Dynamic server assignment policies for assembly‐type queues with flexible servers

We seek dynamic server assignment policies in finite‐capacity queueing systems with flexible and collaborative servers, which involve an assembly and/or a disassembly operation. The objective is to maximize the steady‐state throughput. We completely characterize the optimal policy for a Markovian system with two servers, two feeder stations, and instantaneous assembly and disassembly operations. This optimal policy allocates one server per station unless one of the stations is blocked, in which case both servers work at the unblocked station. For Markovian systems with three stations and instantaneous assembly and/or disassembly operations, we consider similar policies that move a server away from his/her “primary” station only when that station is blocked or starving. We determine the optimal assignment of each server whose primary station is blocked or starving in systems with three stations and zero buffers, by formulating the problem as a Markov decision process. Using this optimal assignment, we develop heuristic policies for systems with three or more stations and positive buffers, and show by means of a numerical study that these policies provide near‐optimal throughput. Furthermore, our numerical study shows that these policies developed for assembly‐type systems also work well in tandem systems. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Minimizing the makespan in open‐shop scheduling problems with a convex resource consumption function

We consider open‐shop scheduling problems where operation‐processing times are a convex decreasing function of a common limited nonrenewable resource. The scheduler's objective is to determine the optimal job sequence on each machine and the optimal resource allocation for each operation in order to minimize the makespan. We prove that this problem is NP‐hard, but for the special case of the two‐machine problem we provide an efficient optimization algorithm. We also provide a fully polynomial approximation scheme for solving the preemptive case. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

A misclassification cost‐minimizing evolutionary–neural classification approach

Machine learning algorithms that incorporate misclassification costs have recently received considerable attention. In this paper, we use the principles of evolution to develop and test an evolutionary/genetic algorithm (GA)‐based neural approach that incorporates asymmetric Type I and Type II error costs. Using simulated, real‐world medical and financial data sets, we compare the results of the proposed approach with other statistical, mathematical, and machine learning approaches, which include statistical linear discriminant analysis, back‐propagation artificial neural network, integrated cost preference‐based linear mathematical programming‐based minimize squared deviations, linear integrated cost preference‐based GA, decision trees (C 5.0, and CART), and inexpensive classification with expensive tests algorithm. Our results indicate that the proposed approach incorporating asymmetric error costs results in equal or lower holdout sample misclassification cost when compared with the other statistical, mathematical, and machine learning misclassification cost‐minimizing approaches. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

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.     

Bounding the optimal burn‐in time for a system with two types of failure

Burn‐in is a widely used method to improve the quality of products or systems after they have been produced. In this paper, we consider the problem of determining bounds to the optimal burn‐in time and optimal replacement policy maximizing the steady state availability of a repairable system. It is assumed that two types of system failures may occur: One is Type I failure (minor failure), which can be removed by a minimal repair, and the other is Type II failure (catastrophic failure), which can be removed only by a complete repair. Assuming that the underlying lifetime distribution of the system has a bathtub‐shaped failure rate function, upper and lower bounds for the optimal burn‐in time are provided. Furthermore, some other applications of optimal burn‐in are also considered. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004     

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.     

Priority and dynamic scheduling in a make‐to‐stock queue with hyperexponential demand

We consider the scheduling problem in a make‐to‐stock queue with two demand classes that can be differentiated based on their variability. One class experiences Poisson arrivals and the other class experiences hyperexponential renewal arrivals. We provide an exact analysis of the case where the demand class with higher variability is given non‐preemptive priority. The results are then used to compare the inventory cost performance of three scheduling disciplines, first‐come first‐serve and priority to either class. We then build on an existing dynamic scheduling heuristic to propose a modification that works well for our system. Extensions of the heuristic to more than two classes and to the case where demand state is known are also discussed. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

Optimal job splitting on a multi‐slot machine with applications in the printing industry

In this article, we define a scheduling/packing problem called the Job Splitting Problem, motivated by the practices in the printing industry. There are n types of items to be produced on an m‐slot machine. A particular assignment of the types to the slots is called a “run” configuration and requires a setup cost. Once a run begins, the production continues according to that configuration and the “length” of the run represents the quantity produced in each slot during that run. For each unit of production in excess of demand, there is a waste cost. Our goal is to construct a production plan, i.e., a set of runs, such that the total setup and waste cost is minimized. We show that the problem is strongly NP‐hard and propose two integer programming formulations, several preprocessing steps, and two heuristics. We also provide a worst‐case bound for one of the heuristics. Extensive tests on real‐world and randomly generated instances show that the heuristics are both fast and effective, finding near‐optimal solutions. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Using a birth‐and‐death process to estimate the steady‐state distribution of a periodic queue

If the number of customers in a queueing system as a function of time has a proper limiting steady‐state distribution, then that steady‐state distribution can be estimated from system data by fitting a general stationary birth‐and‐death (BD) process model to the data and solving for its steady‐state distribution using the familiar local‐balance steady‐state equation for BD processes, even if the actual process is not a BD process. We show that this indirect way to estimate the steady‐state distribution can be effective for periodic queues, because the fitted birth and death rates often have special structure allowing them to be estimated efficiently by fitting parametric functions with only a few parameters, for example, 2. We focus on the multiserver M_t/GI/s queue with a nonhomogeneous Poisson arrival process having a periodic time‐varying rate function. We establish properties of its steady‐state distribution and fitted BD rates. We also show that the fitted BD rates can be a useful diagnostic tool to see if an M_t/GI/s model is appropriate for a complex queueing system. © 2015 Wiley Periodicals, Inc. Naval Research Logistics 62: 664–685, 2015     

Technical note: Worst‐case performance of power‐of‐two policies for serial inventory systems with incremental quantity discounts

This study presents power‐of‐two policies for a serial inventory system with constant demand rate and incremental quantity discounts at the most upstream stage. It is shown that an optimal solution is nested and follows a zero‐inventory ordering policy. To prove the effectiveness of power‐of‐two policies, a lower bound on the optimal cost is obtained. A policy that has a cost within 6% of the lower bound is developed for a fixed base planning period. For a variable base planning period, a 98% effective policy is provided. An extension is included for a system with price dependent holding costs. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Two‐agent scheduling on a single sequential and compatible batching machine

We study two‐agent scheduling on a single sequential and compatible batching machine in which jobs in each batch are processed sequentially and compatibility means that jobs of distinct agents can be processed in a common batch. A fixed setup time is required before each batch is started. Each agent seeks to optimize some scheduling criterion that depends on the completion times of its own jobs only. We consider several scheduling problems arising from different combinations of some regular scheduling criteria, including the maximum cost (embracing lateness and makespan as its special cases), the total completion time, and the (weighted) number of tardy jobs. Our goal is to find an optimal schedule that minimizes the objective value of one agent, subject to an upper bound on the objective value of the other agent. For each problem under consideration, we provide either a polynomial‐time or a pseudo‐polynomial‐time algorithm to solve it. We also devise a fully polynomial‐time approximation scheme when both agents’ scheduling criteria are the weighted number of tardy jobs.     

A stochastic model for burn‐in procedures in accelerated environment

Burn‐in procedure is a manufacturing technique that is intended to eliminate early failures of system or product. Burning‐in a component or system means to subject it to a period of use prior to being used in field. Generally, burn‐in is considered expensive and so the length of burn‐in is typically limited. Thus, burn‐in is most often accomplished in an accelerated environment in order to shorten the burn‐in process. A new failure rate model for an accelerated burn‐in procedure, which incorporates the accelerated ageing process induced by the accelerated environmental stress, is proposed. Under a more general assumption on the shape of failure rate function of products, which includes the traditional bathtub‐shaped failure rate function as a special case, upper bounds for optimal burn‐in time will be derived. A numerical example will also be given for illustration. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

On the reduction of total‐cost and average‐cost MDPs to discounted MDPs

This article provides conditions under which total‐cost and average‐cost Markov decision processes (MDPs) can be reduced to discounted ones. Results are given for transient total‐cost MDPs with transition rates whose values may be greater than one, as well as for average‐cost MDPs with transition probabilities satisfying the condition that there is a state such that the expected time to reach it is uniformly bounded for all initial states and stationary policies. In particular, these reductions imply sufficient conditions for the validity of optimality equations and the existence of stationary optimal policies for MDPs with undiscounted total cost and average‐cost criteria. When the state and action sets are finite, these reductions lead to linear programming formulations and complexity estimates for MDPs under the aforementioned criteria.© 2017 Wiley Periodicals, Inc. Naval Research Logistics 66:38–56, 2019     

Replicated batch means for steady‐state simulations

This paper studies a new steady‐state simulation output analysis method called replicated batch means in which a small number of replications are conducted and the observations in these replications are grouped into batches. This paper also introduces and compares methods for selecting the initial state of each replication. More specifically, we show that confidence intervals constructed by the replicated batch means method are valid for large batch sizes and derive expressions for the expected values and variances of the steady‐state mean and variance estimators for stationary processes and large sample sizes. We then use these expressions, analytical examples, and numerical experiments to compare the replicated batch means method with the standard batch means and multiple replications methods. The numerical results, which are obtained from an AR(1) process and a small, nearly‐decomposable Markov chain, show that the multiple replications method often gives confidence intervals with poorer coverage than the standard and replicated batch means methods and that the replicated batch means method, implemented with good choices of initialization method and number of replications, provides confidence interval coverages that range from being comparable with to being noticeably better than coverages obtained by the standard batch means method. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Efficient generation of cycle time‐throughput curves through simulation and metamodeling

A cycle time‐throughput (CT‐TH) curve, which quantifies the relationship of long‐run average cycle time to throughput rate, plays an important role in strategic planning for manufacturing systems. In this paper, a nonlinear regression metamodel supported by queueing theory is developed to represent the underlying CT‐TH curve implied by a manufacturing simulation model. To estimate the model efficiently, simulation experiments are built up sequentially using a multistage procedure. Extensive numerical experiments are presented to demonstrate the effectiveness of the proposed procedure. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

A branch‐and‐price approach for the stochastic generalized assignment problem

In this article, we address a stochastic generalized assignment machine scheduling problem in which the processing times of jobs are assumed to be random variables. We develop a branch‐and‐price (B&P) approach for solving this problem wherein the pricing problem is separable with respect to each machine, and has the structure of a multidimensional knapsack problem. In addition, we explore two other extensions of this method—one that utilizes a dual‐stabilization technique and another that incorporates an advanced‐start procedure to obtain an initial feasible solution. We compare the performance of these methods with that of the branch‐and‐cut (B&C) method within CPLEX. Our results show that all B&P‐based approaches perform better than the B&C method, with the best performance obtained for the B&P procedure that includes both the extensions aforementioned. We also utilize a Monte Carlo method within the B&P scheme, which affords the use of a small subset of scenarios at a time to estimate the “true” optimal objective function value. Our experimental investigation reveals that this approach readily yields solutions lying within 5% of optimality, while providing more than a 10‐fold savings in CPU times in comparison with the best of the other proposed B&P procedures. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 131–143, 2014     

Optimal and asymptotically optimal policies for assemble‐to‐order n‐ and W‐systems

We consider two specially structured assemble‐to‐order (ATO) systems—the N‐ and W‐systems—under continuous review, stochastic demand, and nonidentical component replenishment leadtimes. Using a hybrid approach that combines sample‐path analysis, linear programming, and the tower property of conditional expectation, we characterize the optimal component replenishment policy and common‐component allocation rule, present comparative statics of the optimal policy parameters, and show that some commonly used heuristic policies can lead to significant optimality loss. The optimality results require certain symmetry in the cost parameters. In the absence of this symmetry, we show that, for systems with high demand volume, the asymptotically optimal policy has essentially the same structure; otherwise, the optimal policies have no clear structure. For these latter systems, we develop heuristic policies and show their effectiveness. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 62: 617–645, 2015     

Vertically restrictive pricing in supply chains with price‐dependent demand

We examine the behavior of a manufacturer and a retailer in a decentralized supply chain under price‐dependent, stochastic demand. We model a retail fixed markup (RFM) policy, which can arise as a form of vertically restrictive pricing in a supply chain, and we examine its effect on supply chain performance. We prove the existence of the optimal pricing and replenishment policies when demand has a linear additive form and the distribution of the uncertainty component has a nondecreasing failure rate. We numerically compare the relative performance of RFM to a price‐only contract and we find that RFM results in greater profit for the supply chain than the price‐only contract in a variety of scenarios. We find that RFM can lead to Pareto‐improving solutions where both the supplier and the retailer earn more profit than under a price‐only contract. Finally, we compare RFM to a buyback contract and explore the implications of allowing the fixed markup parameter to be endogenous to the model. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

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     

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