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     

Path optimization for the resource‐constrained searcher

We formulate and solve a discrete‐time path‐optimization problem where a single searcher, operating in a discretized three‐dimensional airspace, looks for a moving target in a finite set of cells. The searcher is constrained by maximum limits on the consumption of one or more resources such as time, fuel, and risk along any path. We develop a specialized branch‐and‐bound algorithm for this problem that uses several network reduction procedures as well as a new bounding technique based on Lagrangian relaxation and network expansion. The resulting algorithm outperforms a state‐of‐the‐art algorithm for solving time‐constrained problems and also is the first algorithm to solve multi‐constrained problems. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

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 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.     

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.     

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     

An asymptotically optimal greedy heuristic for the multiperiod single‐sourcing problem: The cyclic case

The dynamics of the environment in which supply chains evolve requires that companies frequently redesign their logistics distribution networks. In this paper we address a multiperiod single‐sourcing problem that can be used as a strategic tool for evaluating the costs of logistics network designs in a dynamic environment. The distribution networks that we consider consist of a set of production and storage facilities, and a set of customers who do not hold inventories. The facilities face production capacities, and each customer's demand needs to be delivered by a single facility in each period. We deal with the assignment of customers to facilities, as well as the location, timing, and size of inventories. In addition, to mitigate start and end‐of‐study effects, we view the planning period as a typical future one, which will repeat itself. This leads to a cyclic model, in which starting and ending inventories are equal. Based on an assignment formulation of the problem, we propose a greedy heuristic, and prove that this greedy heuristic is asymptotically feasible and optimal in a probabilistic sense. We illustrate the behavior of the greedy heuristic, as well as some improvements where the greedy heuristic is used as the starting point of a local interchange procedure, on a set of randomly generated test problems. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 412–437, 2003     

A specially structured nonlinear integer resource allocation problem

We present an algorithm for solving a specially structured nonlinear integer resource allocation problem. This problem was motivated by a capacity planning study done at a large Health Maintenance Organization in Texas. Specifically, we focus on a class of nonlinear resource allocation problems that involve the minimization of a convex function over one general convex constraint, a set of block diagonal convex constraints, and bounds on the integer variables. The continuous variable problem is also considered. The continuous problem is solved by taking advantage of the structure of the Karush‐Kuhn‐Tucker (KKT) conditions. This method for solving the continuous problem is then incorporated in a branch and bound algorithm to solve the integer problem. Various reoptimization results, multiplier bounding results, and heuristics are used to improve the efficiency of the algorithms. We show how the algorithms can be extended to obtain a globally optimal solution to the nonconvex version of the problem. We further show that the methods can be applied to problems in production planning and financial optimization. Extensive computational testing of the algorithms is reported for a variety of applications on continuous problems with up to 1,000,000 variables and integer problems with up to 1000 variables. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 770–792, 2003.     

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.     

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     

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.     

The fixed charge problem

The fixed charge problem is a nonlinear programming problem of practical interest in business and industry. Yet, until now no computationally feasible exact method of solution for large problems had been developed. In this paper an exact algorithm is presented which is computationally feasible for large problems. The algorithm is based upon a branch and bound approach, with the additional feature that the amount of computer storage required remains constant throughout (for a problem of any given size). Also presented are three suboptimal heuristic algorithms which are of interest because, although they do not guarantee that the true optimal solution will be found, they usually yield very good solutions and are extremely rapid techniques. Computational results are described for several of the heuristic methods and for the branch and bound algorithm.     

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     

A combination of Lagrangian relaxation and column generation for order batching in steelmaking and continuous‐casting production

This article considers the order batching problem in steelmaking and continuous‐casting production. The problem is to jointly specify the slabs needed to satisfy each customer order and group all the slabs of different customer orders into production batches. A novel mixed integer programming model is formulated for the problem. Through relaxing the order assignment constraints, a Lagrangian relaxation model is then obtained. By exploiting the relationship between Lagrangian relaxation and column generation, we develop a combined algorithm that contains nested double loops. At the inner loop, the subgradient method is applied for approximating the Lagrangian dual problem and pricing out columns of the master problem corresponding to the linear dual form of the Lagrangian dual problem. At the outer loop, column generation is employed to solve the master problem exactly and adjust Lagrangian multipliers. Computational experiments are carried out using real data collected from a large steel company, as well as on large‐scaled problem instances randomly generated. The results demonstrate that the combined algorithm can obtain tighter lower bound and higher quality solution within an acceptable computation time as compared to the conventional Lagrangian relaxation algorithm. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Dual‐ascent and primal heuristics for production‐assembly‐distribution system design

This article proposes two dual‐ascent algorithms and uses each in combination with a primal drop heuristic embedded within a branch and bound framework to solve the uncapacitated production assembly distribution system (i.e., supply chain) design problem, which is formulated as a mixed integer program. Computational results indicate that one approach, which combines primal drop and dual‐ascent heuristics, can solve instances within reasonable time and prescribes solutions with gaps between the primal and dual solution values that are less than 0.15%, an efficacy suiting it for actual large‐scale applications. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2013     

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     

Cyclic preference scheduling for nurses using branch and price

This paper presents a new methodology to solve the cyclic preference scheduling problem for hourly workers. The focus is on nurse rostering but is applicable to any organization in which the midterm scheduling decision must take into account a complex of legal, institutional, and preferential constraints. The objective is to strike a balance between satisfying individual preferences and minimizing personnel costs. The common practice is to consider each planning period independently and to generate new rosters at the beginning of each. To reduce some of the instability in the process, there is a growing trend toward cyclic schedules, which are easier to manage and are generally perceived to be more equitable. To address this problem, a new integer programming model is presented that combines the elements of both cyclic and preference scheduling. To find solutions, a branch‐and‐price algorithm is developed that makes use of several branching rules and an extremely effective rounding heuristic. A unique feature of the formulation is that the master problem contains integer rather than binary variables. Computational results are reported for problem instances with up to 200 nurses. Most were solved within 10 minutes and many within 3 minutes when a double aggregation approach was applicable. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007.     

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     

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     

Optimal FCFS allocation rules for periodic‐review assemble‐to‐order systems

In Assemble‐To‐Order (ATO) systems, situations may arise in which customer demand must be backlogged due to a shortage of some components, leaving available stock of other components unused. Such unused component stock is called remnant stock. Remnant stock is a consequence of both component ordering decisions and decisions regarding allocation of components to end‐product demand. In this article, we examine periodic‐review ATO systems under linear holding and backlogging costs with a component installation stock policy and a First‐Come‐First‐Served (FCFS) allocation policy. We show that the FCFS allocation policy decouples the problem of optimal component allocation over time into deterministic period‐by‐period optimal component allocation problems. We denote the optimal allocation of components to end‐product demand as multimatching. We solve the multi‐matching problem by an iterative algorithm. In addition, an approximation scheme for the joint replenishment and allocation optimization problem with both upper and lower bounds is proposed. Numerical experiments for base‐stock component replenishment policies show that under optimal base‐stock policies and optimal allocation, remnant stock holding costs must be taken into account. Finally, joint optimization incorporating optimal FCFS component allocation is valuable because it provides a benchmark against which heuristic methods can be compared. © 2015 Wiley Periodicals, Inc. Naval Research Logistics 62: 158–169, 2015