A multifacility capacity expansion model with joint expansion set-up costs

This article describes a multifacility capacity expansion model in which the different facility types represent different quality levels. These facility types are used to satisfy a variety of deterministic demands over a finite number of discrete time periods. Applications for the model can be found in cable sizing problems associated with the planning of communication networks. It is assumed that the cost function associated with expanding the capacity of any facility type is concave, and that a joint set-up cost is incurred in any period in which one or more facilities are expanded. The model is formulated as a network flow problem from which properties associated with optimal solutions are derived. Using these properties, we develop a dynamic programming algorithm that finds optimal solutions for problems with a few facilities, and a heuristic algorithm that finds near-optimal solutions for larger problems. Numerical examples for both algorithms are discussed.     

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     

The dynamic lot size model with quantity discount: Counterexamples and correction

Federgruen and Lee ([3]) proposed an optimal algorithm for the single-item dynamic lot size model with all-unit discount. In this note we show that their algorithm fails to find the optimal solution for some special cases. We also provide a modification to the algorithm to handle them. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 419–422, 1998     

Capacitated warehouse location model with risk pooling

In this article, we introduce the capacitated warehouse location model with risk pooling (CLMRP), which captures the interdependence between capacity issues and the inventory management at the warehouses. The CLMRP models a logistics system in which a single plant ships one type of product to a set of retailers, each with an uncertain demand. Warehouses serve as the direct intermediary between the plant and the retailers for the shipment of the product and also retain safety stock to provide appropriate service levels to the retailers. The CLMRP minimizes the sum of the fixed facility location, transportation, and inventory carrying costs. The model simultaneously determines warehouse locations, shipment sizes from the plant to the warehouses, the working inventory, and safety stock levels at the warehouses and the assignment of retailers to the warehouses. The costs at each warehouse exhibit initially economies of scale and then an exponential increase due to the capacity limitations. We show that this problem can be formulated as a nonlinear integer program in which the objective function is neither concave nor convex. A Lagrangian relaxation solution algorithm is proposed. The Lagrangian subproblem is also a nonlinear integer program. An efficient algorithm is developed for the linear relaxation of this subproblem. The Lagrangian relaxation algorithm provides near‐optimal solutions with reasonable computational requirements for large problem instances. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

A heuristic for capacity expansion planning with multiple facility types

A capacity expansion model with multiple facility types is examined, where different facility types represent different quality levels. Applications for the model can be found in communications networks and production facilities. The model assumes a finite number of discrete time periods. The facilities are expanded over time. Capacity of a high-quality facility can be converted to satisfy demand for a lower-quality facility. The costs considered include capacity expansion costs and excess capacity holding costs. All cost functions are nondecreasing and concave. An algorithm that finds optimal expansion policies requires extensive computations and is practical only for small scale problems. Here, we develop a heuristic that employs so-called distributed expansion policies. It also attempts to decompose the problem into several smaller problems solved independently. The heuristic is computationally efficient. Further, it has consistently found near-optimal solutions.     

Transportation type problems with quantity discounts

It is known to be real that the per unit transportation cost from a specific supply source to a given demand sink is dependent on the quantity shipped, so that there exist finite intervals for quantities where price breaks are offered to customers. Thus, such a quantity discount results in a nonconvex, piecewise linear functional. In this paper, an algorithm is provided to solve this problem. This algorithm, with minor modifications, is shown to encompass the “incremental” quantity discount and the “fixed charge” transportation problems as well. It is based upon a branch-and-bound solution procedure. The branches lead to ordinary transportation problems, the results of which are obtained by utilizing the “cost operator” for one branch and “rim operator” for another branch. Suitable illustrations and extensions are also provided.     

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.     

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     

Coping with shortages caused by disruptive events in automobile supply chains

Unpredictable disruptive events significantly increase the difficulty of the management of automobile supply chains. In this paper, we propose an automobile production planning problem with component chips substitution in a finite planning horizon. The shortage of one chip can be compensated by another chip of the same type with a higher-end feature at an additional cost. Therefore, the automobile manufacturer can divert the on-hand inventory of chips to product lines that are more profitable in the event of shortages caused by supply chain disruptions. To cope with this, we propose a max-min robust optimization model that captures the uncertain supplies of chips. We show that the robust model has a mixed-integer programming equivalence that can be solved by a commercial IP solver directly. We compare the max-min robust model with the corresponding deterministic and two-stage stochastic models for the same problem through extensive numerical experiments. The computational results show that the max-min robust model outperforms the other two models in terms of the average and worst-case profits.     

A continuous‐time strategic capacity planning model

Capacity planning decisions affect a significant portion of future revenue. In the semiconductor industry, they need to be made in the presence of both highly volatile demand and long capacity installation lead‐times. In contrast to traditional discrete‐time models, we present a continuous‐time stochastic programming model for multiple resource types and product families. We show how this approach can solve capacity planning problems of reasonable size and complexity with provable efficiency. This is achieved by an application of the divide‐and‐conquer algorithm, convexity, submodularity, and the open‐pit mining problem. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

A facility reliability problem: Formulation,properties, and algorithm

Having a robustly designed supply chain network is one of the most effective ways to hedge against network disruptions because contingency plans in the event of a disruption are often significantly limited. In this article, we study the facility reliability problem: how to design a reliable supply chain network in the presence of random facility disruptions with the option of hardening selected facilities. We consider a facility location problem incorporating two types of facilities, one that is unreliable and another that is reliable (which is not subject to disruption, but is more expensive). We formulate this as a mixed integer programming model and develop a Lagrangian Relaxation‐based solution algorithm. We derive structural properties of the problem and show that for some values of the disruption probability, the problem reduces to the classical uncapacitated fixed charge location problem. In addition, we show that the proposed solution algorithm is not only capable of solving large‐scale problems, but is also computationally effective. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Stochastic production capacity: A bane or a boon for quick response supply chains?

The quick response (QR) system that can cope with demand volatility by shortening lead time has been well studied in the literature. Much of the existing literature assumes implicitly or explicitly that the manufacturers under QR can always meet the demand because the production capacity is always sufficient. However, when the order comes with a short lead time under QR, availability of the manufacturer's production capacity is not guaranteed. This motivates us to explore QR in supply chains with stochastic production capacity. Specifically, we study QR in a two-echelon supply chain with Bayesian demand information updating. We consider the situation where the manufacturer's production capacity under QR is uncertain. We first explore how stochastic production capacity affects supply chain decisions and QR implementation. We then incorporate the manufacturer's ability to expand capacity into the model. We explore how the manufacturer determines the optimal capacity expansion decision, and the value of such an ability to the supply chain and its agents. Finally, we extend the model to the two-stage two-ordering case and derive the optimal ordering policy by dynamic programming. We compare the single-ordering and two-ordering cases to generate additional managerial insights about how ordering flexibility affects QR when production capacity is stochastic. We also explore the transparent supply chain and find that our main results still hold.     

The effect of a temporary product distribution channel on supply chain performance

We analyze a supply chain of a manufacturer and two retailers, a permanent retailer who always stocks the manufacturer's product and an intermittent deal‐of‐the day retailer who sells the manufacturer's product online for a short time. We find that without a deal‐of‐the‐day (DOTD) retailer, it is suboptimal for the manufacturer to offer a quantity discount while it is optimal for the retailer to offer periodic price discounts to consumers. With the addition of a DOTD retailer, it is likely to be optimal for the manufacturer to offer a quantity discount. We show that even without market expansion, i.e., no exclusive DOTD retailer consumers, opening the intermittent channel can leave the permanent retailer no worse‐off while increasing the manufacturer's profit. We identify the regular and discounted wholesale prices and the threshold quantity at which the manufacturer should give the discount. We also identify the optimal retail prices. We find that opening the intermittent channel increases the profit of the manufacturer, is likely to decrease the average retail price and to increase sales, and may increase the permanent retailer's profit. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 505–528, 2016     

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     

Dynamic multiattribute models for mixed manpower systems

This paper reviews a wide variety of manpower and personnel models of the goal programming variety. This is done from a strategy-oriented point of view addressing the problems of interest for immediate implementation as well as basic problems of manpower model research development. Particular emphasis in this paper is concerned with how analytical models can be brought to bear on the problems of combining military and civilian manpower into one management system. This includes a discussion of the computer support arrangements necessary to implement the models. First, we discuss an extension of multilevel models to provide an integrated approach to program planning which includes the dynamics of the manpower requirements-inventory relationships of mixed military-civilian manpower systems. Then, focus is given to some of the potential Navy applications particularly in terms of ways the outputs from the global multilevel model might be interfaced with assignment models for operational planning. The paper concludes with a discussion of static and dynamic multiattribute assignment models which operate on the individual man-job matching level. It is at this level of detail that dynamic mixed manpower systems might be constructed for use in equal employment opportunity planning and for local organization design studies.     

卫星任务调度问题的约束规划模型

卫星任务规划与调度是空间资源管理的重要内容之一,其目的在于为卫星系统的任务计划编制提供科学合理的决策手段与依据。卫星任务调度问题的重要特点在于,调度任务存在可见时间窗口约束。只有在可见时间窗口内,调度任务才可能执行并完成。在进行合理假设的基础上,建立卫星任务调度问题的约束规划模型。对基本禁忌搜索算法进行改进,提出了模型求解的变邻域禁忌搜索算法。应用结果表明,约束规划模型的建立与求解是合理的。     

On the polyhedral structure of two‐level lot‐sizing problems with supplier selection

In this article, we study a two‐level lot‐sizing problem with supplier selection (LSS), which is an NP‐hard problem arising in different production planning and supply chain management applications. After presenting various formulations for LSS, and computationally comparing their strengths, we explore the polyhedral structure of one of these formulations. For this formulation, we derive several families of strong valid inequalities, and provide conditions under which they are facet‐defining. We show numerically that incorporating these valid inequalities within a branch‐and‐cut framework leads to significant improvements in computation. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 647–666, 2017     

Optimal production ramp-up in the smartphone manufacturing industry

Motivated by challenges in the smartphone manufacturing industry, we develop a dynamic production ramp-up model that can be applied to economically satisfy nonstationary demand for short-life-cycle products by high-tech companies. Due to shorter life cycles and more rapid evolution of smartphones, production ramp-up has been increasingly critical to the success of a new smartphone. In the production ramp-up, the key challenge is to match the increasing capacity to nonstationary demand. The high-tech smartphone manufacturers are urged to jointly consider the effect of increasing capacity and decreasing demand. We study the production planning problem using a high-dimensional Markov decision process (MDP) model to characterize the production ramp-up. To address the curse of dimensionality, we refine Monte Carlo tree search (MCTS) algorithm and theoretically analyze its convergence and computational complexity. In a real case study, we find that the MDP model achieves revenue improvement by stopping producing the existing product earlier than the benchmark policy. In synthetic instances, we validate that the proposed MCTS algorithm saves computation time without loss of solution quality compared with traditional value iteration algorithm. As part of the Lenovo production solution, our MDP model enables high-tech smartphone manufacturers to better plan the production ramp-up.     

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     

Strategic obfuscation of production capacities

Recent supply‐chain models that study competition among capacity‐constrained producers omit the possibility of producers strategically setting wholesale prices to create uncertainty with regards to (i.e., to obfuscate) their production capacities. To shed some light on this possibility, we study strategic obfuscation in a supply‐chain model comprised of two competing producers and a retailer, where one of the producers faces a privately‐known capacity constraint. We show that capacity obfuscation can strictly increase the obfuscating producer's profit, therefore, presenting a clear incentive for such practices. Moreover, we identify conditions under which both producers' profits increase. In effect, obfuscation enables producers to tacitly collude and charge higher wholesale prices by moderating competition between producers. The retailer, in contrast, suffers a loss in profit, raises retail prices, while overall channel profits decrease. We show that the extent of capacity obfuscation is limited by its cost and by a strategic retailer's incentive to facilitate a deterrence. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 244–267, 2014