Capacitated lot‐sizing and scheduling with parallel machines,back‐orders,and setup carry‐over

We address the capacitated lot‐sizing and scheduling problem with setup times, setup carry‐over, back‐orders, and parallel machines as it appears in a semiconductor assembly facility. The problem can be formulated as an extension of the capacitated lot‐sizing problem with linked lot‐sizes (CLSPL). We present a mixed integer (MIP) formulation of the problem and a new solution procedure. The solution procedure is based on a novel “aggregate model,” which uses integer instead of binary variables. The model is embedded in a period‐by‐period heuristic and is solved to optimality or near‐optimality in each iteration using standard procedures (CPLEX). A subsequent scheduling routine loads and sequences the products on the parallel machines. Six variants of the heuristic are presented and tested in an extensive computational study. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Single‐warehouse multi‐retailer inventory systems with full truckload shipments

We consider a multi‐stage inventory system composed of a single warehouse that receives a single product from a single supplier and replenishes the inventory of n retailers through direct shipments. Fixed costs are incurred for each truck dispatched and all trucks have the same capacity limit. Costs are stationary, or more generally monotone as in Lippman (Management Sci 16, 1969, 118–138). Demands for the n retailers over a planning horizon of T periods are given. The objective is to find the shipment quantities over the planning horizon to satisfy all demands at minimum system‐wide inventory and transportation costs without backlogging. Using the structural properties of optimal solutions, we develop (1) an O(T²) algorithm for the single‐stage dynamic lot sizing problem; (2) an O(T³) algorithm for the case of a single‐warehouse single‐retailer system; and (3) a nested shortest‐path algorithm for the single‐warehouse multi‐retailer problem that runs in polynomial time for a given number of retailers. To overcome the computational burden when the number of retailers is large, we propose aggregated and disaggregated Lagrangian decomposition methods that make use of the structural properties and the efficient single‐stage algorithm. Computational experiments show the effectiveness of these algorithms and the gains associated with coordinated versus decentralized systems. Finally, we show that the decentralized solution is asymptotically optimal. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

The one‐warehouse multiretailer problem with an order‐up‐to level inventory policy

We consider a two‐level system in which a warehouse manages the inventories of multiple retailers. Each retailer employs an order‐up‐to level inventory policy over T periods and faces an external demand which is dynamic and known. A retailer's inventory should be raised to its maximum limit when replenished. The problem is to jointly decide on replenishment times and quantities of warehouse and retailers so as to minimize the total costs in the system. Unlike the case in the single level lot‐sizing problem, we cannot assume that the initial inventory will be zero without loss of generality. We propose a strong mixed integer program formulation for the problem with zero and nonzero initial inventories at the warehouse. The strong formulation for the zero initial inventory case has only T binary variables and represents the convex hull of the feasible region of the problem when there is only one retailer. Computational results with a state‐of‐the art solver reveal that our formulations are very effective in solving large‐size instances to optimality. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

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     

Competition under time‐varying demands and dynamic lot sizing costs

We develop a competitive pricing model which combines the complexity of time‐varying demand and cost functions and that of scale economies arising from dynamic lot sizing costs. Each firm can replenish inventory in each of the T periods into which the planning horizon is partitioned. Fixed as well as variable procurement costs are incurred for each procurement order, along with inventory carrying costs. Each firm adopts, at the beginning of the planning horizon, a (single) price to be employed throughout the horizon. On the basis of each period's system of demand equations, these prices determine a time series of demands for each firm, which needs to service them with an optimal corresponding dynamic lot sizing plan. We establish the existence of a price equilibrium and associated optimal dynamic lotsizing plans, under mild conditions. We also design efficient procedures to compute the equilibrium prices and dynamic lotsizing plans.© 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

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.     

The single and multi‐item transshipment problem with fixed transshipment costs

This article deals with supply chain systems in which lateral transshipments are allowed. For a system with two retailers facing stochastic demand, we relax the assumption of negligible fixed transshipment costs, thus, extending existing results for the single‐item case and introducing a new model with multiple items. The goal is to determine optimal transshipment and replenishment policies, such that the total centralized expected profit of both retailers is maximized. For the single‐item problem with fixed transshipment costs, we develop optimality conditions, analyze the expected profit function, and identify the optimal solution. We extend our analysis to multiple items with joint fixed transshipment costs, a problem that has not been investigated previously in the literature, and show how the optimality conditions may be extended for any number of items. Due to the complexity involved in solving these conditions, we suggest a simple heuristic based on the single‐item results. Finally, we conduct a numerical study that provides managerial insights on the solutions obtained in various settings and demonstrates that the suggested heuristic performs very well. © 2014 Wiley Periodicals, Inc. Naval Research Logistics, 61: 637–664, 2014     

Strategic capacity decision‐making in a stochastic manufacturing environment using real‐time approximate dynamic programming

In this study, we illustrate a real‐time approximate dynamic programming (RTADP) method for solving multistage capacity decision problems in a stochastic manufacturing environment, by using an exemplary three‐stage manufacturing system with recycle. The system is a moderate size queuing network, which experiences stochastic variations in demand and product yield. The dynamic capacity decision problem is formulated as a Markov decision process (MDP). The proposed RTADP method starts with a set of heuristics and learns a superior quality solution by interacting with the stochastic system via simulation. The curse‐of‐dimensionality associated with DP methods is alleviated by the adoption of several notions including “evolving set of relevant states,” for which the value function table is built and updated, “adaptive action set” for keeping track of attractive action candidates, and “nonparametric k nearest neighbor averager” for value function approximation. The performance of the learned solution is evaluated against (1) an “ideal” solution derived using a mixed integer programming (MIP) formulation, which assumes full knowledge of future realized values of the stochastic variables (2) a myopic heuristic solution, and (3) a sample path based rolling horizon MIP solution. The policy learned through the RTADP method turned out to be superior to polices of 2 and 3. © 2010 Wiley Periodicals, Inc. Naval Research Logistics 2010     

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     

A probabilistic analysis of a fixed partition policy for the inventory‐routing problem

We consider the Inventory‐Routing Problem (IRP) where n geographically dispersed retailers must be supplied by a central facility. The retailers experience demand for the product at a deterministic rate, and incur holding costs for keeping inventory. Distribution is performed by a fleet of capacitated vehicles. The objective is to minimize the average transportation and inventory costs per unit time over the infinite horizon. We focus on the set of Fixed Partition Policies (FPP). In an FPP, the retailers are partitioned into disjoint and collectively exhaustive sets. Each set of retailers is served independently of the others and at its optimal replenishment rate. Previous research has measured the effectiveness of an FPP solution relative to a lower bound over all policies. We propose an additional measure that is relative to the optimal FPP. In this paper we construct a polynomial‐time partitioning scheme that is shown to yield an FPP whose cost is asymptotically within 1.5% + ? of the cost of an optimal FPP, for arbitrary ? > 0. In addition, in some cases, our polynomial‐time scheme yields an FPP whose cost is asymptotically within 1.5% + ? of the minimal policy's cost (over all feasible policies). © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004     

Multi‐item capacitated lot‐sizing problems with setup times and pricing decisions

We study a multi‐item capacitated lot‐sizing problem with setup times and pricing (CLSTP) over a finite and discrete planning horizon. In this class of problems, the demand for each independent item in each time period is affected by pricing decisions. The corresponding demands are then satisfied through production in a single capacitated facility or from inventory, and the goal is to set prices and determine a production plan that maximizes total profit. In contrast with many traditional lot‐sizing problems with fixed demands, we cannot, without loss of generality, restrict ourselves to instances without initial inventories, which greatly complicates the analysis of the CLSTP. We develop two alternative Dantzig–Wolfe decomposition formulations of the problem, and propose to solve their relaxations using column generation and the overall problem using branch‐and‐price. The associated pricing problem is studied under both dynamic and static pricing strategies. Through a computational study, we analyze both the efficacy of our algorithms and the benefits of allowing item prices to vary over time. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

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

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

Non‐greedy heuristics and augmented neural networks for the open‐shop scheduling problem

In this paper we propose some non‐greedy heuristics and develop an Augmented‐Neural‐Network (AugNN) formulation for solving the classical open‐shop scheduling problem (OSSP). AugNN is a neural network based meta‐heuristic approach that allows integration of domain‐specific knowledge. The OSSP is framed as a neural network with multiple layers of jobs and machines. Input, output and activation functions are designed to enforce the problem constraints and embed known heuristics to generate a good feasible solution fast. Suitable learning strategies are applied to obtain better neighborhood solutions iteratively. The new heuristics and the AugNN formulation are tested on several benchmark problem instances in the literature and on some new problem instances generated in this study. The results are very competitive with other meta‐heuristic approaches, both in terms of solution quality and computational times. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Heuristics for the multi‐resource generalized assignment problem

The well‐known generalized assignment problem (GAP) involves the identification of a minimum‐cost assignment of tasks to agents when each agent is constrained by a resource in limited supply. The multi‐resource generalized assignment problem (MRGAP) is the generalization of the GAP in which there are a number of different potentially constraining resources associated with each agent. This paper explores heuristic procedures for the MRGAP. We first define a three‐phase heuristic which seeks to construct a feasible solution to MRGAP and then systematically attempts to improve the solution. We then propose a modification of the heuristic for the MRGAP defined previously by Gavish and Pirkul. The third procedure is a hybrid heuristic that combines the first two heuristics, thus capturing their relative strengths. We discuss extensive computational experience with the heuristics. The hybrid procedure is seen to be extremely effective in solving MRGAPs, generating feasible solutions to more than 99% of the test problems and consistently producing near‐optimal solutions. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 468–483, 2001     

Inventory control in divergent supply chains with time‐based dispatching and shipment consolidation

This article analyses a divergent supply chain consisting of a central warehouse and N nonidentical retailers. The focus is on joint evaluation of inventory replenishment and shipment consolidation effects. A time‐based dispatching and shipment consolidation policy is used at the warehouse in conjunction with real‐time point‐of‐sale data and centralized inventory information. This represents a common situation, for example, in various types of vendor managed inventory systems. The main contribution is the derivation of an exact recursive procedure for determining the expected inventory holding and backorder costs for the system, under the assumption of Poisson demand. Two heuristics for determining near optimal shipment intervals are also presented. The results are applicable both for single‐item and multiitem systems. © 2011 Wiley Periodicals, Inc. Naval Research Logistics 58: 59–71, 2011     

A m‐parallel crane scheduling problem with a non‐crossing constraint

In this paper, we study a m‐parallel machine scheduling problem with a non‐crossing constraint motivated by crane scheduling in ports. We decompose the problem to allow time allocations to be determined once crane assignments are known and construct a backtracking search scheme that manipulates domain reduction and pruning strategies. Simple approximation heuristics are developed, one of which guarantees solutions to be at most two times the optimum. For large‐scale problems, a simulated annealing heuristic that uses random neighborhood generation is provided. Computational experiments are conducted to test the algorithms. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007.     

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     

Case‐based reasoning and improved adaptive search for project scheduling

Most scheduling problems are notoriously intractable, so the majority of algorithms for them are heuristic in nature. Priority rule‐based methods still constitute the most important class of these heuristics. Of these, in turn, parametrized biased random sampling methods have attracted particular interest, due to the fact that they outperform all other priority rule‐based methods known. Yet, even the “best” such algorithms are unable to relate to the full range of instances of a problem: Usually there will exist instances on which other algorithms do better. We maintain that asking for the one best algorithm for a problem may be asking too much. The recently proposed concept of control schemes, which refers to algorithmic schemes allowing to steer parametrized algorithms, opens up ways to refine existing algorithms in this regard and improve their effectiveness considerably. We extend this approach by integrating heuristics and case‐based reasoning (CBR), an approach that has been successfully used in artificial intelligence applications. Using the resource‐constrained project scheduling problem as a vehicle, we describe how to devise such a CBR system, systematically analyzing the effect of several criteria on algorithmic performance. Extensive computational results validate the efficacy of our approach and reveal a performance similar or close to state‐of‐the‐art heuristics. In addition, the analysis undertaken provides new insight into the behaviour of a wide class of scheduling heuristics. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 201–222, 2000     

Integrated scheduling of loading and transportation with tractors and semitrailers separated

Motivated by some practical applications, we study a new integrated loading and transportation scheduling problem. Given a set of jobs, a single crane is available to load jobs, one by one, onto semitrailers with a given capacity. Loaded semitrailers are assigned to tractors for transportation tasks. Subject to limited resources (crane, semitrailers, and tractors), the problem is to determine (1) an assignment of jobs to semitrailers for loading tasks, (2) a sequence for the crane to load jobs onto semitrailers, (3) an assignment of loaded semitrailers to tractors for transportation tasks, and (4) a transportation schedule of assigned tractors such that the completion time of the last transportation task is minimized. We first formulate the problem as a mixed integer linear programming model (MILPM) and prove that the problem is strongly NP‐hard. Then, optimality properties are provided which are useful in establishing an improved MILPM and designing solution algorithms. We develop a constructive heuristic, two LP‐based heuristics, and a recovering beam search heuristic to solve this problem. An improved procedure for solutions by heuristics is also presented. Furthermore, two branch‐and‐bound (B&B) algorithms with two different lower bounds are developed to solve the problem to optimality. Finally, computational experiments using both real data and randomly generated data demonstrate that our heuristics are highly efficient and effective. In terms of computational time and the number of instances solved to optimality in a time limit, the B&B algorithms are better than solving the MILPM. © 2015 Wiley Periodicals, Inc. Naval Research Logistics 62: 416–433, 2015