Inventory cost impact of order processing priorities based on demand uncertainty

We evaluate an approach to decrease inventory costs at retail inventory locations that share a production facility. The retail locations sell the same product but differ in the variance of retail demand. Inventory policies at retail locations generate replenishment orders for the production facility. The production facility carries no finished goods inventory. Thus, production lead time for an order is the sojourn time in a single server queueing system. This lead time affects inventory costs at retail locations. We examine the impact of moving from a First Come First Served (FCFS) production rule for orders arriving at the production facility to a rule in which we provide non‐preemptive priority (PR) to orders from retail locations with higher demand uncertainty. We provide three approximations for the ratio of inventory costs under PR and FCFS and use them to identify conditions under which PR decreases retail inventory costs over FCFS. We then use a Direct Approach to establish conditions when PR decreases retail inventory costs over FCFS. We extend the results to orders from locations that differ in the mean and variance of demand uncertainty. The analysis suggests that tailoring lead times to product demand characteristics may decrease system inventory costs. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 376–390, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10016     

A computationally efficient approach for determining inventory levels in a capacitated multiechelon production‐distribution system

The system under study is a single item, two‐echelon production‐inventory system consisting of a capacitated production facility, a central warehouse, and M regional distribution centers that satisfy stochastic demand. Our objective is to determine a system base‐stock level which minimizes the long run average system cost per period. Central to the approach are (1) an inventory allocation model and associated convex cost function designed to allocate a given amount of system inventory across locations, and (2) a characterization of the amount of available system inventory using the inventory shortfall random variable. An exact model must consider the possibility that inventories may be imbalanced in a given period. By assuming inventory imbalances cannot occur, we develop an approximation model from which we obtain a lower bound on the per period expected cost. Through an extensive simulation study, we analyze the quality of our approximation, which on average performed within 0.50% of the lower bound. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 377–398, 2000     

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     

An optimal critical level policy for inventory systems with two demand classes

Traditional inventory systems treat all demands of a given item equally. This approach is optimal if the penalty costs of all customers are the same, but it is not optimal if the penalty costs are different for different customer classes. Then, demands of customers with high penalty costs must be filled before demands of customers with low penalty costs. A commonly used inventory policy for dealing with demands with different penalty costs is the critical level inventory policy. Under this policy demands with low penalty costs are filled as long as inventory is above a certain critical level. If the inventory reaches the critical level, only demands with high penalty costs are filled and demands with low penalty costs are backordered. In this article, we consider a critical level policy for a periodic review inventory system with two demand classes. Because traditional approaches cannot be used to find the optimal parameters of the policy, we use a multidimensional Markov chain to model the inventory system. We use a sample path approach to prove several properties of this inventory system. Although the cost function is not convex, we can build on these properties to develop an optimization approach that finds the optimal solution. We also present some numerical results. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

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.     

The impact of inventory information distortion due to customer order cancellations

In this paper we study the impact of cancellations of customer orders on an inventory system. We develop a periodic review (s, S) inventory model with Poisson demands, deterministic demand leadtimes and supply leadtimes. When no set up cost is present for replenishment, the behavior of the system cost can be studied analytically. For the case with a fixed set up cost, we derive the operating characteristics of the model via an embedded Markov chain analysis. Based on this, we formulate the total cost function and suggest a two‐phase approach to optimization. Our model can be used to compute cancellation fees and to evaluate the impacts of various conditions of cancellation. We find that cancellations, as major sources of inventory information distortion, increase total system costs, and the magnitude of the cost impact depends on the probability of cancellation and the expected cancellation time. Other relevant lessons and insights are also discussed. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 213–231, 1999     

Optimal control of a production‐inventory system with both backorders and lost sales

We consider the optimal control of a production inventory‐system with a single product and two customer classes where items are produced one unit at a time. Upon arrival, customer orders can be fulfilled from existing inventory, if there is any, backordered, or rejected. The two classes are differentiated by their backorder and lost sales costs. At each decision epoch, we must determine whether or not to produce an item and if so, whether to use this item to increase inventory or to reduce backlog. At each decision epoch, we must also determine whether or not to satisfy demand from a particular class (should one arise), backorder it, or reject it. In doing so, we must balance inventory holding costs against the costs of backordering and lost sales. We formulate the problem as a Markov decision process and use it to characterize the structure of the optimal policy. We show that the optimal policy can be described by three state‐dependent thresholds: a production base‐stock level and two order‐admission levels, one for each class. The production base‐stock level determines when production takes place and how to allocate items that are produced. This base‐stock level also determines when orders from the class with the lower shortage costs (Class 2) are backordered and not fulfilled from inventory. The order‐admission levels determine when orders should be rejected. We show that the threshold levels are monotonic (either nonincreasing or nondecreasing) in the backorder level of Class 2. We also characterize analytically the sensitivity of these thresholds to the various cost parameters. Using numerical results, we compare the performance of the optimal policy against several heuristics and show that those that do not allow for the possibility of both backordering and rejecting orders can perform poorly.© 2010 Wiley Periodicals, Inc. Naval Research Logistics 2010     

Optimal base stock policies and truck capacity in a two-echelon system

With the recent trend toward just-in-time deliveries and reduction of inventories, many firms are reexamining their inventory and logistics policies. Some firms have dramatically altered their inventory, production, and shipping policies with the goal of reducing costs and improving service. Part of this restructuring may involve a specific contract with a trucking company, or it may entail establishing in-house shipping capabilities. This restructuring, however, raises new questions regarding the choice of optimal trucking capacity, shipping frequency, and inventory levels. In this study, we examine a two-level distribution system composed of a warehouse and a retailer. We assume that demand at the retailer is random. Since the warehouse has no advance notice of the size of the retailer order, inventory must be held there as well as at the retailer. We examine inventory policies at both the warehouse and the retailer, and we explicitly consider the trucking capacity, and the frequency of deliveries from the warehouse to the retailer. Both linear and concave fixed transportation costs are examined. We find the optimal base stock policies at both locations, the optimal in-house or contracted regular truck capacity, and the optimal review period (or, equivalently, delivery frequency). For the case of normally distributed demand we provide analytical results and numerical examples that yield insight into systems of this type. Some of our results are counterintuitive. For instance, we find some cases in which the optimal truck capacity decreases as the variability of demand increases. In other cases the truck capacity increases with variability of demand. © 1993 John Wiley & Sons, Inc.     

Optimal outbound dispatch policies: Modeling inventory and cargo capacity

In this paper, we present an optimization model for coordinating inventory and transportation decisions at an outbound distribution warehouse that serves a group of customers located in a given market area. For the practical problems which motivated this paper, the warehouse is operated by a third party logistics provider. However, the models developed here may be applicable in a more general context where outbound distribution is managed by another supply chain member, e.g., a manufacturer. We consider the case where the aggregate demand of the market area is constant and known per period (e.g., per day). Under an immediate delivery policy, an outbound shipment is released each time a demand is realized (e.g., on a daily basis). On the other hand, if these shipments are consolidated over time, then larger (hence more economical) outbound freight quantities can be dispatched. In this case, the physical inventory requirements at the third party warehouse (TPW) are determined by the consolidated freight quantities. Thus, stock replenishment and outbound shipment release policies should be coordinated. By optimizing inventory and freight consolidation decisions simultaneously, we compute the parameters of an integrated inventory/outbound transportation policy. These parameters determine: (i) how often to dispatch a truck so that transportation scale economies are realized and timely delivery requirements are met, and (ii) how often, and in what quantities, the stock should be replenished at the TPW. We prove that the optimal shipment release timing policy is nonstationary, and we present algorithms for computing the policy parameters for both the uncapacitated and finite cargo capacity problems. The model presented in this study is considerably different from the existing inventory/transportation models in the literature. The classical inventory literature assumes that demands should be satisfied as they arrive so that outbound shipment costs are sunk costs, or else these costs are covered by the customer. Hence, the classical literature does not model outbound transportation costs. However, if a freight consolidation policy is in place then the outbound transportation costs can no longer be ignored in optimization. Relying on this observation, this paper models outbound transportation costs, freight consolidation decisions, and cargo capacity constraints explicitly. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 531–556, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10030     

Ordering policies for an inventory system with three supply modes

This article explores ordering policies for inventory systems with three supply modes. This model is particularly interesting because the optimal ordering decision needs to balance the inventory and purchase costs, as well as the costs for earlier and later periods. The latter cost trade-off is present only in inventory systems with three or more supply modes. Therefore, the result not only offers guidelines for the operation of the concerned inventory systems, but also provides valuable insight into the complex cost trade-offs when more supply modes are available. We assume that the difference between the lead times is one period, and the inventory holding and shortage costs are linear. We analyze two cases and obtain the structure of the optimal ordering policy. Moreover, in the first case, explicit formulas are derived to calculate the optimal order-up-to levels. In the second case, although the optimal order-up-to levels are functions of the initial inventory state and are not obtained in closed form, their properties are discussed. We also develop heuristic ordering policies based on the news-vendor model. Our numerical experiments suggest that the heuristic policies perform reasonably well. © 1996 John Wiley & Sons, Inc.     

Note: Dual sourcing with nonidentical suppliers

We analyze a dual-sourcing inventory model with exponential lead times and constant unit demand in which the order quantity is split in some proportion between two sources of supply. Unlike earlier studies, we do not require that the two sources be identical in terms of the lead-time parameters or the supply prices. We compare the expected total annual costs for the two-source and the traditional single-source models over a wide range of parameter values. We confirm the findings of earlier studies that, under stochastic lead times, dual sourcing yields savings in holding and shortage costs that could outweigh the incremental ordering costs. With this more general model, we demonstrate that savings from dual sourcing are possible even where the mean or the variability of the second source is higher. © 1993 John Wiley & Sons, Inc.     

Performance evaluation of a production/inventory system with periodic review and endogenous lead times

This paper considers a discrete time, single item production/inventory system with random period demands. Inventory levels are reviewed periodically and managed using a base‐stock policy. Replenishment orders are placed with the production system which is capacitated in the sense that there is a single server that sequentially processes the items one at a time with stochastic unit processing times. In this setting the variability in demand determines the arrival pattern of production orders at the queue, influencing supply lead times. In addition, the inventory behavior is impacted by the correlation between demand and lead times: a large demand size corresponds to a long lead time, depleting the inventory longer. The contribution of this paper is threefold. First, we present an exact procedure based on matrix‐analytic techniques for computing the replenishment lead time distribution given an arbitrary discrete demand distribution. Second, we numerically characterize the distribution of inventory levels, and various other performance measures such as fill rate, base‐stock levels and optimal safety stocks, taking the correlation between demand and lead times into account. Third, we develop an algorithm to fit the first two moments of the demand and service time distribution to a discrete phase‐type distribution with a minimal number of phases. This provides a practical tool to analyze the effect of demand variability, as measured by its coefficient of variation, on system performance. We also show that our model is more appropriate than some existing models of capacitated systems in discrete time. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

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.     

Inventory rotation policies for slow moving items

In this article we present a stochastic model for determining inventory rotation policies for a retail firm which must stock many hundreds of distinctive items having uncertain heterogeneous sales patterns. The model develops explicit decision rules for determining (1) the length of time that an item should remain in inventory before the decision is made on whether or not to rotate the item out of inventory and (2) the minimum sales level necessary for retaining the item in inventory. Two inventory rotation policies are developed, the first of which maximizes cumulative expected sales over a finite planning horizon and the second of which maximizes cumulative expected profit. We also consider the statistical behavior of items having uncertain, discrete, and heterogeneous sales patterns using a two-period prediction methodology where period 1 is used to accumulate information on individual sales rates and this knowledge is then used, in a Bayesian context, to make sales predictions for period 2. This methodology assumes that over an arbitrary time interval sales for each item are Poisson with unknown but stationary mean sales rates and the mean sales rates are distributed gamma across all items. We also report the application of the model to a retail firm which stocks many hundreds of distinctive unframed poster art titles. The application provides some useful insights into the behavior of the model as well as some interesting aspects pertaining to the implementation of the results in a “real-world” situation.     

Predicting the cost performance of inventory control systems by retrospective simulation

When an inventory-control system is designed to utilized statistical demand information in computing an (s,S) policy, it may be necessary to use performance forecasts to calibrate the relationship between control parameters and performance measures. Using a simulation model to test prediction by retrospective simulation we estimated the bias and variance of forecasts for expected costs and other operating characteristics. The results show the sensitivity of the prediction bias to changes in demand, cost, and lead time parameters and to choices made in system design.     

A dynamic,nonstationary inventory problem for a price/quantity setting firm

A dynamic and nonstationary model is formulated for a firm which attempts to minimize total expected costs over a finite planning horizon. The control variables are price and production. The price p and the demand ζ are linked through the relationship ζ = g(p) + η, where g(p) is the riskless demand curve and η is a random variable. The general model allows for proportional ordering costs, convex holding and stockout costs, downward sloping riskless demand curve, backlogging, partial backlogging, lost sales, partial spoilage of inventory, and two modes of collecting revenue. Sufficient conditions are developed for this problem to have an optimal policy which resembles the single critical number policy known from stochastic inventory theory. It is also shown what set of parameters will satisfy these sufficiency conditions.     

A two product dynamic economic lot size production model with either-or production constraints

This paper considers the production of two products with known demands over a finite set of periods. The production and inventory carrying costs for each product are assumed to be concave. We seek the minimum cost production schedule meeting all demands, without backlogging, assuming that at most one of the two products can be produced in any period. The optimization problem is first stated as a nonlinear programming problem, which allows the proof of a result permitting the search for the optimal policy to be restricted to those which produce a product only when its inventory level is zero. A dynamic programming formulation is given and the model is then formulated as a shortest route problem in a specially constructed network.     

An economic lot‐sizing problem with perishable inventory and economies of scale costs: Approximation solutions and worst case analysis

The costs of many economic activities such as production, purchasing, distribution, and inventory exhibit economies of scale under which the average unit cost decreases as the total volume of the activity increases. In this paper, we consider an economic lot‐sizing problem with general economies of scale cost functions. Our model is applicable to both nonperishable and perishable products. For perishable products, the deterioration rate and inventory carrying cost in each period depend on the age of the inventory. Realizing that the problem is NP‐hard, we analyze the effectiveness of easily implementable policies. We show that the cost of the best Consecutive‐Cover‐Ordering (CCO) policy, which can be found in polynomial time, is guaranteed to be no more than (4 + 5)/7 ≈ 1.52 times the optimal cost. In addition, if the ordering cost function does not change from period to period, the cost of the best CCO policy is no more than 1.5 times the optimal cost. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

A two-echelon inventory model with purchases,dispositions, shipments,returns and transshipments

This paper presents a one-period two-echelon inventory model with one warehouse in the first echelon and n warehouses in the second echelon. At the beginning of the period the stock levels at all facilities are adjusted by purchasing or disposing of items at the first echelon, returning or shipping items between the echelons and transshipping items within the second echelon. During the period, demands (which may be negative) are placed on all warehouses in the second echelon and an attempt is made to satisfy shortages either by an expedited shipment from the first echelon to the second echelon or an expedited transshipment within the second echelon. The decision problem is to choose an initial stock level at the first echelon (by a purchase or a disposition) and an initial allocation so as to minimize the initial stock movement costs during the period plus inventory carrying costs and system shortage costs at the end of the period. It is shown that the objective function takes on one of four forms, depending on the relative magnitudes of the various shipping costs. All four forms of the objective function are derived and proven to be convex. Several applications of this general model are considered. We also consider multi-period extensions of the general model and an important special case is solved explicitly.     

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