is presented. © 1992 John Wiley & Sons, Inc.     

Approximations for the consolidation of multiechelon repair facilities

This paper develops and illustrates an approximate approach for analytically assessing the impacts on both costs and service of consolidation of repair facilities. The repair facilities are two echelon generalizations of the classical repairmen problem in which two types of failures, say major and minor, can occur, each type requiring repair at a different echelon: The questions addressed are the reductions possible in spares, repairmen, and service rates due to the consolidated system's increased efficiency, as well as the physical separation between the users and the consolidated repair facility that is economical. The method of analysis is based upon asymptotic approximations developed for the repairmen problem, valid when the number of operational equipments is large (greater than 50); it is helpful since it provides a tractable means for predicting the steady-state performance of the decentralized and consolidated installations as a function of the many parameters involved without having to resort to an exhaustive computation of all the exact steady-state probabilities.     

Using stochastic programming to solve an outpatient appointment scheduling problem with random service and arrival times

We study a stochastic outpatient appointment scheduling problem (SOASP) in which we need to design a schedule and an adaptive rescheduling (i.e., resequencing or declining) policy for a set of patients. Each patient has a known type and associated probability distributions of random service duration and random arrival time. Finding a provably optimal solution to this problem requires solving a multistage stochastic mixed‐integer program (MSMIP) with a schedule optimization problem solved at each stage, determining the optimal rescheduling policy over the various random service durations and arrival times. In recognition that this MSMIP is intractable, we first consider a two‐stage model (TSM) that relaxes the nonanticipativity constraints of MSMIP and so yields a lower bound. Second, we derive a set of valid inequalities to strengthen and improve the solvability of the TSM formulation. Third, we obtain an upper bound for the MSMIP by solving the TSM under the feasible (and easily implementable) appointment order (AO) policy, which requires that patients are served in the order of their scheduled appointments, independent of their actual arrival times. Fourth, we propose a Monte Carlo approach to evaluate the relative gap between the MSMIP upper and lower bounds. Finally, in a series of numerical experiments, we show that these two bounds are very close in a wide range of SOASP instances, demonstrating the near‐optimality of the AO policy. We also identify parameter settings that result in a large gap in between these two bounds. Accordingly, we propose an alternative policy based on neighbor‐swapping. We demonstrate that this alternative policy leads to a much tighter upper bound and significantly shrinks the gap.     

Optimal renewal policies for complex systems

Most maintenance and replacement models for industrial equipment have been developed for independent single-component machines. Most equipment, however, consists of multiple components. Also, when the maintenance crew services several machines, the maintenance policy for each machine is not independent of the states of the other machines. In this paper, two dynamic programming replacement models are presented. The first is used to determine the optimal replacement policy for multi-component equipment. The second is used to determine the optimal replacement policy for a multi-machine system which uses one replacement crew to service several machines. In addition, an approach is suggested for developing an efficient replacement policy for a multi-component, multi-machine system.     

Decentralized stockage policies in a multiechelon environment

Characteristics of supply performance at the top echelon of an optimally managed multiechelon supply system are investigated; insights are developed which are useful in devising coordinated single-echelon policies which can approximate the benefits derived from multiechelon management.     

A dual-based optimization procedure for the two-echelon uncapacitated facility location problem

The two-echelon uncapacitated facility location problem (TUFLP) is a generalization of the uncapacitated facility location problem (UFLP) and multiactivity facility location problem (MAFLP). In TUFLP there are two echelons of facilities through which products may flow in route to final customers. The objective is to determine the least-cost number and locations of facilities at each echelon in the system, the flow of product between facilities, and the assignment of customers to supplying facilities. We propose a new dual-based solution procedure for TUFLP that can be used as a heuristic or incorporated into branch-and-bound procedures to obtain optimal solutions to TUFLP. The algorithm is an extension of the dual ascent and adjustment procedures developed by Erlenkotter for UFLP. We report computational experience gained by solving over 420 test problems. The largest problems solved have 25 possible facility locations at each echelon and 35 customer zones, implying 650 integer variables and 21,875 continuous variables.     

基于级库存的维修器材整合供应策略研究

针对传统器材供应模式效率低的问题,借助供应链管理的思想提出了多需求点整合供应模式,并建立了基于级库存策略的整合优化模型,对成本各组成部分分析求解,得到了最优总成本对应的策略参数,其中总成本考虑了供应中心补货成本、库存持有成本、供应成本和供应延迟成本．最后通过算例与直接供应策略进行了比较,证明了整合供应策略的有效性．     

An exact analysis of a joint production‐inventory problem in two‐echelon inventory systems

We consider a two‐echelon inventory system with a manufacturer operating from a warehouse supplying multiple distribution centers (DCs) that satisfy the demand originating from multiple sources. The manufacturer has a finite production capacity and production times are stochastic. Demand from each source follows an independent Poisson process. We assume that the transportation times between the warehouse and DCs may be positive which may require keeping inventory at both the warehouse and DCs. Inventory in both echelons is managed using the base‐stock policy. Each demand source can procure the product from one or more DCs, each incurring a different fulfilment cost. The objective is to determine the optimal base‐stock levels at the warehouse and DCs as well as the assignment of the demand sources to the DCs so that the sum of inventory holding, backlog, and transportation costs is minimized. We obtain a simple equation for finding the optimal base‐stock level at each DC and an upper bound for the optimal base‐stock level at the warehouse. We demonstrate several managerial insights including that the demand from each source is optimally fulfilled entirely from a single distribution center, and as the system's utilization approaches 1, the optimal base‐stock level increases in the transportation time at a rate equal to the demand rate arriving at the DC. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

On the optimality of the bayes prediction policy in two-echelon multistation inventory models

The present paper provides a proof that the Bayes prediction ordering policy developed in [3] is an optimal policy, in the sense that it minimizes the total expected discounted cost of ordering for any finite planning horizon.     

Base‐stock policies in capacitated assembly systems: Convexity properties

We study an assembly system with a single finished product managed using an echelon base‐stock or order‐up‐to policy. Some or all operations have capacity constraints. Excess demand is either backordered in every period or lost in every period. We show that the shortage penalty cost over any horizon is jointly convex with respect to the base‐stock levels and capacity levels. When the holding costs are also included in the objective function, we show that the cost function can be written as a sum of a convex function and a concave function. Throughout the article, we discuss algorithmic implications of our results for making optimal inventory and capacity decisions in such systems.© 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010