Algorithm to solve a chance‐constrained network capacity design problem with stochastic demands and finite support

We consider the problem of determining the capacity to assign to each arc in a given network, subject to uncertainty in the supply and/or demand of each node. This design problem underlies many real‐world applications, such as the design of power transmission and telecommunications networks. We first consider the case where a set of supply/demand scenarios are provided, and we must determine the minimum‐cost set of arc capacities such that a feasible flow exists for each scenario. We briefly review existing theoretical approaches to solving this problem and explore implementation strategies to reduce run times. With this as a foundation, our primary focus is on a chance‐constrained version of the problem in which α% of the scenarios must be feasible under the chosen capacity, where α is a user‐defined parameter and the specific scenarios to be satisfied are not predetermined. We describe an algorithm which utilizes a separation routine for identifying violated cut‐sets which can solve the problem to optimality, and we present computational results. We also present a novel greedy algorithm, our primary contribution, which can be used to solve for a high quality heuristic solution. We present computational analysis to evaluate the performance of our proposed approaches. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 236–246, 2016     

Optimal capacity in a coordinated supply chain

We consider a supply chain in which a retailer faces a stochastic demand, incurs backorder and inventory holding costs and uses a periodic review system to place orders from a manufacturer. The manufacturer must fill the entire order. The manufacturer incurs costs of overtime and undertime if the order deviates from the planned production capacity. We determine the optimal capacity for the manufacturer in case there is no coordination with the retailer as well as in case there is full coordination with the retailer. When there is no coordination the optimal capacity for the manufacturer is found by solving a newsvendor problem. When there is coordination, we present a dynamic programming formulation and establish that the optimal ordering policy for the retailer is characterized by two parameters. The optimal coordinated capacity for the manufacturer can then be obtained by solving a nonlinear programming problem. We present an efficient exact algorithm and a heuristic algorithm for computing the manufacturer's capacity. We discuss the impact of coordination on the supply chain cost as well as on the manufacturer's capacity. We also identify the situations in which coordination is most beneficial. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

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.     

An EOQ model with multiple suppliers and random capacity

We consider an EOQ model with multiple suppliers that have random capacities, which leads to uncertain yield in orders. A given order is fully received from a supplier if the order quantity is less than the supplier's capacity; otherwise, the quantity received is equal to the available capacity. The optimal order quantities for the suppliers can be obtained as the unique solution of an implicit set of equations in which the expected unsatisfied order is the same for each supplier. Further characterizations and properties are obtained for the uniform and exponential capacity cases with discussions on the issues related to diversification among suppliers. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

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     

Optimal capacity expansion

We consider the problem of temporal expansion of the capacity of, say, a plant or road given estimates of its desired usage (demand). The basic problem is: given a sequence of predicted demands for N time periods, determine the optimal investment decision in each period to minimize a linear investment cost and a strictly convex cost of capacity. The relationship between capacity and the investment decisions is assumed to be linear, but time varying. Constraints on both the individual decisions and on the sum of the decisions are considered. An algorithm for solving this problem is derived.     

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.     

Bicriteria product design optimization: An efficient solution procedure using AND/OR trees

Competitive imperatives are causing manufacturing firms to consider multiple criteria when designing products. However, current methods to deal with multiple criteria in product design are ad hoc in nature. In this paper we present a systematic procedure to efficiently solve bicriteria product design optimization problems. We first present a modeling framework, the AND/OR tree, which permits a simplified representation of product design optimization problems. We then show how product design optimization problems on AND/OR trees can be framed as network design problems on a special graph—a directed series‐parallel graph. We develop an enumerative solution algorithm for the bicriteria problem that requires as a subroutine the solution of the parametric shortest path problem. Although this parametric problem is hard on general graphs, we show that it is polynomially solvable on the series‐parallel graph. As a result we develop an efficient solution algorithm for the product design optimization problem that does not require the use of complex and expensive linear/integer programming solvers. As a byproduct of the solution algorithm, sensitivity analysis for product design optimization is also efficiently performed under this framework. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 574–592, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10031     

Simultaneous price,location, and capacity decisions on a line of time‐sensitive customers

Consider a monopolist who sells a single product to time‐sensitive customers located on a line segment. Customers send their orders to the nearest distribution facility, where the firm processes (customizes) these orders on a first‐come, first‐served basis before delivering them. We examine how the monopolist would locate its facilities, set their capacities, and price the product offered to maximize profits. We explicitly model customers' waiting costs due to both shipping lead times and queueing congestion delays and allow each customer to self‐select whether she orders or not, based on her reservation price. We first analyze the single‐facility problem and derive a number of interesting insights regarding the optimal solution. We show, for instance, that the optimal capacity relates to the square root of the customer volume and that the optimal price relates additively to the capacity and transportation delay costs. We also compare our solutions to a similar problem without congestion effects. We then utilize our single‐facility results to treat the multi‐facility problem. We characterize the optimal policy for serving a fixed interval of customers from multiple facilities when customers are uniformly distributed on a line. We also show how as the length of the customer interval increases, the optimal policy relates to the single‐facility problem of maximizing expected profit per unit distance. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

A network flow approach for capacity expansion problems with two facility types

A deterministic capacity expansion model for two facility types with a finite number of discrete time periods is described. The model generalizes previous work by allowing for capacity disposals, in addition to capacity expansions and conversions from one facility type to the other. Furthermore, shortages of capacity are allowed and upper bounds on both shortages and idle capacities can be imposed. The demand increments for additional capacity of any type in any time period can be negative. All cost functions are assumed to be piecewise, concave and nondecreasing away from zero. The model is formulated as a shortest path problem for an acyclic network, and an efficient search procedure is developed to determine the costs associated with the links of this network.     

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.     

A three‐stage procurement optimization problem under uncertainty

This article examines a problem faced by a firm procuring a material input or good from a set of suppliers. The cost to procure the material from any given supplier is concave in the amount ordered from the supplier, up to a supplier‐specific capacity limit. This NP‐hard problem is further complicated by the observation that capacities are often uncertain in practice, due for instance to production shortages at the suppliers, or competition from other firms. We accommodate this uncertainty in a worst‐case (robust) fashion by modeling an adversarial entity (which we call the “follower”) with a limited procurement budget. The follower reduces supplier capacity to maximize the minimum cost required for our firm to procure its required goods. To guard against uncertainty, the firm can “protect” any supplier at a cost (e.g., by signing a contract with the supplier that guarantees supply availability, or investing in machine upgrades that guarantee the supplier's ability to produce goods at a desired level), ensuring that the anticipated capacity of that supplier will indeed be available. The problem we consider is thus a three‐stage game in which the firm first chooses which suppliers' capacities to protect, the follower acts next to reduce capacity from unprotected suppliers, and the firm then satisfies its demand using the remaining capacity. We formulate a three‐stage mixed‐integer program that is well‐suited to decomposition techniques and develop an effective cutting‐plane algorithm for its solution. The corresponding algorithmic approach solves a sequence of scaled and relaxed problem instances, which enables solving problems having much larger data values when compared to standard techniques. © 2013 Wiley Periodicals, Inc. Naval Research Logistics, 2013     

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.     

Distribution network design: Selection and sizing of congested connections

This paper focuses on certain types of distribution networks in which commodity flows must go through connections that are subject to congestion. Connections serve as transshipment and/or switching points and are modeled as M/G/1 queues. The goal is to select connections, assign flows to the connections, and size their capacities, simultaneously. The capacities are controlled by both the mean and the variability of service time at each connection. We formulate this problem as a mixed integer nonlinear optimization problem for both the fixed and variable service rate cases. For the fixed service rate case, we prove that the objective function is convex and then develop an outer approximation algorithm. For the variable service rate case, both mean and second moment of service time are decision variables. We establish that the utilization rates at the homogeneous connections are identical for an optimal solution. Based on this key finding, we develop a Lagrangian relaxation algorithm. Numerical experiments are conducted to verify the quality of the solution techniques proposed. The essential contribution of this work is the explicit modeling of connection capacity (through the mean and the variability of service time) using a queueing framework. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Lateral capacity exchange and its impact on capacity investment decisions

We study the problem of capacity exchange between two firms in anticipation of the mismatch between demand and capacity, and its impact on firm's capacity investment decisions. For given capacity investment levels of the two firms, we demonstrate how capacity price may be determined and how much capacity should be exchanged when either manufacturer acts as a Stackelberg leader in the capacity exchange game. By benchmarking against the centralized system, we show that a side payment may be used to coordinate the capacity exchange decisions. We then study the firms' capacity investment decisions using a biform game framework in which capacity investment decisions are made individually and exchange decisions are made as in a centralized system. We demonstrate the existence and uniqueness of the Nash equilibrium capacity investment levels and study the impact of firms' share of the capacity exchange surplus on their capacity investment levels.© 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

A stochastic approximation algorithm to compute bid prices for joint capacity allocation and overbooking over an airline network

In this article, we develop a stochastic approximation algorithm to find good bid price policies for the joint capacity allocation and overbooking problem over an airline network. Our approach is based on visualizing the total expected profit as a function of the bid prices and searching for a good set of bid prices by using the stochastic gradients of the total expected profit function. We show that the total expected profit function that we use is differentiable with respect to the bid prices and derive a simple expression that can be used to compute its stochastic gradients. We show that the iterates of our stochastic approximation algorithm converge to a stationary point of the total expected profit function with probability 1. Our computational experiments indicate that the bid prices computed by our approach perform significantly better than those computed by standard benchmark strategies and the performance of our approach is relatively insensitive to the frequency with which we recompute the bid prices over the planning horizon. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

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.     

Multi‐period maintenance scheduling of tree networks with minimum flow disruption

We introduce a multi‐period tree network maintenance scheduling model and investigate the effect of maintenance capacity restrictions on traffic/information flow interruptions. Network maintenance refers to activities that are performed to keep a network operational. For linear networks with uniform flow between every pair of nodes, we devise a polynomial‐time combinatorial algorithm that minimizes flow disruption. The spiral structure of the optimal maintenance schedule sheds insights into general network maintenance scheduling. The maintenance problem on linear networks with a general flow structure is strongly NP‐hard. We formulate this problem as a linear integer program, derive strong valid inequalities, and conduct a polyhedral study of the formulation. Polyhedral analysis shows that the relaxation of our linear network formulation is tight when capacities and flows are uniform. The linear network formulation is then extended to an integer program for solving the tree network maintenance scheduling problem. Preliminary computations indicate that the strengthened formulations can solve reasonably sized problems on tree networks and that the intuitions gained from the uniform flow case continue to hold in general settings. Finally, we extend the approach to directed networks and to maintenance of network nodes. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Allocation of resources of modular sizes with an application to Internet Protocol (IP) address allocation

We consider a resource allocation problem, where resources of different capacities must satisfy multiple demands. The demand sizes and the resource capacities are limited to sizes that are power‐of‐two integers (i.e., 1, 2, 4, 8, …). The cost of the resources exhibit economies‐of‐scale savings, i.e., the cost per capacity unit is smaller for resources with larger capacity. The problem is to select the minimum‐cost set of resources that satisfies the demands, while each of the demands must be assigned to a single resource and the number of selected resources does not exceed a specified upper bound. We present algorithms that take advantage of the special structure of the problem and provide optimal solutions in a negligible computing effort. This problem is important for the allocation of blocks of Internet Protocol (IP) addresses, referred to as subnets. In typical IP networks, subnets are allocated at a large number of nodes. An effective allocation attempts to balance the volume of excess addresses that are not used versus fragmentation of addresses at nodes to too many subnets with a discontinuous range of addresses. Due to the efficiency of the algorithms, they can readily be used as valuable modules in IP address management systems. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

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