Markovian approximation for manufacturing systems of unreliable machines in tandem

This paper studies production planning of manufacturing systems of unreliable machines in tandem. The manufacturing system considered here produces one type of product. The demand is assumed to be a Poisson process and the processing time for one unit of product in each machine is exponentially distributed. A broken machine is subject to a sequence of repairing processes. The up time and the repairing time in each phase are assumed to be exponentially distributed. We study the manufacturing system by considering each machine as an individual system with stochastic supply and demand. The Markov Modulated Poisson Process (MMPP) is applied to model the process of supply. Numerical examples are given to demonstrate the accuracy of the proposed method. We employ (s, S) policy as production control. Fast algorithms are presented to solve the average running costs of the machine system for a given (s, S) policy and hence the approximated optimal (s, S) policy. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 65–78, 2001     

Contractual agreements for coordination and vendor‐managed delivery under explicit transportation considerations

We consider the coordination problem between a vendor and a buyer operating under generalized replenishment costs that include fixed costs as well as stepwise freight costs. We study the stochastic demand, single‐period setting where the buyer must decide on the order quantity to satisfy random demand for a single item with a short product life cycle. The full order for the cycle is placed before the cycle begins and no additional orders are accepted by the vendor. Due to the nonrecurring nature of the problem, the vendor's replenishment quantity is determined by the buyer's order quantity. Consequently, by using an appropriate pricing schedule to influence the buyer's ordering behavior, there is an opportunity for the vendor to achieve substantial savings from transportation expenses, which are represented in the generalized replenishment cost function. For the problem of interest, we prove that the vendor's expected profit is not increasing in buyer's order quantity. Therefore, unlike the earlier work in the area, it is not necessarily profitable for the vendor to encourage larger order quantities. Using this nontraditional result, we demonstrate that the concept of economies of scale may or may not work by identifying the cases where the vendor can increase his/her profits either by increasing or decreasing the buyer's order quantity. We prove useful properties of the expected profit functions in the centralized and decentralized models of the problem, and we utilize these properties to develop alternative incentive schemes for win–win solutions. Our analysis allows us to quantify the value of coordination and, hence, to identify additional opportunities for the vendor to improve his/her profits by potentially turning a nonprofitable transaction into a profitable one through the use of an appropriate tariff schedule or a vendor‐managed delivery contract. We demonstrate that financial gain associated with these opportunities is truly tangible under a vendor‐managed delivery arrangement that potentially improves the centralized solution. Although we take the viewpoint of supply chain coordination and our goal is to provide insights about the effect of transportation considerations on the channel coordination objective and contractual agreements, the paper also contributes to the literature by analyzing and developing efficient approaches for solving the centralized problem with stepwise freight costs in the single‐period setting. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

When to commit in a serial supply chain with forecast updating

Negotiations between an end product manufacturer and a parts supplier often revolve around two main issues: the supplier's price and the length of time the manufacturer is contractually held to its order quantity, commonly termed the “commitment time frame.” Because actual demand is unknown, the specification of the commitment time frame determines how the demand risk is shared among the members of the supply chain. Casual observation indicates that most manufacturers prefer to delay commitments as long as possible while suppliers prefer early commitments. In this paper, we investigate whether these goals are always in the firm's best interest. In particular, we find that the manufacturer may sometimes be better off with a contract that requires an early commitment to its order quantity, before the supplier commits resources and the supplier may sometimes be better off with a delayed commitment. We also find that the preferred commitment time frame depends upon which member of the supply chain has the power to set their exchange price. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2003     

Selecting review periods for a coordinated multi‐item inventory model with staggered deliveries

Consider an N‐item, periodic review, infinite‐horizon, undiscounted, inventory model with stochastic demands, proportional holding and shortage costs, and full backlogging. For 1 ≤ j ≤ N, orders for item j can arrive in every period, and the cost of receiving them is negligible (as in a JIT setting). Every T_j periods, one reviews the current stock level of item j and decides on deliveries for each of the next T_j periods, thus incurring an item‐by‐item fixed cost k_j. There is also a joint fixed cost whenever any item is reviewed. The problem is to find review periods T₁, T₂, …, T_N and an ordering policy satisfying the average cost criterion. The current article builds on earlier results for the single‐item case. We prove an optimal policy exists, give conditions where it has a simple form, and develop a branch and bound algorithm for its computation. We also provide two heuristic policies with O(N) computational requirements. Computational experiments indicate that the branch and bound algorithm can handle normal demand problems with N ≤ 10 and that both heuristics do well for a wide variety of problems with N ranging from 2 to 200; moreover, the performance of our heuristics seems insensitive to N. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48:430–449, 2001     

Algorithms for the multi‐item multi‐vehicles dynamic lot sizing problem

We consider a two‐stage supply chain, in which multi‐items are shipped from a manufacturing facility or a central warehouse to a downstream retailer that faces deterministic external demand for each of the items over a finite planning horizon. The items are shipped through identical capacitated vehicles, each incurring a fixed cost per trip. In addition, there exist item‐dependent variable shipping costs and inventory holding costs at the retailer for items stored at the end of the period; these costs are constant over time. The sum of all costs must be minimized while satisfying the external demand without backlogging. In this paper we develop a search algorithm to solve the problem optimally. Our search algorithm, although exponential in the worst case, is very efficient empirically due to new properties of the optimal solution that we found, which allow us to restrict the number of solutions examined. Second, we perform a computational study that compares the empirical running time of our search methods to other available exact solution methods to the problem. Finally, we characterize the conditions under which each of the solution methods is likely to be faster than the others and suggest efficient heuristic solutions that we recommend using when the problem is large in all dimensions. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

Optimal policies for a multi-product inventory system with negotiable lead times

The objective of this paper is to determine the optimum inventory policy for a multi-product periodic review dynamic inventory system. At the beginning of each period two decisions are made for each product. How much to “normal order” with a lead time of λ_n periods and how much to “emergency order” with a lead time of λ_e periods, where λe = λ_n - 1. It is assumed that the emergency ordering costs are higher than the normal ordering costs. The demands for each product in successive periods are assumed to form a sequence of independent identically distributed random variables with known densities. Demands for individual products within a period are assumed to be non-negative, but they need not be independent. Whenever demand exceeds inventory their difference is backlogged rather than lost. The ordering decisions are based on certain costs and two revenue functions. Namely, the procurement costs which are assumed to be linear for both methods of ordering, convex holding and penalty costs, concave salvage gain functions, and linear credit functions. There is a restriction on the total amount that can be emergency ordered for all products. The optimal ordering policy is determined for the one and N-period models.     

Optimal control of a production‐inventory system with both backorders and lost sales

We consider the optimal control of a production inventory‐system with a single product and two customer classes where items are produced one unit at a time. Upon arrival, customer orders can be fulfilled from existing inventory, if there is any, backordered, or rejected. The two classes are differentiated by their backorder and lost sales costs. At each decision epoch, we must determine whether or not to produce an item and if so, whether to use this item to increase inventory or to reduce backlog. At each decision epoch, we must also determine whether or not to satisfy demand from a particular class (should one arise), backorder it, or reject it. In doing so, we must balance inventory holding costs against the costs of backordering and lost sales. We formulate the problem as a Markov decision process and use it to characterize the structure of the optimal policy. We show that the optimal policy can be described by three state‐dependent thresholds: a production base‐stock level and two order‐admission levels, one for each class. The production base‐stock level determines when production takes place and how to allocate items that are produced. This base‐stock level also determines when orders from the class with the lower shortage costs (Class 2) are backordered and not fulfilled from inventory. The order‐admission levels determine when orders should be rejected. We show that the threshold levels are monotonic (either nonincreasing or nondecreasing) in the backorder level of Class 2. We also characterize analytically the sensitivity of these thresholds to the various cost parameters. Using numerical results, we compare the performance of the optimal policy against several heuristics and show that those that do not allow for the possibility of both backordering and rejecting orders can perform poorly.© 2010 Wiley Periodicals, Inc. Naval Research Logistics 2010     

Two‐stage component test plans for testing the reliability of a series system

A system reliability is often evaluated by individual tests of components that constitute the system. These component test plans have advantages over complete system based tests in terms of time and cost. In this paper, we consider the series system with n components, where the lifetime of the i‐th component follows exponential distribution with parameter λ_i. Assuming test costs for the components are different, we develop an efficient algorithm to design a two‐stage component test plan that satisfies the usual probability requirements on the system reliability and in addition minimizes the maximum expected cost. For the case of prior information in the form of upper bounds on λ_i's, we use the genetic algorithm to solve the associated optimization problems which are otherwise difficult to solve using mathematical programming techniques. The two‐stage component test plans are cost effective compared to single‐stage plans developed by Rajgopal and Mazumdar. We demonstrate through several numerical examples that our approach has the potential to reduce the overall testing costs significantly. © 2002 John Wiley & Sons, Inc. Naval Research Logistics, 49: 95–116, 2002; DOI 10.1002/nav.1051     

Capacity games for partially complementary products under multivariate random demands

In this study, we consider n firms, each of which produces and sells a different product. The n firms face a common demand stream which requests all their products as a complete set. In addition to the common demand stream, each firm also faces a dedicated demand stream which requires only its own product. The common and dedicated demands are uncertain and follow a general, joint, continuous distribution. Before the demands are realized, each firm needs to determine its capacity or production quantity to maximize its own expected profit. We formulate the problem as a noncooperative game. The sales price per unit for the common demand could be higher or lower than the unit price for the dedicated demand, which affects the firm's inventory rationing policy. Hence, the outcome of the game varies. All of the prices are first assumed to be exogenous. We characterize Nash equilibrium(s) of the game. At the end of the article, we also provide some results for the endogenous pricing. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 59: 146–159, 2012     

Discrete equal‐capacity p‐median problem

This paper examines the discrete equal‐capacity p‐median problem that seeks to locate p new facilities (medians) on a network, each having a given uniform capacity, in order to minimize the sum of distribution costs while satisfying the demand on the network. Such problems arise, for example, in local access and transport area telecommunication network design problems where any number of a set of p facility units can be constructed at the specified candidate sites (hence, the net capacity is an integer multiple of a given unit capacity). We develop various valid inequalities, a separation routine for generating cutting planes that are specific members of such inequalities, as well as an enhanced reformulation that constructs a partial convex hull representation that subsumes an entire class of valid inequalities via its linear programming relaxation. We also propose suitable heuristic schemes for this problem, based on sequentially rounding the continuous relaxation solutions obtained for the various equivalent formulations of the problem. Extensive computational results are provided to demonstrate the effectiveness of the proposed valid inequalities, enhanced formulations, and heuristic schemes. The results indicate that the proposed schemes for tightening the underlying relaxations play a significant role in enhancing the performance of both exact and heuristic solution methods for this class of problems. © 2000 John & Sons, Inc. Naval Research Logistics 47: 166–183, 2000.     

A diffusion model for the control of a multipurpose reservoir system

This paper develops a methodology for optimizing operation of a multipurpose reservoir with a finite capacity V. The input of water into the reservoir is a Wiener process with positive drift. There are n purposes for which water is demanded. Water may be released from the reservoir at any rate, and the release rate can be increased or decreased instantaneously with zero cost. In addition to the reservoir, a supplementary source of water can supply an unlimited amount of water demanded during any period of time. There is a cost of C_i dollars per unit of demand supplied by the supplementary source to the i^th purpose (i = 1, 2, …, n). At any time, the demand rate R_i associated with the i^th purpose (i = 1, 2, …, n) must be supplied. A controller must continually decide the amount of water to be supplied by the reservoir for each purpose, while the remaining demand will be supplied through the supplementary source with the appropriate costs. We consider the problem of specifying an output policy which minimizes the long run average cost per unit time.     

Assessing the value of demand sharing in supply chains

We consider the problem of assessing the value of demand sharing in a multistage supply chain in which the retailer observes stationary autoregressive moving average demand with Gaussian white noise (shocks). Similar to previous research, we assume each supply chain player constructs its best linear forecast of the leadtime demand and uses it to determine the order quantity via a periodic review myopic order‐up‐to policy. We demonstrate how a typical supply chain player can determine the extent of its available information in the presence of demand sharing by studying the properties of the moving average polynomials of adjacent supply chain players. The retailer's demand is driven by the random shocks appearing in the autoregressive moving average representation for its demand. Under the assumptions we will make in this article, to the retailer, knowing the shock information is equivalent to knowing the demand process (assuming that the model parameters are also known). Thus (in the event of sharing) the retailer's demand sequence and shock sequence would contain the same information to the retailer's supplier. We will show that, once we consider the dynamics of demand propagation further up the chain, it may be that a player's demand and shock sequences will contain different levels of information for an upstream player. Hence, we study how a player can determine its available information under demand sharing, and use this information to forecast leadtime demand. We characterize the value of demand sharing for a typical supply chain player. Furthermore, we show conditions under which (i) it is equivalent to no sharing, (ii) it is equivalent to full information shock sharing, and (iii) it is intermediate in value to the two previously described arrangements. Although it follows from existing literature that demand sharing is equivalent to full information shock sharing between a retailer and supplier, we demonstrate and characterize when this result does not generalize to upstream supply chain players. We then show that demand propagates through a supply chain where any player may share nothing, its demand, or its full information shocks (FIS) with an adjacent upstream player as quasi‐ARMA in—quasi‐ARMA out. We also provide a convenient form for the propagation of demand in a supply chain that will lend itself to future research applications. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 515–531, 2014     

Simultaneous production of market‐specific and global products: A two‐stage stochastic program with additional demand after recourse

This paper analyzes the simultaneous production of market‐specific products tailored to the needs of individual regions and a global product that could be sold in many regions. We assume that the global product costs more to manufacture, but allows the decision concerning the allocation of products to regions to be delayed until after the manufacturing process has been completed. We further assume that there is additional demand after the region allocation but prior to delivery, extending the two‐stage stochastic program with recourse to include additional stochastic demand after the recourse. This scenario arises, for example, when there is additional uncertainty during a delivery delay which might occur with transoceanic shipments. We develop conditions for optimality assuming a single build‐allocate‐deliver cycle and stochastic demand during both the build and deliver periods. The optimal policy calls for the simultaneous production of market‐specific and global products, even when the global product is substantially more costly than the market‐specific product. In addition, we develop bounds on the performance of the optimal policy for the multicycle problem. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 438–461, 2003     

Optimal control policies for an inventory system with commitment lead time

We consider a firm which faces a Poisson customer demand and uses a base‐stock policy to replenish its inventories from an outside supplier with a fixed lead time. The firm can use a preorder strategy which allows the customers to place their orders before their actual need. The time from a customer's order until the date a product is actually needed is called commitment lead time. The firm pays a commitment cost which is strictly increasing and convex in the length of the commitment lead time. For such a system, we prove the optimality of bang‐bang and all‐or‐nothing policies for the commitment lead time and the base‐stock policy, respectively. We study the case where the commitment cost is linear in the length of the commitment lead time in detail. We show that there exists a unit commitment cost threshold which dictates the optimality of either a buy‐to‐order (BTO) or a buy‐to‐stock strategy. The unit commitment cost threshold is increasing in the unit holding and backordering costs and decreasing in the mean lead time demand. We determine the conditions on the unit commitment cost for profitability of the BTO strategy and study the case with a compound Poisson customer demand.     

Periodic review inventory management with contingent use of two freight modes with fixed costs

We study a stochastic inventory model of a firm that periodically orders a product from a make‐to‐order manufacturer. Orders can be shipped by a combination of two freight modes that differ in lead‐times and costs, although orders are not allowed to cross. Placing an order as well as each use of each freight mode has a fixed and a quantity proportional cost. The decision of how to allocate units between the two freight modes utilizes information about demand during the completion of manufacturing. We derive the optimal freight mode allocation policy, and show that the optimal policy for placing orders is not an (s,S) policy in general. We provide tight bounds for the optimal policy that can be calculated by solving single period problems. Our analysis enables insights into the structure of the optimal policy specifying the conditions under which it simplifies to an (s,S) policy. We characterize the best (s,S) policy for our model, and through extensive numerical investigation show that its performance is comparable with the optimal policy in most cases. Our numerical study also sheds light on the benefits of the dual freight model over the single freight models. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Optimal inventory control policy for periodic‐review inventory systems with inventory‐level‐dependent demand

We consider a setting in which inventory plays both promotional and service roles; that is, higher inventories not only improve service levels but also stimulate demand by serving as a promotional tool (e.g., as the result of advertising effect by the enhanced product visibility). Specifically, we study the periodic‐review inventory systems in which the demand in each period is uncertain but increases with the inventory level. We investigate the multiperiod model with normal and expediting orders in each period, that is, any shortage will be met through emergency replenishment. Such a model takes the lost sales model as a special case. For the cases without and with fixed order costs, the optimal inventory replenishment policy is shown to be of the base‐stock type and of the (s,S) type, respectively. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2012     

Spatial pricing and product allocation in online retailing

Spatial pricing means a retailer price discriminates its customers based on their geographic locations. In this article, we study how an online retailer should jointly allocate multiple products and facilitate spatial price discrimination to maximize profits. When deciding between a centralized product allocation ((i.e., different products are allocated to the same fulfillment center) and decentralized product allocation (ie, different products are allocated to different fulfillment centers), the retailer faces the tradeoff between shipment pooling (ie, shipping multiple products in one package), and demand localization (ie, stocking products to satisfy local demand) based on its understanding of customers' product valuations. In our basic model, we consider two widely used spatial pricing policies: free on board (FOB) pricing that charges each customer the exact amount of shipping cost, and uniform delivered (UD) pricing that provides free shipping. We propose a stylized model and find that centralized product allocation is preferred when demand localization effect is relatively low or shipment pooling benefit is relatively high under both spatial pricing policies. Moreover, centralized product allocation is more preferred under the FOB pricing which encourages the purchase of virtual bundles of multiple products. Furthermore, we respectively extend the UD and FOB pricing policies to flat rate shipping (ie, the firm charges a constant shipping fee for each purchase), and linear rate shipping (ie, the firm sets the shipping fee as a fixed proportion of firm's actual fulfillment costs). While similar observations from the basic model still hold, we find the firm can improve its profit by sharing the fulfillment cost with its customers via the flat rate or linear rate shipping fee structure.     

On‐line algorithms for minimizing makespan on batch processing machines

We consider problem of scheduling jobs on‐line on batch processing machines with dynamic job arrivals to minimize makespan. A batch machine can handle up to B jobs simultaneously. The jobs that are processed together from a batch, and all jobs in a batch start and complete at the same time. The processing time of a batch is given by the longest processing time of any job in the batch. Each job becomes available at its arrival time, which is unknown in advance, and its processing time becomes known upon its arrival. In the first part of this paper, we address the single batch processing machine scheduling problem. First we deal with two variants: the unbounded model where B is sufficiently large and the bounded model where jobs have two distinct arrival times. For both variants, we provide on‐line algorithms with worst‐case ratio (the inverse of the Golden ratio) and prove that these results are the best possible. Furthermore, we generalize our algorithms to the general case and show a worst‐case ratio of 2. We then consider the unbounded case for parallel batch processing machine scheduling. Lower bound are given, and two on‐line algorithms are presented. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 241–258, 2001     

A cost–benefit analysis of terrorist attacks

A cost–benefit analysis of terrorist attacks is developed and placed within a systematic theoretical structure. For the target or object of the attack, we consider the lost value of human lives, lost economic value, and lost influence value, counted as benefits for the terrorist. The corresponding losses for the terrorist are counted as costs. The terrorist attacks if benefits outweigh costs. Bounded rationality is enabled where the three kinds of benefits and costs can be weighted differently. We account for two ex ante probabilities of successful planning and attack, and enable the terrorist to assign different weights to its multiple stakeholders. We introduce multiple time periods, time discounting, attitudes towards risk, and subcategories for the benefits and costs. The cost–benefit analysis is illustrated with the 11 September 2001 attack, and 53 incidents in the Global Terrorism Database yielding both positive and negative expected utilities. The paper is intended as a tool for scientists and policy-makers, as a way of thinking about costs and benefits of terrorist attacks.     

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.