Development programs for one‐shot systems using multiple‐state design reliability models

Design reliability at the beginning of a product development program is typically low, and development costs can account for a large proportion of total product cost. We consider how to conduct development programs (series of tests and redesigns) for one‐shot systems (which are destroyed at first use or during testing). In rough terms, our aim is to both achieve high final design reliability and spend as little of a fixed budget as possible on development. We employ multiple‐state reliability models. Dynamic programming is used to identify a best test‐and‐redesign strategy and is shown to be presently computationally feasible for at least 5‐state models. Our analysis is flexible enough to allow for the accelerated stress testing needed in the case of ultra‐high reliability requirements, where testing otherwise provides little information on design reliability change. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004     

Two‐stage component test plans for testing the reliability of a series system

A system reliability is often evaluated by individual tests of components that constitute the system. These component test plans have advantages over complete system based tests in terms of time and cost. In this paper, we consider the series system with n components, where the lifetime of the i‐th component follows exponential distribution with parameter λ_i. Assuming test costs for the components are different, we develop an efficient algorithm to design a two‐stage component test plan that satisfies the usual probability requirements on the system reliability and in addition minimizes the maximum expected cost. For the case of prior information in the form of upper bounds on λ_i's, we use the genetic algorithm to solve the associated optimization problems which are otherwise difficult to solve using mathematical programming techniques. The two‐stage component test plans are cost effective compared to single‐stage plans developed by Rajgopal and Mazumdar. We demonstrate through several numerical examples that our approach has the potential to reduce the overall testing costs significantly. © 2002 John Wiley & Sons, Inc. Naval Research Logistics, 49: 95–116, 2002; DOI 10.1002/nav.1051     

Supply contracts in manufacturer‐retailer interactions with manufacturer‐quality and retailer effort‐induced demand

We consider a decentralized distribution channel where demand depends on the manufacturer‐chosen quality of the product and the selling effort chosen by the retailer. The cost of selling effort is private information for the retailer. We consider three different types of supply contracts in this article: price‐only contract where the manufacturer sets a wholesale price; fixed‐fee contract where manufacturer sells at marginal cost but charges a fixed (transfer) fee; and, general franchise contract where manufacturer sets a wholesale price and charges a fixed fee as well. The fixed‐fee and general franchise contracts are referred to as two‐part tariff contracts. For each contract type, we study different contract forms including individual, menu, and pooling contracts. In the analysis of the different types and forms of contracts, we show that the price only contract is dominated by the general franchise menu contract. However, the manufacturer may prefer to offer the fixed‐fee individual contract as compared to the general franchise contract when the retailer's reservation utility and degree of information asymmetry in costs are high. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Capacitated selection problem

Optimizing the selection of resources to accomplish a set of tasks involves evaluating the tradeoffs between the cost of maintaining the resources necessary to accomplish the tasks and the penalty cost associated with unfinished tasks. We consider the case where resources are categorized into types, and limits (capacity) are imposed on the number of each type that can be selected. The objective is to minimize the sum of penalty costs and resource costs. This problem has several practical applications including production planning, new product design, menu selection and inventory management. We develop a branch‐and‐bound algorithm to find exact solutions to the problem. To generate bounds, we utilize a dual ascent procedure which exploits the special structure of the problem. Information from the dual and recovered primal solutions are used to select branching variables. We generate strong valid inequalities and use them to fix other variables at each branching step. Results of tests performed on reasonably sized problems are presented. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 19–37, 1999     

Inventory pooling games for expensive,low‐demand spare parts

We consider several independent decision makers who stock expensive, low‐demand spare parts for their high‐tech machines. They can collaborate by full pooling of their inventories via free transshipments. We examine the stability of such pooling arrangements, and we address the issue of fairly distributing the collective holding and downtime costs over the participants, by applying concepts from cooperative game theory. We consider two settings: one where each party maintains a predetermined stocking level and one where base stock levels are optimized. For the setting with fixed stocking levels, we unravel the possibly conflicting effects of implementing a full pooling arrangement and study these effects separately to establish intuitive conditions for existence of a stable cost allocation. For the setting with optimized stocking levels, we provide a simple proportional rule that accomplishes a population monotonic allocation scheme if downtime costs are symmetric among participants. Although our whole analysis is motivated by spare parts applications, all results are also applicable to other pooled resource systems of which the steady‐state behavior is equivalent to that of an Erlang loss system. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2012     

Selecting T for a periodic review inventory model with staggered deliveries

Consider a single‐item, periodic review, infinite‐horizon, undiscounted, inventory model with stochastic demands, proportional holding and shortage costs, and full backlogging. Orders can arrive in every period, and the cost of receiving them is negligible (as in a JIT setting). Every T periods, one audits the current stock level and decides on deliveries for the next T periods, thus incurring a fixed audit cost and—when one schedules deliveries—a fixed order cost. The problem is to find a review period T and an ordering policy that satisfy the average cost criterion. The current article extends an earlier treatment of this problem, which assumed that the fixed order cost is automatically incurred once every T periods. We characterize an optimal ordering policy when T is fixed, prove that an optimal review period T** exists, and develop a global search algorithm for its computation. We also study the behavior of four approximations to T** based on the assumption that the fixed order cost is incurred during every cycle. Analytic results from a companion article (where μ/σ is large) and extensive computational experiments with normal and gamma demand test problems suggest these approximations and associated heuristic policies perform well when μ/σ ≥ 2. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 329–352, 2000     

Optimal retail assortments for substitutable items purchased in sets

We consider the problem of optimizing assortments in a multi‐item retail inventory system. In addition to the usual holding and stockout costs, there is a fixed cost for including any item in the assortment. Customers' preferences for items include both probabilistic substitution patterns and the desire to purchase sets of complementary items. We develop a demand model to capture this behavior, and derive tractable approximations that allow us to formulate the optimization problem as a 0–1 mixed integer linear program. Numerical examples are solved to illustrate key insights into how both complementary and substitute items affect the optimal assortment and the expected profit. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 793–822, 2003.     

Optimal scheduling of reader—systems

We consider a reader—writer system consisting of a single server and a fixed number of jobs (or customers) belonging to two classes. Class one jobs are called readers and any number of them can be processed simultaneously. Class two jobs are called writers and they have to be processed one at a time. When a writer is being processed no other writer or readers can be processed. A fixed number of readers and writers are ready for processing at time 0. Their processing times are independent random variables. Each reader and writer has a fixed waiting cost rate. We find optimal scheduling rules that minimize the expected total waiting cost (expected total weighted flowtime). We consider both nonpreemptive and preemptive scheduling. The optimal nonpreemptive schedule is derived by a variation of the usual interchange argument, while the optimal schedule in the preemptive case is given by a Gittins index policy. These index policies continue to be optimal for systems in which new writers enter the system in a Poisson fashion. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 483–495, 1998     

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.     

Optimal control policies for an inventory system with commitment lead time

We consider a firm which faces a Poisson customer demand and uses a base‐stock policy to replenish its inventories from an outside supplier with a fixed lead time. The firm can use a preorder strategy which allows the customers to place their orders before their actual need. The time from a customer's order until the date a product is actually needed is called commitment lead time. The firm pays a commitment cost which is strictly increasing and convex in the length of the commitment lead time. For such a system, we prove the optimality of bang‐bang and all‐or‐nothing policies for the commitment lead time and the base‐stock policy, respectively. We study the case where the commitment cost is linear in the length of the commitment lead time in detail. We show that there exists a unit commitment cost threshold which dictates the optimality of either a buy‐to‐order (BTO) or a buy‐to‐stock strategy. The unit commitment cost threshold is increasing in the unit holding and backordering costs and decreasing in the mean lead time demand. We determine the conditions on the unit commitment cost for profitability of the BTO strategy and study the case with a compound Poisson customer demand.     

Production/distribution system design with inventory considerations

This study addresses the design of a three‐stage production/distribution system where the first stage includes the set of established retailers and the second and third stages include the sets of potential distribution centers (DCs) and potential capacitated suppliers, respectively. In this problem, in addition to the fixed location/operating costs associated with locating DCs and suppliers, we consider the coordinated inventory replenishment decisions at the located DCs and retailers along with the appropriate inventory costs explicitly. In particular, we account for the replenishment and holding costs at the retailers and selected DCs, and the fixed plus distance‐based transportation costs between the selected plants and their assigned DCs, and between the selected DCs and their respective retailers, explicitly. The resulting formulation is a challenging mixed‐integer nonlinear programming model for which we propose efficient heuristic solution approaches. Our computational results demonstrate the performance of the heuristic approaches as well as the value of integrated decision‐making by verifying that significant cost savings are realizable when the inventory decisions and costs are incorporated in the production distribution system design. © 2012 Wiley Periodicals, Inc. Naval Research Logistics 59: 172–195, 2012     

Benders decomposition with alternative multiple cuts for a multi‐product closed‐loop supply chain network design model

In this article, we consider a multi‐product closed‐loop supply chain network design problem where we locate collection centers and remanufacturing facilities while coordinating the forward and reverse flows in the network so as to minimize the processing, transportation, and fixed location costs. The problem of interest is motivated by the practice of an original equipment manufacturer in the automotive industry that provides service parts for vehicle maintenance and repair. We provide an effective problem formulation that is amenable to efficient Benders reformulation and an exact solution approach. More specifically, we develop an efficient dual solution approach to generate strong Benders cuts, and, in addition to the classical single Benders cut approach, we propose three different approaches for adding multiple Benders cuts. These cuts are obtained via dual problem disaggregation based either on the forward and reverse flows, or the products, or both. We present computational results which illustrate the superior performance of the proposed solution methodology with multiple Benders cuts in comparison to the branch‐and‐cut approach as well as the traditional Benders decomposition approach with a single cut. In particular, we observe that the use of multiple Benders cuts generates stronger lower bounds and promotes faster convergence to optimality. We also observe that if the model parameters are such that the different costs are not balanced, but, rather, are biased towards one of the major cost categories (processing, transportation or fixed location costs), the time required to obtain the optimal solution decreases considerably when using the proposed solution methodology as well as the branch‐and‐cut approach. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Lateral stock transshipments in a two‐location inventory system with fixed and joint replenishment costs

We address the problem of inventory management in a two‐location inventory system, in which the transshipments are carried out as means of emergency or alternative supply after demand has been realized. This model differs from previous ones as regards its replenishment costs structure, in which nonnegligible fixed replenishment costs and a joint replenishment cost are considered. The single period planning horizon is analyzed, with the form and several properties of the optimal replenishment and transshipment policies developed, discussed and illustrated. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 525–547, 1999     

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 dynamic transshipment problem

We investigate the strategy of transshipments in a dynamic deterministic demand environment over a finite planning horizon. This is the first time that transshipments are examined in a dynamic or deterministic setting. We consider a system of two locations which replenish their stock from a single supplier, and where transshipments between the locations are possible. Our model includes fixed (possibly joint) and variable replenishment costs, fixed and variable transshipment costs, as well as holding costs for each location and transshipment costs between locations. The problem is to determine how much to replenish and how much to transship each period; thus this work can be viewed as a synthesis of transshipment problems in a static stochastic setting and multilocation dynamic deterministic lot sizing problems. We provide interesting structural properties of optimal policies which enhance our understanding of the important issues which motivate transshipments and allow us to develop an efficient polynomial time algorithm for obtaining the optimal strategy. By exploring the reasons for using transshipments, we enable practitioners to envision the sources of savings from using this strategy and therefore motivate them to incorporate it into their replenishment strategies. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48:386–408, 2001     

A cost–benefit analysis of terrorist attacks

A cost–benefit analysis of terrorist attacks is developed and placed within a systematic theoretical structure. For the target or object of the attack, we consider the lost value of human lives, lost economic value, and lost influence value, counted as benefits for the terrorist. The corresponding losses for the terrorist are counted as costs. The terrorist attacks if benefits outweigh costs. Bounded rationality is enabled where the three kinds of benefits and costs can be weighted differently. We account for two ex ante probabilities of successful planning and attack, and enable the terrorist to assign different weights to its multiple stakeholders. We introduce multiple time periods, time discounting, attitudes towards risk, and subcategories for the benefits and costs. The cost–benefit analysis is illustrated with the 11 September 2001 attack, and 53 incidents in the Global Terrorism Database yielding both positive and negative expected utilities. The paper is intended as a tool for scientists and policy-makers, as a way of thinking about costs and benefits of terrorist attacks.     

Allocation of quality improvement targets based on investments in learning

Purchased materials often account for more than 50% of a manufacturer's product nonconformance cost. A common strategy for reducing such costs is to allocate periodic quality improvement targets to suppliers of such materials. Improvement target allocations are often accomplished via ad hoc methods such as prescribing a fixed, across‐the‐board percentage improvement for all suppliers, which, however, may not be the most effective or efficient approach for allocating improvement targets. We propose a formal modeling and optimization approach for assessing quality improvement targets for suppliers, based on process variance reduction. In our models, a manufacturer has multiple product performance measures that are linear functions of a common set of design variables (factors), each of which is an output from an independent supplier's process. We assume that a manufacturer's quality improvement is a result of reductions in supplier process variances, obtained through learning and experience, which require appropriate investments by both the manufacturer and suppliers. Three learning investment (cost) models for achieving a given learning rate are used to determine the allocations that minimize expected costs for both the supplier and manufacturer and to assess the sensitivity of investment in learning on the allocation of quality improvement targets. Solutions for determining optimal learning rates, and concomitant quality improvement targets are derived for each learning investment function. We also account for the risk that a supplier may not achieve a targeted learning rate for quality improvements. An extensive computational study is conducted to investigate the differences between optimal variance allocations and a fixed percentage allocation. These differences are examined with respect to (i) variance improvement targets and (ii) total expected cost. For certain types of learning investment models, the results suggest that orders of magnitude differences in variance allocations and expected total costs occur between optimal allocations and those arrived at via the commonly used rule of fixed percentage allocations. However, for learning investments characterized by a quadratic function, there is surprisingly close agreement with an “across‐the‐board” allocation of 20% quality improvement targets. © John Wiley & Sons, Inc. Naval Research Logistics 48: 684–709, 2001     

A partial characterization of the optimal ordering/rationing policy for a periodic review system with two demand classes and backordering

We consider a finite horizon periodic review, single product inventory system with a fixed setup cost and two stochastic demand classes that differ in their backordering costs. In each period, one must decide whether and how much to order, and how much demand of the lower class should be satisfied. We show that the optimal ordering policy can be characterized as a state dependent (s,S) policy, and the rationing structure is partially obtained based on the subconvexity of the cost function. We then propose a simple heuristic rationing policy, which is easy to implement and close to optimal for intensive numerical examples. We further study the case when the first demand class is deterministic and must be satisfied immediately. We show the optimality of the state dependent (s,S) ordering policy, and obtain additional rationing structural properties. Based on these properties, the optimal ordering and rationing policy for any state can be generated by finding the optimal policy of only a finite set of states, and for each state in this set, the optimal policy is obtained simply by choosing a policy from at most two alternatives. An efficient algorithm is then proposed. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Scheduling with variable time slot costs

In this article, we study a class of new scheduling models where time slot costs have to be taken into consideration. In such models, processing a job will incur certain cost which is determined by the time slots occupied by the job in a schedule. The models apply when operational costs vary over time. The objective of the scheduling models is to minimize the total time slot costs plus a traditional scheduling performance measure. We consider the following performance measures: total completion time, maximum lateness/tardiness, total weighted number of tardy jobs, and total tardiness. We prove the intractability of the models under general parameters and provide polynomial‐time algorithms for special cases with non‐increasing time slot costs.© 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

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

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