One- and two-stage scheduling of two products with distributed inserted idle time: The benefits of a controllable production rate

Consider the problem of scheduling two products on a single machine or through two machines in series when demand is constant and there is a changeover cost between runs of different products on the same machine. As well as setting batch sizes, it is assumed that the production scheduler can choose the production rate for each product, provided an upper bound is not exceeded. This is equivalent to permitting distributed inserted idle time over the production run. It is shown that characteristic of the optimum schedule is that there is no idle time concentrated between runs; it is all distributed over the run. If the inventory charge is based on average inventory then one product is always produced at maximum rate on the bottleneck stage; however, if there is an inventory constraint based on maximum inventory then in the single-stage case it can occur that neither product is produced at maximum rate.     

Optimal control of a capacitated inventory system with multiple demand classes

This article studies the optimal control of a periodic‐review make‐to‐stock system with limited production capacity and multiple demand classes. In this system, a single product is produced to fulfill several classes of demands. The manager has to make the production and inventory allocation decisions. His objective is to minimize the expected total discounted cost. The production decision is made at the beginning of each period and determines the amount of products to be produced. The inventory allocation decision is made after receiving the random demands and determines the amount of demands to be satisfied. A modified base stock policy is shown to be optimal for production, and a multi‐level rationing policy is shown to be optimal for inventory allocation. Then a heuristic algorithm is proposed to approximate the optimal policy. The numerical studies show that the heuristic algorithm is very effective. © 2011 Wiley Periodicals, Inc. Naval Research Logistics 58: 43–58, 2011     

Multiperiod capacity expansion and shipment planning with linear costs

In this paper we consider a multiperiod deterministic capacity expansion and shipment planning problem for a single product. The product can be manufactured in several producing regions and is required in a number of markets. The demands for each of the markets are non-decreasing over time and must be met exactly during each time period (i.e., no backlogging or inventorying for future periods is permitted). Each region is assumed to have an initial production capacity, which may be increased at a given cost in any period. The demand in a market can be satisfied by production and shipment from any of the regions. The problem is to find a schedule of capacity expansions for the regions and a schedule of shipments from the regions to the markets so as to minimize the discounted capacity expansion and shipment costs. The problem is formulated as a linear programming model, and solved by an efficient algorithm using the operator theory of parametric programming for the transporation problem. Extensions to the infinite horizon case are also provided.     

Discounted production scheduling and employment smoothing

We consider the problem of minimizing the sum of production, employment smoothing, and inventory costs over a finite number of time periods where demands are known. The fundamental difference between our model and that treated in [1] is that here we permit the smoothing cost to be nonstationary, thereby admitting a model with discounting. We show that the values of the instrumental variables are nondecreasing in time when demands are nondecreasing. We also derive some asymptotic properties of optimal policies.     

Capacity games for partially complementary products under multivariate random demands

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

Exact algorithms for integrated facility location and production planning problems

We consider a class of facility location problems with a time dimension, which requires assigning every customer to a supply facility in each of a finite number of periods. Each facility must meet all assigned customer demand in every period at a minimum cost via its production and inventory decisions. We provide exact branch‐and‐price algorithms for this class of problems and several important variants. The corresponding pricing problem takes the form of an interesting class of production planning and order selection problems. This problem class requires selecting a set of orders that maximizes profit, defined as the revenue from selected orders minus production‐planning‐related costs incurred in fulfilling the selected orders. We provide polynomial‐time dynamic programming algorithms for this class of pricing problems, as well as for generalizations thereof. Computational testing indicates the advantage of our branch‐and‐price algorithm over various approaches that use commercial software packages. These tests also highlight the significant cost savings possible from integrating location with production and inventory decisions and demonstrate that the problem is rather insensitive to forecast errors associated with the demand streams. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Coordination of pricing and inventory control across products

We consider the joint pricing and inventory‐control problem for a retailer who orders, stocks, and sells two products. Cross‐price effects exist between the two products, which means that the demand of each product depends on the prices of both products. We derive the optimal pricing and inventory‐control policy and show that this policy differs from the base‐stock list‐price policy, which is optimal for the one‐product problem. We find that the retailer can significantly improve profits by managing the two products jointly as opposed to independently, especially when the cross‐price demand elasticity is high. We also find that the retailer can considerably improve profits by using dynamic pricing as opposed to static pricing, especially when the demand is nonstationary. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2009     

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     

Optimal production growth for the machine loading problem

This paper investigates a production growth logistics system for the machine loading problem (generalized transportation model), with a linear cost structure and minimum levels on total machine hours (resources) and product types (demands). An algorithm is provided for tracing the production growth path of this system, viz. in determining the optimal machine loading schedule of machines for product types, when the volumes of (i) total machine hours, and (ii) the total amount of product types are increased either individually for each total or simultaneously for both. Extensions of this methodology, when (i) the costs of production are convex and piecewise linear, and (ii) when the costs are nonconvex due to quantity discounts, and (iii) when there are upper bounds for productions are also discussed. Finally, a “goal-programming” production growth model where the specified demands are treated as just goals and not as absolute quantities to be satisfied is also considered.     

Integrating decisions with advance supply information in an assemble-to-order system

We study a periodic-review assemble-to-order (ATO) system with multiple components and multiple products, in which the inventory replenishment for each component follows an independent base-stock policy and stochastic product demands are satisfied according to a First-Come-First-Served rule. We assume that the replenishment for various component suffers from lead time uncertainty. However, the decision maker has the so-called advance supply information (ASI) associated with the lead times and thus can take advantage of the information for system optimization. We propose a multistage stochastic integer program that incorporates ASI to address the joint optimization of inventory replenishment and component allocation. The optimal base-stock policy for the inventory replenishment is determined using the sample average approximation algorithm. Also, we provide a modified order-based component allocation (MOBCA) heuristic for the component allocation. We additionally consider a special case of the variable lead times where the resulting two-stage stochastic programming model can be characterized as a single-scenario case of the proposed multistage model. We carry out extensive computational studies to quantify the benefits of integrating ASI into joint optimization and to explore the possibility of employing the two-stage model as a relatively efficient approximation scheme for the multistage model.     

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

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

Optimal inventory policies in contagious demand models

In the past, contagious distributions have been successfully applied in bacteriology, entomology, and accident statistics. This paper applies the notion of contagious distributions in the inventory control of new products and seasonal or style goods, which have an lying “true contagion” for their demands, namely, the influence of past demands on occurrence of demands. A contagious distribution is derived by assuming a nonstationary Poisson process where the demand rate at any instant depends on the past demands to that instant. Using this contagious distribution, an inventory model is developed seasonal goods and new product lines. Optimal order policies as a function of the initial level and the review period are derived.     

Dynamic pricing and replenishment: Optimality,bounds, and asymptotics

In many applications, managers face the problem of replenishing and selling products during a finite time horizon. We investigate the problem of making dynamic and joint decisions on product replenishment and selling in order to improve profit. We consider a backlog scenario in which penalty cost (resulting from fulfillment delay) and accommodation cost (resulting from shortage at the end of the selling horizon) are incurred. Based on continuous‐time and discrete‐state dynamic programming, we study the optimal joint decisions and characterize their structural properties. We establish an upper bound for the optimal expected profit and develop a fluid policy by resorting to the deterministic version of the problem (ie, the fluid problem). The fluid policy is shown to be asymptotically optimal for the original stochastic problem when the problem size is sufficiently large. The static nature of the fluid policy and its lack of flexibility in matching supply with demand motivate us to develop a “target‐inventory” heuristic, which is shown, numerically, to be a significant improvement over the fluid policy. Scenarios with discrete feasible sets and lost‐sales are also discussed in this article.     

Minimizing logistic costs in multistage supply chains

We consider the problem in which a set of products has to be shipped from a common origin to a common destination through one or several intermediate nodes with the objective of minimizing the sum of inventory and transportation costs when a set of possible shipping frequencies is given on each link. From the theoretical point of view, the main issue is the computation of the inventory cost in the intermediate nodes. From the computational point of view, given that the simpler single link problem is known to be NP-hard, we present four classes of heuristic algorithms. The first two classes are based on the decomposition of the sequence in links, the third class on the adaptation of the EOQ-type solution known for the continuous case, and the fourth on the optimal solution of a simpler problem through dynamic programming techniques. Finally, we compare them on a set of randomly generated problem instances. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 399–417, 1999     

Fulfillment by Amazon versus fulfillment by seller: An interpretable risk-adjusted fulfillment model

With dual-channel choices, E-retailers fulfill their demands by either the inventory stored in third-party distribution centers, or by in-house inventory. In this article, using data from a wedding gown E-retailer in China, we analyze the differences between two fulfillment choices—fulfillment by Amazon (FBA) and fulfillment by seller (FBS). In particular, we want to understand the impact of FBA that will bring to sales and profit, compared to FBS, and how the impact is related to product features such as sizes and colors. We develop a risk-adjusted fulfillment model to address this problem, where the E-retailer's risk attitude to FBA is incorporated. We denote the profit gaps between FBA and FBS as the rewards for this E-retailer fulfilling products using FBA, our goal is to maximize the E-retailer's total rewards using predictive analytics. We adopt the generalized linear model to predict the expected rewards, while controlling for the variability of the reward distribution. We apply our model on a set of real data, and develop an explicit decision rule that can be easily implemented in practice. The numerical experiments show that our interpretable decision rule can improve the E-retailer's total rewards by more than 35%.     

Performance evaluation of a production/inventory system with periodic review and endogenous lead times

This paper considers a discrete time, single item production/inventory system with random period demands. Inventory levels are reviewed periodically and managed using a base‐stock policy. Replenishment orders are placed with the production system which is capacitated in the sense that there is a single server that sequentially processes the items one at a time with stochastic unit processing times. In this setting the variability in demand determines the arrival pattern of production orders at the queue, influencing supply lead times. In addition, the inventory behavior is impacted by the correlation between demand and lead times: a large demand size corresponds to a long lead time, depleting the inventory longer. The contribution of this paper is threefold. First, we present an exact procedure based on matrix‐analytic techniques for computing the replenishment lead time distribution given an arbitrary discrete demand distribution. Second, we numerically characterize the distribution of inventory levels, and various other performance measures such as fill rate, base‐stock levels and optimal safety stocks, taking the correlation between demand and lead times into account. Third, we develop an algorithm to fit the first two moments of the demand and service time distribution to a discrete phase‐type distribution with a minimal number of phases. This provides a practical tool to analyze the effect of demand variability, as measured by its coefficient of variation, on system performance. We also show that our model is more appropriate than some existing models of capacitated systems in discrete time. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

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

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

Optimal service rates of a service facility with perishable inventory items

In this paper we optimally control service rates for an inventory system of service facilities with perishable products. We consider a finite capacity system where arrivals are Poisson‐distributed, lifetime of items have exponential distribution, and replenishment is instantaneous. We determine the service rates to be employed at each instant of time so that the long‐run expected cost rate is minimized for fixed maximum inventory level and capacity. The problem is modelled as a semi‐Markov decision problem. We establish the existence of a stationary optimal policy and we solve it by employing linear programming. Several numerical examples which provide insight to the behavior of the system are presented. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 464–482, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10021     

Scheduling and lot streaming in two‐machine open shops with no‐wait in process

We study the problem of minimizing the makespan in no‐wait two‐machine open shops producing multiple products using lot streaming. In no‐wait open shop scheduling, sublot sizes are necessarily consistent; i.e., they remain the same over all machines. This intractable problem requires finding sublot sizes, a product sequence for each machine, and a machine sequence for each product. We develop a dynamic programming algorithm to generate all the dominant schedule profiles for each product that are required to formulate the open shop problem as a generalized traveling salesman problem. This problem is equivalent to a classical traveling salesman problem with a pseudopolynomial number of cities. We develop and test a computationally efficient heuristic for the open shop problem. Our results indicate that solutions can quickly be found for two machine open shops with up to 50 products. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Optimal joint preventive maintenance and production policies

We study joint preventive maintenance (PM) and production policies for an unreliable production‐inventory system in which maintenance/repair times are non‐negligible and stochastic. A joint policy decides (a) whether or not to perform PM and (b) if PM is not performed, then how much to produce. We consider a discrete‐time system, formulating the problem as a Markov decision process (MDP) model. The focus of the work is on the structural properties of optimal joint policies, given the system state comprised of the system's age and the inventory level. Although our analysis indicates that the structure of optimal joint policies is very complex in general, we are able to characterize several properties regarding PM and production, including optimal production/maintenance actions under backlogging and high inventory levels, and conditions under which the PM portion of the joint policy has a control‐limit structure. In further special cases, such as when PM set‐up costs are negligible compared to PM times, we are able to establish some additional structural properties. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.