Some approximations in multi-item,multi-echelon inventory systems for recoverable items

The optimization problem as formulated in the METRIC model takes the form of minimizing the expected number of total system backorders in a two-echelon inventory system subject to a budget constraint. The system contains recoverable items – items subject to repair when they fail. To solve this problem, one needs to find the optimal Lagrangian multiplier associated with the given budget constraint. For any large-scale inventory system, this task is computationally not trivial. Fox and Landi proposed one method that was a significant improvement over the original METRIC algorithm. In this report we first develop a method for estimating the value of the optimal Lagrangian multiplier used in the Fox-Landi algorithm, present alternative ways for determining stock levels, and compare these proposed approaches with the Fox-Landi algorithm, using two hypothetical inventory systems – one having 3 bases and 75 items, the other 5 bases and 125 items. The comparison shows that the computational time can be reduced by nearly 50 percent. Another factor that contributes to the higher requirement for computational time in obtaining the solution to two-echelon inventory systems is that it has to allocate stock optimally to the depot as well as to bases for a given total-system stock level. This essentially requires the evaluation of every possible combination of depot and base stock levels – a time-consuming process for many practical inventory problems with a sizable system stock level. This report also suggests a simple approximation method for estimating the optimal depot stock level. When this method was applied to the same two hypotetical inventory systems indicated above, it was found that the estimate of optimal depot stock is quite close to the optimal value in all cases. Furthermore, the increase in expected system backorders using the estimated depot stock levels rather than the optimal levels is generally small.     

Cost allocation rules for elastic single‐attribute situations

Many cooperative games, especially ones stemming from resource pooling in queueing or inventory systems, are based on situations in which each player is associated with a single attribute (a real number representing, say, a demand) and in which the cost to optimally serve any sum of attributes is described by an elastic function (which means that the per‐demand cost is non‐increasing in the total demand served). For this class of situations, we introduce and analyze several cost allocation rules: the proportional rule, the serial cost sharing rule, the benefit‐proportional rule, and various Shapley‐esque rules. We study their appeal with regard to fairness criteria such as coalitional rationality, benefit ordering, and relaxations thereof. After showing the impossibility of combining coalitional rationality and benefit ordering, we show for each of the cost allocation rules which fairness criteria it satisfies. © 2017 Wiley Periodicals, Inc. Naval Research Logistics 64: 271–286, 2017     

Scheduling a production–distribution system to optimize the tradeoff between delivery tardiness and distribution cost

We consider a make‐to‐order production–distribution system with one supplier and one or more customers. A set of orders with due dates needs to be processed by the supplier and delivered to the customers upon completion. The supplier can process one order at a time without preemption. Each customer is at a distinct location and only orders from the same customer can be batched together for delivery. Each delivery shipment has a capacity limit and incurs a distribution cost. The problem is to find a joint schedule of order processing at the supplier and order delivery from the supplier to the customers that optimizes an objective function involving the maximum delivery tardiness and the total distribution cost. We first study the solvability of various cases of the problem by either providing an efficient algorithm or proving the intractability of the problem. We then develop a fast heuristic for the general problem. We show that the heuristic is asymptotically optimal as the number of orders goes to infinity. We also evaluate the performance of the heuristic computationally by using lower bounds obtained by a column generation approach. Our results indicate that the heuristic is capable of generating near optimal solutions quickly. Finally, we study the value of production–distribution integration by comparing our integrated approach with two sequential approaches where scheduling decisions for order processing are made first, followed by order delivery decisions, with no or only partial integration of the two decisions. We show that in many cases, the integrated approach performs significantly better than the sequential approaches. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Warehouse sizing to minimize inventory and storage costs

This paper considers a warehouse sizing problem whose objective is to minimize the total cost of ordering, holding, and warehousing of inventory. Unlike typical economic lot sizing models, the warehousing cost structure examined here is not the simple unit rate type, but rather a more realistic step function of the warehouse space to be acquired. In the cases when only one type of stock‐keeping unit (SKU) is warehoused, or when multiple SKUs are warehoused, but, with separable inventory costs, closed form solutions are obtained for the optimal warehouse size. For the case of multi‐SKUs with joint inventory replenishment cost, a heuristic with a provable performance bound of 94% is provided. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 299–312, 2001     

A bicriterion approach to common flow allowances due window assignment and scheduling with controllable processing times

We investigate a single‐machine scheduling problem for which both the job processing times and due windows are decision variables to be determined by the decision maker. The job processing times are controllable as a linear or convex function of the amount of a common continuously divisible resource allocated to the jobs, where the resource allocated to the jobs can be used in discrete or continuous quantities. We use the common flow allowances due window assignment method to assign due windows to the jobs. We consider two performance criteria: (i) the total weighted number of early and tardy jobs plus the weighted due window assignment cost, and (ii) the resource consumption cost. For each resource consumption function, the objective is to minimize the first criterion, while keeping the value of the second criterion no greater than a given limit. We analyze the computational complexity, devise pseudo‐polynomial dynamic programming solution algorithms, and provide fully polynomial‐time approximation schemes and an enhanced volume algorithm to find high‐quality solutions quickly for the considered problems. We conduct extensive numerical studies to assess the performance of the algorithms. The computational results show that the proposed algorithms are very efficient in finding optimal or near‐optimal solutions. © 2017 Wiley Periodicals, Inc. Naval Research Logistics, 64: 41–63, 2017     

On the first come–first served rule in multi‐echelon inventory control

A two‐echelon distribution inventory system with a central warehouse and a number of retailers is considered. The retailers face stochastic demand and replenish from the warehouse, which, in turn, replenishes from an outside supplier. The system is reviewed continuously and demands that cannot be met directly are backordered. Standard holding and backorder costs are considered. In the literature on multi‐echelon inventory control it is standard to assume that backorders at the warehouse are served according to a first come–first served policy (FCFS). This allocation rule simplifies the analysis but is normally not optimal. It is shown that the FCFS rule can, in the worst case, lead to an asymptotically unbounded relative cost increase as the number of retailers approaches infinity. We also provide a new heuristic that will always give a reduction of the expected costs. A numerical study indicates that the average cost reduction when using the heuristic is about two percent. The suggested heuristic is also compared with two existing heuristics. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Base‐stock policies in capacitated assembly systems: Convexity properties

We study an assembly system with a single finished product managed using an echelon base‐stock or order‐up‐to policy. Some or all operations have capacity constraints. Excess demand is either backordered in every period or lost in every period. We show that the shortage penalty cost over any horizon is jointly convex with respect to the base‐stock levels and capacity levels. When the holding costs are also included in the objective function, we show that the cost function can be written as a sum of a convex function and a concave function. Throughout the article, we discuss algorithmic implications of our results for making optimal inventory and capacity decisions in such systems.© 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Exact analysis of a two-echelon inventory system for recoverable items under batch inspection policy

We investigate a two-echelon (base-depot) inventory system of recoverable (repairable) items. The arrivals of demand at the bases are in a Poisson manner and the order sizes are random. The failed units can be repaired either at the base or at the depot, and the units beyond economic repair are condemned. Inspection of the failed units is carried out in the batches they arrive, that is, arrival batches are not broken up. The exact expressions for stationary distribution of depot inventory position, and of the number of backorders, onhand inventory, in-repair inventory at all locations are derived under the assumptions of constant repair and lead times. Special cases of complete recoverability, nonrecoverability, and of the unit order size are also discussed.     

A location‐inventory model with lateral transshipments

We study an infinite horizon periodic stochastic inventory system consisting of retail outlets and customers located on a homogenous line segment. In each period, the total demand, generated by the customers on the line, is normally distributed. To better match supply and demand, we incorporate lateral transshipments. We propose a compact model in which the strategic decisions—the number and locations of retail outlets—are determined simultaneously with the operational decisions—the inventory replenishment and transshipment quantities. We find the optimal balance between the risk‐pooling considerations, which drive down the optimal number of retail outlets, and lateral transshipments, which drive up the optimal number of retail outlets. We also explore the sensitivity of the optimal number of retail outlets to various problem parameters. This article presents a novel way of integrating lateral transshipments in the context of an inventory‐location model. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Dynamic learning,pricing, and ordering by a censored newsvendor

We address the problem of determining optimal ordering and pricing policies in a finite‐horizon newsvendor model with unobservable lost sales. The demand distribution is price‐dependent and involves unknown parameters. We consider both the cases of perishable and nonperishable inventory. A very general class of demand functions is studied in this paper. We derive the optimal ordering and pricing policies as unique functions of the stocking factor (which is a linear transformation of the safety factor). An important expression is obtained for the marginal expected value of information. As a consequence, we show when lost sales are unobservable, with perishable inventory the optimal stocking factor is always at least as large as the one given by the single‐period model; however, if inventory is nonperishable, this result holds only under a strong condition. This expression also helps to explain why the optimal stocking factor of a period may not increase with the length of the problem. We compare this behavior with that of a full information model. We further examine the implications of the results to the special cases when demand uncertainty is described by additive and multiplicative models. For the additive case, we show that if demand is censored, the optimal policy is to order more as well as charge higher retail prices when compared to the policies in the single‐period model and the full information model. We also compare the optimal and myopic policies for the additive and multiplicative models. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

An exact analysis of a joint production‐inventory problem in two‐echelon inventory systems

We consider a two‐echelon inventory system with a manufacturer operating from a warehouse supplying multiple distribution centers (DCs) that satisfy the demand originating from multiple sources. The manufacturer has a finite production capacity and production times are stochastic. Demand from each source follows an independent Poisson process. We assume that the transportation times between the warehouse and DCs may be positive which may require keeping inventory at both the warehouse and DCs. Inventory in both echelons is managed using the base‐stock policy. Each demand source can procure the product from one or more DCs, each incurring a different fulfilment cost. The objective is to determine the optimal base‐stock levels at the warehouse and DCs as well as the assignment of the demand sources to the DCs so that the sum of inventory holding, backlog, and transportation costs is minimized. We obtain a simple equation for finding the optimal base‐stock level at each DC and an upper bound for the optimal base‐stock level at the warehouse. We demonstrate several managerial insights including that the demand from each source is optimally fulfilled entirely from a single distribution center, and as the system's utilization approaches 1, the optimal base‐stock level increases in the transportation time at a rate equal to the demand rate arriving at the DC. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

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     

Optimal control of a capacitated inventory system with multiple demand classes

This article studies the optimal control of a periodic‐review make‐to‐stock system with limited production capacity and multiple demand classes. In this system, a single product is produced to fulfill several classes of demands. The manager has to make the production and inventory allocation decisions. His objective is to minimize the expected total discounted cost. The production decision is made at the beginning of each period and determines the amount of products to be produced. The inventory allocation decision is made after receiving the random demands and determines the amount of demands to be satisfied. A modified base stock policy is shown to be optimal for production, and a multi‐level rationing policy is shown to be optimal for inventory allocation. Then a heuristic algorithm is proposed to approximate the optimal policy. The numerical studies show that the heuristic algorithm is very effective. © 2011 Wiley Periodicals, Inc. Naval Research Logistics 58: 43–58, 2011     

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     

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     

Optimal staffing in nonstationary service centers with constraints

This paper considers optimal staffing in service centers. We construct models for profit and cost centers using dynamic rate queues. To allow for practical optimal controls, we approximate the queueing process using a Gaussian random variable with equal mean and variance. We then appeal to the Pontryagin's maximum principle to derive a closed form square root staffing (SRS) rule for optimal staffing. Unlike most traditional SRS formulas, the main parameter in our formula is not the probability of delay but rather a cost‐to‐benefit ratio that depends on the shadow price. We show that the delay experienced by customers can be interpreted in terms of this ratio. Throughout the article, we provide theoretical support of our analysis and conduct extensive numerical experiments to reinforce our findings. To this end, various scenarios are considered to evaluate the change in the staffing levels as the cost‐to‐benefit ratio changes. We also assess the change in the service grade and the effects of a service‐level agreement constraint. Our analysis indicates that the variation in the ratio of customer abandonment over service rate particularly influences staffing levels and can lead to drastically different policies between profit and cost service centers. Our main contribution is the introduction of new analysis and managerial insights into the nonstationary optimal staffing of service centers, especially when the objective is to maximize profitability. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 615–630, 2017     

Dynamic inventory control with limited capital and short‐term financing

For most firms, especially the small‐ and medium‐sized ones, the operational decisions are affected by their internal capital and ability to obtain external capital. However, the majority of the literature on dynamic inventory control ignores the firm's financial status and financing issues. An important question that arises is: what are the optimal inventory and financing policies for firms with limited internal capital and limited access to external capital? In this article, we study a dynamic inventory control problem where a capital‐constrained firm periodically purchases a product from a supplier and sells it to a market with random demands. In each period, the firm can use its own capital and/or borrow a short‐term loan to purchase the product, with the interest rate being nondecreasing in the loan size. The objective is to maximize the firm's expected terminal wealth at the end of the planning horizon. We show that the optimal inventory policy in each period is an equity‐level‐dependent base‐stock policy, where the equity level is the sum of the firm's capital level and the value of its on‐hand inventory evaluated at the purchasing cost; and the structure of the optimal policy can be characterized by four intervals of the equity level. Our results shed light on the dynamic inventory control for firms with limited capital and short‐term financing capabilities.Copyright © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 184–201, 2014     

Flow shop scheduling with earliness,tardiness, and intermediate inventory holding costs

We consider the problem of scheduling customer orders in a flow shop with the objective of minimizing the sum of tardiness, earliness (finished goods inventory holding), and intermediate (work‐in‐process) inventory holding costs. We formulate this problem as an integer program, and based on approximate solutions to two different, but closely related, Dantzig‐Wolfe reformulations, we develop heuristics to minimize the total cost. We exploit the duality between Dantzig‐Wolfe reformulation and Lagrangian relaxation to enhance our heuristics. This combined approach enables us to develop two different lower bounds on the optimal integer solution, together with intuitive approaches for obtaining near‐optimal feasible integer solutions. To the best of our knowledge, this is the first paper that applies column generation to a scheduling problem with different types of strongly ????‐hard pricing problems which are solved heuristically. The computational study demonstrates that our algorithms have a significant speed advantage over alternate methods, yield good lower bounds, and generate near‐optimal feasible integer solutions for problem instances with many machines and a realistically large number of jobs. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Exact algorithms and bounds for the dynamic assignment interdiction problem

We study a multi‐stage dynamic assignment interdiction (DAI) game in which two agents, a user and an attacker, compete in the underlying bipartite assignment graph. The user wishes to assign a set of tasks at the minimum cost, and the attacker seeks to interdict a subset of arcs to maximize the user's objective. The user assigns exactly one task per stage, and the assignment costs and interdiction impacts vary across stages. Before any stage commences in the game, the attacker can interdict arcs subject to a cardinality constraint. An interdicted arc can still be used by the user, but at an increased assignment cost. The goal is to find an optimal sequence of assignments, coupled with the attacker's optimal interdiction strategy. We prove that this problem is strongly NP‐hard, even when the attacker can interdict only one arc. We propose an exact exponential‐state dynamic‐programming algorithm for this problem as well as lower and upper bounds on the optimal objective function value. Our bounds are based on classical interdiction and robust optimization models, and on variations of the DAI game. We examine the efficiency of our algorithms and the quality of our bounds on a set of randomly generated instances. © 2017 Wiley Periodicals, Inc. Naval Research Logistics 64: 373–387, 2017     

Optimal joint preventive maintenance and production policies

We study joint preventive maintenance (PM) and production policies for an unreliable production‐inventory system in which maintenance/repair times are non‐negligible and stochastic. A joint policy decides (a) whether or not to perform PM and (b) if PM is not performed, then how much to produce. We consider a discrete‐time system, formulating the problem as a Markov decision process (MDP) model. The focus of the work is on the structural properties of optimal joint policies, given the system state comprised of the system's age and the inventory level. Although our analysis indicates that the structure of optimal joint policies is very complex in general, we are able to characterize several properties regarding PM and production, including optimal production/maintenance actions under backlogging and high inventory levels, and conditions under which the PM portion of the joint policy has a control‐limit structure. In further special cases, such as when PM set‐up costs are negligible compared to PM times, we are able to establish some additional structural properties. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.