A general strategic capacity planning model under demand uncertainty

Capacity planning decisions affect a significant portion of future revenue. In equipment intensive industries, these decisions usually need to be made in the presence of both highly volatile demand and long capacity installation lead times. For a multiple product case, we present a continuous‐time capacity planning model that addresses problems of realistic size and complexity found in current practice. Each product requires specific operations that can be performed by one or more tool groups. We consider a number of capacity allocation policies. We allow tool retirements in addition to purchases because the stochastic demand forecast for each product can be decreasing. We present a cluster‐based heuristic algorithm that can incorporate both variance reduction techniques from the simulation literature and the principles of a generalized maximum flow algorithm from the network optimization literature. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Robust capacity planning in semiconductor manufacturing

We present a stochastic programming approach to capacity planning under demand uncertainty in semiconductor manufacturing. Given multiple demand scenarios together with associated probabilities, our aim is to identify a set of tools that is a good compromise for all these scenarios. More precisely, we formulate a mixed‐integer program in which expected value of the unmet demand is minimized subject to capacity and budget constraints. This is a difficult two‐stage stochastic mixed‐integer program which cannot be solved to optimality in a reasonable amount of time. We instead propose a heuristic that can produce near‐optimal solutions. Our heuristic strengthens the linear programming relaxation of the formulation with cutting planes and performs limited enumeration. Analyses of the results in some real‐life situations are also presented. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Integrated capacity,demand, and production planning with subcontracting and overtime options

Models for integrated production and demand planning decisions can serve to improve a producer's ability to effectively match demand requirements with production capabilities. In contexts with price‐sensitive demands, economies of scale in production, and multiple capacity options, such integrated planning problems can quickly become complex. To address these complexities, this paper provides profit‐maximizing production planning models for determining optimal demand and internal production capacity levels under price‐sensitive deterministic demands, with subcontracting and overtime options. The models determine a producer's optimal price, production, inventory, subcontracting, overtime, and internal capacity levels, while accounting for production economies of scale and capacity costs through concave cost functions. We use polyhedral properties and dynamic programming techniques to provide polynomial‐time solution approaches for obtaining an optimal solution for this class of problems when the internal capacity level is time‐invariant. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

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     

The continuous‐time single‐sourcing problem with capacity expansion opportunities

This paper develops a new model for allocating demand from retailers (or customers) to a set of production/storage facilities. A producer manufactures a product in multiple production facilities, and faces demand from a set of retailers. The objective is to decide which of the production facilities should satisfy each retailer's demand, in order minimize total production, inventory holding, and assignment costs (where the latter may include, for instance, variable production costs and transportation costs). Demand occurs continuously in time at a deterministic rate at each retailer, while each production facility faces fixed‐charge production costs and linear holding costs. We first consider an uncapacitated model, which we generalize to allow for production or storage capacities. We then explore situations with capacity expansion opportunities. Our solution approach employs a column generation procedure, as well as greedy and local improvement heuristic approaches. A broad class of randomly generated test problems demonstrates that these heuristics find high quality solutions for this large‐scale cross‐facility planning problem using a modest amount of computation time. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Designing safety space in a supply chain to handle system‐wide disruptions

In some supply chains serious disruptions are system wide. This happens during periods of severe weather, as when storms cause shuttle tankers serving oil platforms in the North Sea to stop movements of crude oil, barges are frozen in the Mississippi, or all airplanes are grounded after a blizzard. Other notable instances of system‐wide disruption happened after the attack on the World Trade Center when all aircraft were grounded and the natural gas and crude‐oil pipelines were tangled by hurricanes in 2005. We model a situation where shutting down supply facilities is very difficult and expensive because of excessive inventory buildup from an inability to move out the production. We present a planning model that balances the cost of spare capacity versus shutting down production when planning for disruptions. The model uses an assignment model embedded in a simulation. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

A concave‐cost production planning problem with remanufacturing options

We focus on the concave‐cost version of a production planning problem where a manufacturer can meet demand by either producing new items or by remanufacturing used items. Unprocessed used items are disposed. We show the NP‐hardness of the problem even when all the costs are stationary. Utilizing the special structure of the extreme‐point optimal solutions for the minimum concave‐cost problem with a network flow type feasible region, we develop a polynomial‐time heuristic for the problem. Our computational study indicates that the heuristic is a very efficient way to solve the problem as far as solution speed and quality are concerned. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

A generalized assignment model for dynamic supply chain capacity planning

We consider a generalization of the well‐known generalized assignment problem (GAP) over discrete time periods encompassed within a finite planning horizon. The resulting model, MultiGAP, addresses the assignment of tasks to agents within each time period, with the attendant single‐period assignment costs and agent‐capacity constraint requirements, in conjunction with transition costs arising between any two consecutive periods in which a task is reassigned to a different agent. As is the case for its single‐period antecedent, MultiGAP offers a robust tool for modeling a wide range of capacity planning problems occurring within supply chain management. We provide two formulations for MultiGAP and establish that the second (alternative) formulation provides a tighter bound. We define a Lagrangian relaxation‐based heuristic as well as a branch‐and‐bound algorithm for MultiGAP. Computational experience with the heuristic and branch‐and‐bound algorithm on over 2500 test problems is reported. The Lagrangian heuristic consistently generates high‐quality and in many cases near‐optimal solutions. The branch‐and‐bound algorithm is also seen to constitute an effective means for solving to optimality MultiGAP problems of reasonable size. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2012     

Risk‐sensitive sizing of responsive facilities

We develop a risk‐sensitive strategic facility sizing model that makes use of readily obtainable data and addresses both capacity and responsiveness considerations. We focus on facilities whose original size cannot be adjusted over time and limits the total production equipment they can hold, which is added sequentially during a finite planning horizon. The model is parsimonious by design for compatibility with the nature of available data during early planning stages. We model demand via a univariate random variable with arbitrary forecast profiles for equipment expansion, and assume the supporting equipment additions are continuous and decided ex‐post. Under constant absolute risk aversion, operating profits are the closed‐form solution to a nontrivial linear program, thus characterizing the sizing decision via a single first‐order condition. This solution has several desired features, including the optimal facility size being eventually decreasing in forecast uncertainty and decreasing in risk aversion, as well as being generally robust to demand forecast uncertainty and cost errors. We provide structural results and show that ignoring risk considerations can lead to poor facility sizing decisions that deteriorate with increased forecast uncertainty. Existing models ignore risk considerations and assume the facility size can be adjusted over time, effectively shortening the planning horizon. Our main contribution is in addressing the problem that arises when that assumption is relaxed and, as a result, risk sensitivity and the challenges introduced by longer planning horizons and higher uncertainty must be considered. Finally, we derive accurate spreadsheet‐implementable approximations to the optimal solution, which make this model a practical capacity planning tool.© 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

An approximate planning model for distributed computing networks

We develop an approximate planning model for a distributed computing network in which a control system oversees the assignment of information flows and tasks to a pool of shared computers, and describe several optimization applications using the model. We assume that the computers are multithreaded, and have differing architectures leading to varying and inconsistent processing rates. The model is based on a discrete‐time, continuous flow model developed by Graves [Oper Res 34 (1986), 522–533] which provides the steady‐state moments of production and work‐in‐queue quantities. We make several extensions to Graves' model to represent distributed computing networks. First, we approximately model control rules that are nonlinear functions of the work‐in‐queue at multiple stations through a linearization approach. Second, we introduce an additional noise term on production and show its use in modeling the discretization of jobs. Third, we model groups of heterogeneous computers as aggregate, “virtual computing cells” that process multiple tasks simultaneously, using a judiciously selected control rule. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

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.     

A risk function for the stochastic modeling of electric capacity expansion

We present a stochastic optimization model for planning capacity expansion under capacity deterioration and demand uncertainty. The paper focuses on the electric sector, although the methodology can be used in other applications. The goals of the model are deciding which energy types must be installed, and when. Another goal is providing an initial generation plan for short periods of the planning horizon that might be adequately modified in real time assuming penalties in the operation cost. Uncertainty is modeled under the assumption that the demand is a random vector. The cost of the risk associated with decisions that may need some tuning in the future is included in the objective function. The proposed scheme to solve the nonlinear stochastic optimization model is Generalized Benders' decomposition. We also exploit the Benders' subproblem structure to solve it efficiently. Computational results for moderate‐size problems are presented along with comparison to a general‐purpose nonlinear optimization package. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48:662–683, 2001     

Shock model in Markovian environment

A Markov modulated shock models is studied in this paper. In this model, both the interarrival time and the magnitude of the shock are determined by a Markov process. The system fails whenever a shock magnitude exceeds a pre‐specified level η. Nonexponential bounds of the reliability are given when the interarrival time has heavy‐tailed distribution. The exponential decay of the reliability function and the asymptotic failure rate are also considered for the light‐tailed case. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

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     

Transshipment through crossdocks with inventory and time windows

A major challenge in making supply meet demand is to coordinate transshipments across the supply chain to reduce costs and increase service levels in the face of demand fluctuations, short lead times, warehouse limitations, and transportation and inventory costs. In particular, transshipment through crossdocks, where just‐in‐time objectives prevail, requires precise scheduling between suppliers, crossdocks, and customers. In this work, we study the transshipment problem with supplier and customer time windows where flow is constrained by transportation schedules and warehouse capacities. Transportation is provided by fixed or flexible schedules and lot‐sizing is dealt with through multiple shipments. We develop polynomial‐time algorithms or, otherwise, provide the complexity of the problems studied. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Allocation of resources of modular sizes with an application to Internet Protocol (IP) address allocation

We consider a resource allocation problem, where resources of different capacities must satisfy multiple demands. The demand sizes and the resource capacities are limited to sizes that are power‐of‐two integers (i.e., 1, 2, 4, 8, …). The cost of the resources exhibit economies‐of‐scale savings, i.e., the cost per capacity unit is smaller for resources with larger capacity. The problem is to select the minimum‐cost set of resources that satisfies the demands, while each of the demands must be assigned to a single resource and the number of selected resources does not exceed a specified upper bound. We present algorithms that take advantage of the special structure of the problem and provide optimal solutions in a negligible computing effort. This problem is important for the allocation of blocks of Internet Protocol (IP) addresses, referred to as subnets. In typical IP networks, subnets are allocated at a large number of nodes. An effective allocation attempts to balance the volume of excess addresses that are not used versus fragmentation of addresses at nodes to too many subnets with a discontinuous range of addresses. Due to the efficiency of the algorithms, they can readily be used as valuable modules in IP address management systems. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Single machine scheduling with a restricted rate‐modifying activity

In this paper we consider the problem of scheduling a set of jobs on a single machine on which a rate‐modifying activity may be performed. The rate‐modifying activity is an activity that changes the production rate of the machine. So the processing time of a job is a variable, which depends on whether it is scheduled before or after the rate‐modifying activity. We assume that the rate‐modifying activity can take place only at certain predetermined time points, which is a constrained case of a similar problem discussed in the literature. The decisions under consideration are whether and when to schedule the rate‐modifying activity, and how to sequence the jobs in order to minimize some objectives. We study the problems of minimizing makespan and total completion time. We first analyze the computational complexity of both problems for most of the possible versions. The analysis shows that the problems are NP‐hard even for some special cases. Furthermore, for the NP‐hard cases of the makespan problem, we present a pseudo‐polynomial time optimal algorithm and a fully polynomial time approximation scheme. For the total completion time problem, we provide a pseudo‐polynomial time optimal algorithm for the case with agreeable modifying rates. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Evaluating methods for the reliability of a large 2‐dimensional rectangular k‐within‐consecutive‐(r,s)‐out‐of‐(m,n):F system

A 2‐dimensional rectangular k‐within‐consecutive‐(r, s)‐out‐of‐(m, n):F system consists of m × n components, and fails if and only if k or more components fail in an r × s submatrix. This system can be treated as a reliability model for TFT liquid crystal displays, wireless communication networks, etc. Although an effective method has been developed for evaluating the exact system reliability of small or medium‐sized systems, that method needs extremely high computing time and memory capacity when applied to larger systems. Therefore, developing upper and lower bounds and accurate approximations for system reliability is useful for large systems. In this paper, first, we propose new upper and lower bounds for the reliability of a 2‐dimensional rectangular k‐within‐consecutive‐(r, s)‐out‐of‐(m, n):F system. Secondly, we propose two limit theorems for that system. With these theorems we can obtain accurate approximations for system reliabilities when the system is large and component reliabilities are close to one. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Manpower allocation with time windows and job‐teaming constraints

In this work, we study manpower allocation with time windows and job‐teaming constraints. A set of jobs at dispersed locations requires teams of different types of workers where each job must be carried out in a preestablished time window and requires a specific length of time for completion. A job is satisfied if the required composite team can be brought together at the job's location for the required duration within the job's time window. The objective is to minimize a weighted sum of the total number of workers and the total traveling time. We show that construction heuristics used with simulated annealing is a good approach to solving this NP‐hard problem. In experiments, this approach is compared with solutions found using CPLEX and with lower bounds obtained from a network flow model. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Modeling multiple stage manufacturing systems with generalized costs and capacity issues

This study introduces one modeling methodology that describes a broad range of multiple stage production planning issues, including multiple limited resources with setup times and joint fixed cost relationships. An existing production system is modeled in this fashion, creating a new set of 1350 highly generalized benchmark problems. A computational study is conducted with the 1350 benchmark problems introduced in this paper and 2100 benchmark problems, with more restrictive assumptions, from the existing literature. The relative merits of a decomposition‐based algorithm and a neighborhood search technique known as NIPPA, or the Non‐sequential Incremental Part Period Algorithm, are assessed. NIPPA is generally the more successful of the two techniques, although there are specific instances in which the decomposition‐based algorithm displayed a distinct advantage. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005