Analysis and optimal design of discrete order picking technologies along a line

Order picking accounts for most of the operating expense of a typical distribution center, and thus is often considered the most critical function of a supply chain. In discrete order picking a single worker walks to pick all the items necessary to fulfill a single customer order. Discrete order picking is common not only because of its simplicity and reliability, but also because of its ability to pick orders quickly upon receipt, and thus is commonly used by e‐commerce operations. There are two primary ways to reduce the cost (walking distance required) of the order picking system. First is through the use of technology—conveyor systems and/or the ability to transmit order information to pickers via mobile units. Second is through the design—where best to locate depots (where workers receive pick lists and deposit completed orders) and how best to lay out the product. We build a stochastic model to compare three configurations of different technology requirements: single‐depot, dual‐depot, and no‐depot. For each configuration we explore the optimal design. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Transactional and in-store display data of a large supermarket for data-driven decision-making

This article describes daily and monthly transactional and in-store display data of a large supermarket from January to October in 2019 associated with 28 757 stock-keeping units (SKUs) in 5 categories and 41 subcategories. The database contains five parts, including information about each SKU, in-store display, daily sales, inventory, and replenishment. We also propose some research questions related to assortment planning, pricing, inventory management, and customer behavior. Researchers are welcome to develop data-driven models or other innovative methods to address these questions or other practical problems using this database.     

Warehouse sizing to minimize inventory and storage costs

This paper considers a warehouse sizing problem whose objective is to minimize the total cost of ordering, holding, and warehousing of inventory. Unlike typical economic lot sizing models, the warehousing cost structure examined here is not the simple unit rate type, but rather a more realistic step function of the warehouse space to be acquired. In the cases when only one type of stock‐keeping unit (SKU) is warehoused, or when multiple SKUs are warehoused, but, with separable inventory costs, closed form solutions are obtained for the optimal warehouse size. For the case of multi‐SKUs with joint inventory replenishment cost, a heuristic with a provable performance bound of 94% is provided. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 299–312, 2001     

A recursive branch and bound algorithm for the multidimensional knapsack problem

This paper presents an efficient branch and bound algorithm for the solution of certain multiconstrained knapsack problems. The key to this algorithm is a rigidly defined tree structure in which branching and bounding may be performed through recursive relationships. The algorithm is particularly useful when only limited amounts of core storage are available as only the current and one previous solution is saved at any one time. Execution speeds compare favorably with other algorithms. A numerical example and computational experience is given.     

Tree-search algorithms for quadratic assignment problems

Problems having the mathematical structure of a quadratic assignment problem are found in a diversity of contexts: by the economist in assigning a number of plants or indivisible operations to a number of different geographical locations; by the architect or indusatrial engineer in laying out activities, offices, or departments in a building; by the human engineer in arranging the indicators and controls in an operators control room; by the electronics engineer in laying out components on a backboard; by the computer systems engineer in arranging information in drum and disc storage; by the production scheduler in sequencing work through a production facility; and so on. In this paper we discuss several types of algorithms for solving such problems, presenting a unifying framework for some of the existing algorithms, and dcscribing some new algorithms. All of the algorithms discussed proceed first to a feasible solution and then to better and better feasible solutions, until ultimately one is discovered which is shown to be optimal.     

Resequencing with parallel queues to minimize the maximum number of items in the overflow area

This article treats an elementary optimization problem, where an inbound stream of successive items is to be resequenced with the help of multiple parallel queues in order to restore an intended target sequence. Whenever early items block the one item to be currently released into the target sequence, they are withdrawn from their queue and intermediately stored in an overflow area until their actual release is reached. We aim to minimize the maximum number of items simultaneously stored in the overflow area during the complete resequencing process. We met this problem in industry practice at a large German automobile producer, who has to resequence containers with car seats prior to the assembly process. We formalize the resulting resequencing problem and provide suited exact and heuristic solution algorithms. In our computational study, we also address managerial aspects such as how to properly avoid the negative effects of sequence alterations. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 401–415, 2016     

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     

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     

Flow shop scheduling with earliness,tardiness, and intermediate inventory holding costs

We consider the problem of scheduling customer orders in a flow shop with the objective of minimizing the sum of tardiness, earliness (finished goods inventory holding), and intermediate (work‐in‐process) inventory holding costs. We formulate this problem as an integer program, and based on approximate solutions to two different, but closely related, Dantzig‐Wolfe reformulations, we develop heuristics to minimize the total cost. We exploit the duality between Dantzig‐Wolfe reformulation and Lagrangian relaxation to enhance our heuristics. This combined approach enables us to develop two different lower bounds on the optimal integer solution, together with intuitive approaches for obtaining near‐optimal feasible integer solutions. To the best of our knowledge, this is the first paper that applies column generation to a scheduling problem with different types of strongly ????‐hard pricing problems which are solved heuristically. The computational study demonstrates that our algorithms have a significant speed advantage over alternate methods, yield good lower bounds, and generate near‐optimal feasible integer solutions for problem instances with many machines and a realistically large number of jobs. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

A new storage reduction technique for the solution of the group problem

This paper shows that by making use of an unusual property of the decision table associated with the dynamic programming solution to the goup problem, it is possible to dispense with table storage as such, and instead overlay values for both the objective and history functions. Furthermore, this storage reduction is accomplished with no loss in computational efficiency. An algorithm is presented which makes use of this technique and incorporates various additional efficiencies. The reduction in storage achieved for problems from the literature is shown.     

Short‐term capacity allocation problem with tool and setup constraints

We consider a short‐term capacity allocation problem with tool and setup constraints that arises in the context of operational planning in a semiconductor wafer fabrication facility. The problem is that of allocating the available capacity of parallel nonidentical machines to available work‐in‐process (WIP) inventory of operations. Each machine can process a subset of the operations and a tool setup is required on a machine to change processing from one operation to another. Both the number of tools available for an operation and the number of setups that can be performed on a machine during a specified time horizon are limited. We formulate this problem as a degree‐constrained network flow problem on a bipartite graph, show that the problem is NP‐hard, and propose constant factor approximation algorithms. We also develop constructive heuristics and a greedy randomized adaptive search procedure for the problem. Our computational experiments demonstrate that our solution procedures solve the problem efficiently, rendering the use of our algorithms in real environment feasible. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

New algorithms for (Q,r) systems with complete backordering using a fill-rate criterion

We present an algorithm which determines optimal parameter values for order quantity-reorder point systems with complete backordering. The service level is measured as fraction of demand satisfied directly from shelf, also known as “fill-rate.” This algorithm differs from existing algorithms because an exact cost function is used rather than an approximation. We also present a new heuristic algorithm, which is more efficient computationally than the optimal procedure and provides excellent results. Results of extensive computational experience also are reported.     

Exact algorithms for scheduling multiple families of jobs on parallel machines

In many practical manufacturing environments, jobs to be processed can be divided into different families such that a setup is required whenever there is a switch from processing a job of one family to another job of a different family. The time for setup could be sequence independent or sequence dependent. We consider two particular scheduling problems relevant to such situations. In both problems, we are given a set of jobs to be processed on a set of identical parallel machines. The objective of the first problem is to minimize total weighted completion time of jobs, and that of the second problem is to minimize weighted number of tardy jobs. We propose column generation based branch and bound exact solution algorithms for the problems. Computational experiments show that the algorithms are capable of solving both problems of medium size to optimality within reasonable computational time. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 823–840, 2003.     

基于免疫遗传算法的人上位拣选车作业规划问题求解

针对人上位拣选车的作业轨迹规划问题构建了具有附加安全约束条件的时间最优控制数学模型,并提出了一种免疫遗传求解算法．该算法较单纯遗传算法有效避免了种群退化,且收敛速度更快．实验表明,该算法适用于求解人上位拣选车的作业轨迹规划问题．     

Some approximations in multi-item,multi-echelon inventory systems for recoverable items

The optimization problem as formulated in the METRIC model takes the form of minimizing the expected number of total system backorders in a two-echelon inventory system subject to a budget constraint. The system contains recoverable items – items subject to repair when they fail. To solve this problem, one needs to find the optimal Lagrangian multiplier associated with the given budget constraint. For any large-scale inventory system, this task is computationally not trivial. Fox and Landi proposed one method that was a significant improvement over the original METRIC algorithm. In this report we first develop a method for estimating the value of the optimal Lagrangian multiplier used in the Fox-Landi algorithm, present alternative ways for determining stock levels, and compare these proposed approaches with the Fox-Landi algorithm, using two hypothetical inventory systems – one having 3 bases and 75 items, the other 5 bases and 125 items. The comparison shows that the computational time can be reduced by nearly 50 percent. Another factor that contributes to the higher requirement for computational time in obtaining the solution to two-echelon inventory systems is that it has to allocate stock optimally to the depot as well as to bases for a given total-system stock level. This essentially requires the evaluation of every possible combination of depot and base stock levels – a time-consuming process for many practical inventory problems with a sizable system stock level. This report also suggests a simple approximation method for estimating the optimal depot stock level. When this method was applied to the same two hypotetical inventory systems indicated above, it was found that the estimate of optimal depot stock is quite close to the optimal value in all cases. Furthermore, the increase in expected system backorders using the estimated depot stock levels rather than the optimal levels is generally small.     

Generation and storage dispatch in electricity networks with generator disruptions

We present methods for optimizing generation and storage decisions in an electricity network with multiple unreliable generators, each colocated with one energy storage unit (e.g., battery), and multiple loads under power flow constraints. Our model chooses the amount of energy produced by each generator and the amount of energy stored in each battery in every time period in order to minimize power generation and storage costs when each generator faces stochastic Markovian supply disruptions. This problem cannot be optimized easily using stochastic programming and/or dynamic programming approaches. Therefore, in this study, we present several heuristic methods to find an approximate optimal solution for this system. Each heuristic involves decomposing the network into several single‐generator, single‐battery, multiload systems and solving them optimally using dynamic programming, then obtaining a solution for the original problem by recombining. We discuss the computational performance of the proposed heuristics as well as insights gained from the models. © 2015 Wiley Periodicals, Inc. Naval Research Logistics 62: 493–511, 2015     

The fixed charge problem

The fixed charge problem is a nonlinear programming problem of practical interest in business and industry. Yet, until now no computationally feasible exact method of solution for large problems had been developed. In this paper an exact algorithm is presented which is computationally feasible for large problems. The algorithm is based upon a branch and bound approach, with the additional feature that the amount of computer storage required remains constant throughout (for a problem of any given size). Also presented are three suboptimal heuristic algorithms which are of interest because, although they do not guarantee that the true optimal solution will be found, they usually yield very good solutions and are extremely rapid techniques. Computational results are described for several of the heuristic methods and for the branch and bound algorithm.     

The many-product cargo loading problem

An algorithm, based upon dynamic programming, is developed for a class of fixed-cost cargo loading problems. The problems can be formulated as integer programming problems, but cannot be efficiently solved as such because of computational difficulties. The algorithm developed has proved to be very efficient in an actual operations research study involving over 500 different cargo items, more than 40 possible stops and several types of transportation vehicles. A numerical illustration is provided.     

A two-station stochastic inventory model with exact methods of computing optimal policies

A method is presented for calculating optimal inventory levels in a two-station transactions reporting inventory system. The criterion of optimality is the minimization of expected cost. The computational properties of the model are stressed and the solution method is precise. It is shown that when the model represents a central warehouse which supplies several retail outlets, stocks carried at the central location affect the capacity of the system to handle orders. Stocks carried at the retail level affect only the size of the retail order backlog.     

基于大规模贝叶斯网络的安全性分析算法

贝叶斯网络计算量随着节点数增多呈指数增长,限制了大规模贝叶斯网络在安全性分析中的应用。为此,利用独立性条件分解整个网络,压缩推理时显式表达的项数,给出了计算顶事件发生概率及割集的算法,并分析了算法复杂性。在满足工程需要情况下,将提出算法与基于BDD算法相比,该算法表现出占用内存少、运行速度快的良好性能。