Planning horizon procedures for machine replacement models with several possible replacement alternatives

This paper develops a forward algorithm and planning horizon procedures for an important machine replacement model where it is assumed that the technological environment is improving over time and that the machine-in-use can be replaced by any of the several different kinds of machines available at that time. The set of replacement alternatives may include (i) new machines with different types of technologies such as labor- and capital- intensive, (ii) used machines, (iii) repairs and/or improvements which affect the performance characteristics of the existing machine, and so forth. The forward dynamic programming algorithm in the paper can be used to solve a finite horizon problem. The planning horizon results give a procedure to identify the forecast horizon T such that the optimal replacement decision for the first machine based on the forecast of machine technology until period T remains optimal for any problem with horizon longer than T and, for that matter, for the infinite horizon problem. A flow chart and a numerical example have been included to illustrate the algorithm.     

On parallel machine replacement problems with general replacement cost functions and stochastic deterioration

The parallel machine replacement problem consists of finding a minimum cost replacement policy for a finite population of economically interdependent machines. In this paper, we formulate a stochastic version of the problem and analyze the structure of optimal policies under general classes of replacement cost functions. We prove that for problems with arbitrary cost functions, there can be optimal policies where a machine is replaced only if all machines in worse states are replaced (Worse Cluster Replacement Rule). We then show that, for problems with replacement cost functions exhibiting nonincreasing marginal costs, there are optimal policies such that, in any stage, machines in the same state are either all kept or all replaced (No‐Splitting Rule). We also present an example that shows that economies of scale in replacement costs do not guarantee optimal policies that satisfy the No‐Splitting Rule. These results lead to the fundamental insight that replacement decisions are driven by marginal costs, and not by economies of scale as suggested in the literature. Finally, we describe how the optimal policy structure, i.e., the No‐Splitting and Worse Cluster Replacement Rules, can be used to reduce the computational effort required to obtain optimal replacement policies. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Dynamic pricing and inventory control with learning

Optimal operating policies and corresponding managerial insight are developed for the decision problem of coordinating supply and demand when (i) both supply and demand can be influenced by the decision maker and (ii) learning is pursued. In particular, we determine optimal stocking and pricing policies over time when a given market parameter of the demand process, though fixed, initially is unknown. Because of the initially unknown market parameter, the decision maker begins the problem horizon with a subjective probability distribution associated with demand. Learning occurs as the firm monitors the market's response to its decisions and then updates its characterization of the demand function. Of primary interest is the effect of censored data since a firm's observations often are restricted to sales. We find that the first‐period optimal selling price increases with the length of the problem horizon. However, for a given problem horizon, prices can rise or fall over time, depending on how the scale parameter influences demand. Further results include the characterization of the optimal stocking quantity decision and a computationally viable algorithm. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 303–325, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10013     

Optimal switchover times between two activities utilizing the same resource

The “gold‐mining” decision problem is concerned with the efficient utilization of a delicate mining equipment working in a number of different mines. Richard Bellman was the first to consider this type of a problem. The solution found by Bellman for the finite‐horizon, continuous‐time version of the problem with two mines is not overly realistic since he assumed that fractional parts of the same mining equipment could be used in different mines and this fraction could change instantaneously. In this paper, we provide some extensions to this model in order to produce more operational and realistic solutions. Our first model is concerned with developing an operational policy where the equipment may be switched from one mine to the other at most once during a finite horizon. In the next extension we incorporate a cost component in the objective function and assume that the horizon length is not fixed but it is the second decision variable. Structural properties of the optimal solutions are obtained using nonlinear programming. Each model and its solution is illustrated with a numerical example. The models developed here may have potential applications in other areas including production of items requiring the same machine or choosing a sequence of activities requiring the same resource. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 186–203, 2002; DOI 10.1002/nav.10008     

Parallel machine scheduling with batch deliveries to minimize total flow time and delivery cost

Motivated by the flow of products in the iron and steel industry, we study an identical and parallel machine scheduling problem with batch deliveries, where jobs finished on the parallel machines are delivered to customers in batches. Each delivery batch has a capacity and incurs a cost. The objective is to find a coordinated production and delivery schedule that minimizes the total flow time of jobs plus the total delivery cost. This problem is an extension of the problem considered by Hall and Potts, Ann Oper Res 135 (2005) 41–64, who studied a two‐machine problem with an unbounded number of transporters and unbounded delivery capacity. We first provide a dynamic programming algorithm to solve a special case with a given job assignment to the machines. A heuristic algorithm is then presented for the general problem, and its worst‐case performance ratio is analyzed. The computational results show that the heuristic algorithm can generate near‐optimal solutions. Finally, we offer a fully polynomial‐time approximation scheme for a fixed number of machines. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 492–502, 2016     

On some sequencing problems

The (mxn) sequencing problem may be characterized as follows: There are m machines which can produce a piece consisting of n parts. Each part has a determined order in which it is processed through the machines. It is assumed that each machine cannot deal with more than one part at a time and that the processing required for each part can be accomplished only on one machine. That is, the machines are all specialized so that alternate machines for the same processing on a part is not possible. The problem is to find the best production plan consisting in sequencing the different parts so as to make the whole amount of time from the beginning of work till the piece is completed the shortest possible. Such a plan is called an optimum one. In the first 4 sections of this paper, the problem (2xn) is solved for the (2xn) case in which the order in which parts come on the machine is not constrained by further assumptions. The remainder of the paper then takes up: 1) the (3xn) problem of Bellman-Johnson (viz. the technological processing order through the machine is the same for all parts) for several new special cases; 2) the 2xn problem of sequencing when delay times must also be considered; and, 3) some properties of an approximating method for solving (mxn) problems, including a delineation of cases when the approximating method will yield optimal solutions.     

Scheduling maintenance and semiresumable jobs on a single machine

The majority of scheduling literature assumes that the machines are available at all times. In this paper, we study single machine scheduling problems where the machine maintenance must be performed within certain intervals and hence the machine is not available during the maintenance periods. We also assume that if a job is not processed to completion before the machine is stopped for maintenance, an additional setup is necessary when the processing is resumed. Our purpose is to schedule the maintenance and jobs to minimize some performance measures. The objective functions that we consider are minimizing the total weighted job completion times and minimizing the maximum lateness. In both cases, maintenance must be performed within a fixed period T, and the time for the maintenance is a decision variable. In this paper, we study two scenarios concerning the planning horizon. First, we show that, when the planning horizon is long in relation to T, the problem with either objective function is NP-complete, and we present pseudopolynomial time dynamic programming algorithms for both objective functions. In the second scenario, the planning horizon is short in relation to T. However, part of the period T may have elapsed before we schedule any jobs in this planning horizon, and the remaining time before the maintenance is shorter than the current planning horizon. Hence we must schedule one maintenance in this planning horizon. We show that the problem of minimizing the total weighted completion times in this scenario is NP-complete, while the shortest processing time (SPT) rule and the earliest due date (EDD) rule are optimal for the total completion time problem and the maximum lateness problem respectively. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 845–863, 1999     

A comparative study of three tool replacement/operation sequencing strategies in a flexible manufacturing system

This paper studies three tool replacement/operation sequencing strategies for a flexible manufacturing system over a finite time horizon: (1) failure replacement—replace the tool only upon failure, (2) optimal preventive tool replacement for a fixed sequence of operations, and (3) joint scheduling of the optimal preventive tool replacement times and the optimal sequence of operations. Stochastic dynamic decision models are used for strategies 2 and 3. The optimization criterion for strategies 2 and 3 is the minimization of the total expected cost over the finite time horizon. We will show through numerical studies that, with the same amount of information, the total expected costs can be reduced considerably by choosing an optimal strategy. Our conclusion is that in flexible manufacturing, optimal tool replacement and optimal operations sequencing are not separate issues. They should be considered jointly to minimize the expected total cost. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 479–499, 2000     

Monotone optimal preventive maintenance policies for stochastically failing equipment

This paper examines various models for maintenance of a machine operating subject to stochastic deterioration. Three alternative models are presented for the deterioration process. For each model, in addition to the replacement decision, the option exists of performing preventive maintenance. The effect of this maintenance is to “slow” the deterioration process. With an appropriate reward structure imposed on the processes, the models are formulated as continuous time Markov decision processes. the optimality criterion being the maximization of expected discounted reward earned over an infinite time horizon. For each model conditions are presented under which the optimal maintenance policy exhibits the following monotonic structure. First, there exists a control limit rule for replacement. That is, there exists a number i* such that if the state of machine deterioration exceeds i* the optimal policy replaces the machine by a new machine. Secondly, prior to replacement the optimal level of preventive maintenance is a nonincreasing function of the state of machine deterioration. The conditions which guarantee this result have a cost/benefit interpretation.     

Optimal maintenance policies for serial,multi‐machine systems with non‐instantaneous repairs

We study optimal age‐replacement policies for machines in series with non‐instantaneous repair times by formulating two nonlinear programs: one that minimizes total cost‐rate subject to a steady‐state throughput requirement and another that maximizes steady‐state throughput subject to a cost‐rate budget constraint. Under reasonable assumptions, the single‐machine cost‐optimal and throughput‐optimal solutions are unique and orderable, and the multi‐machine optimal solutions have appealing structure. Furthermore, we establish equivalence between the two formulations and provide an illustrative numerical example. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Disruption management in production planning

We study the problem of recovering a production plan after a disruption, where the disruption may be caused by incidents such as power failure, market change, machine breakdown, supply shortage, worker no‐show, and others. The new recovery plan we seek after has to not only suit the changed environment brought about by the disruption, but also be close to the initial plan so as not to cause too much customer unsatisfaction or inconvenience for current‐stage and downstream operations. For the general‐cost case, we propose a dynamic programming method for the problem. For the convex‐cost case, a general problem which involves both cost and demand disruptions can be solved by considering the cost disruption first and then the demand disruption. We find that a pure demand disruption is easy to handle; and for a pure cost disruption, we propose a greedy method which is provably efficient. Our computational studies also reveal insights that will be helpful to managing disruptions in production planning. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Quality control chart design under Jidoka

We consider design of control charts in the presence of machine stoppages that are exogenously imposed (as under jidoka practices). Each stoppage creates an opportunity for inspection/repair at reduced cost. We first model a single machine facing opportunities arriving according to a Poisson process, develop the expressions for its operating characteristics and construct the optimization problem for economic design of a control chart. We, then, consider the multiple machine setting where individual machine stoppages may create inspection/repair opportunities for other machines. We develop exact expressions for the cases when all machines are either opportunity‐takers or not. On the basis of an approximation for the all‐taker case, we then propose an approximate model for the mixed case. In a numerical study, we examine the opportunity taking behavior of machines in both single and multiple machine settings and the impact of such practices on the design of an X – Q C chart. Our findings indicate that incorporating inspection/repair opportunities into QC chart design may provide considerable cost savings. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

A branch and bound algorithm for computing optimal replacement policies in consecutive k‐out‐of‐n‐systems

This paper presents a branch and bound algorithm for computing optimal replacement policies in a discrete‐time, infinite‐horizon, dynamic programming model of a binary coherent system with n statistically independent components, and then specializes the algorithm to consecutive k‐out‐of‐n systems. The objective is to minimize the long‐run expected average undiscounted cost per period. (Costs arise when the system fails and when failed components are replaced.) An earlier paper established the optimality of following a critical component policy (CCP), i.e., a policy specified by a critical component set and the rule: Replace a component if and only if it is failed and in the critical component set. Computing an optimal CCP is a optimization problem with n binary variables and a nonlinear objective function. Our branch and bound algorithm for solving this problem has memory storage requirement O(n) for consecutive k‐out‐of‐n systems. Extensive computational experiments on such systems involving over 350,000 test problems with n ranging from 10 to 150 find this algorithm to be effective when n ≤ 40 or k is near n. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 288–302, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10017     

Scheduling jobs and maintenance activities on parallel machines

Most machine scheduling models assume that the machines are available all of the time. However, in most realistic situations, machines need to be maintained and hence may become unavailable during certain periods. In this paper, we study the problem of processing a set of n jobs on m parallel machines where each machine must be maintained once during the planning horizon. Our objective is to schedule jobs and maintenance activities so that the total weighted completion time of jobs is minimized. Two cases are studied in this paper. In the first case, there are sufficient resources so that different machines can be maintained simultaneously if necessary. In the second case, only one machine can be maintained at any given time. In this paper, we first show that, even when all jobs have the same weight, both cases of the problem are NP-hard. We then propose branch and bound algorithms based on the column generation approach for solving both cases of the problem. Our algorithms are capable of optimally solving medium sized problems within a reasonable computational time. We note that the general problem where at most j machines, 1 ≤ j ≤ m, can be maintained simultaneously, can be solved similarly by the column generation approach proposed in this paper. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 145–165, 2000     

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     

On valuing appreciating human assets in services

This paper derives optimal policies for when to hire, train, and lay off employees in service organizations when worker productivity appreciates deterministically or stochastically under constant, monotonic, and cyclic service demand. The model, an extension of the machine replacement problem from the engineering economy literature, uses infinite horizon linear programming to produce optimal personnel planning strategies and dual prices that characterize the workforce's economic value. The effect of employee attrition is also considered. In its valuation of human assets, unlike pure accounting approaches that only try to measure, this paper proposes an approach to capture the interaction between firm decisions pertaining to human resources and human resource value. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Capacity allocation with machine duplication in semiconductor manufacturing

The manufacturing process for a computer chip is complex in that it involves a large number of distinct operations requiring a substantial lead‐time for completion. Our observations of such a manufacturing process at a large plant in the United States led us to identify several tactical and operational problems that were being addressed by the production planners on a recurring basis. This paper focuses on one such problem. At a tactical level, given a demand forecast of wafers to be manufactured, one specific problem deals with specifying which machine or machine groups will process different batches of wafers. We address this problem by recognizing the capacity limitations of the individual machines as well as the requirement for reducing operating and investment costs related to the machines. A mathematical model, which is a variation of the well‐known capacitated facility location problem, is proposed to solve this problem. Given the intractability of the model, we first develop problem specific lower bounding procedures based on Lagrangean relaxation. We also propose a heuristic method to obtain “good” solutions with reasonable computational effort. Computational tests, using hypothetical and industry‐based data, indicate that our heuristic approach provides optimal/near optimal solutions fairly quickly. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Optimal pricing and inventory control policy in periodic‐review systems with fixed ordering cost and lost sales

This paper studies a periodic‐review pricing and inventory control problem for a retailer, which faces stochastic price‐sensitive demand, under quite general modeling assumptions. Any unsatisfied demand is lost, and any leftover inventory at the end of the finite selling horizon has a salvage value. The cost component for the retailer includes holding, shortage, and both variable and fixed ordering costs. The retailer's objective is to maximize its discounted expected profit over the selling horizon by dynamically deciding on the optimal pricing and replenishment policy for each period. We show that, under a mild assumption on the additive demand function, at the beginning of each period an (s,S) policy is optimal for replenishment, and the value of the optimal price depends on the inventory level after the replenishment decision has been done. Our numerical study also suggests that for a sufficiently long selling horizon, the optimal policy is almost stationary. Furthermore, the fixed ordering cost (K) plays a significant role in our modeling framework. Specifically, any increase in K results in lower s and higher S. On the other hand, the profit impact of dynamically changing the retail price, contrasted with a single fixed price throughout the selling horizon, also increases with K. We demonstrate that using the optimal policy values from a model with backordering of unmet demands as approximations in our model might result in significant profit penalty. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Optimal replacement under additive damage and other failure models

A machine or production system is subject to random failure. Upon failure the system is replaced by a new one, and the process repeats. A cost is associated with each replacement, and an additional cost is incurred at each failure in service. Thus, there is an incentive for a controller to attempt to replace before failure occurs. The problem is to find an optimal control strategy that balances the cost of replacement with the cost of failure and results in a minimum total long-run average cost per unit time. We attack this problem under the cumulative damage model for system failure. In this failure model, shocks occur to the system in accordance with a Poisson process. Each shock causes a random amount of damage or wear and these damages accumulate additively. At any given shock, the system fails with a known probability that depends on the total damage accumulated to date. We assume that the cumulative damage is observable by the controller and that his decisions may be based on its current value. Supposing that the shock failure probability is an increasing function of the cumulative damage, we show that an optimal policy is to replace either upon failure or when this damage first exceeds a critical control level, and we give an equation which implicitly defines the optimal control level in terms of the cost and other system parameters. Also treated are some more general models that allow for income lost during repair time and other extensions.     

A stochastic constrained optimal replacement model

In this paper a stochastically constrained replacement model is formulated. This model determines a sequence of replacement dates such that the total “current account” cost of all future costs and capital expenditures over an infinite time horizon for the n initial incumbent machines is minimized subject to the constraints that an expected number of machines are in a chosen utility class at any point in time. We then indicate one possible solution method for the model.