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     

Fluctuations of the optimal advertising and inventory policy: A qualitative analysis

This paper discusses the properties of the inventory and advertising policy minimizing the expected discounted cost over a finite horizon in a dynamic nonstationary inventory model with random demand which is influenced by the level of promotion or goodwill. Attention is focused on the relation between the fluctuations over time of the optimal policies and the variations over time of the factors involved, i.e., demand distributions and various costs. The optimal policies are proved to be monotone in the various factors. Also, three types of fluctuations over time of the optimal policies are discussed according to which factor varies over time. For example, if over a finite interval, the random demand increases (stochastically) from one period to the next, reaches a maximum and then decreases, then the optimal inventory level will do the same. Also the period of maximum of demand never precedes that of maximum inventory. The optimal advertising behaves in the opposite way and its minimum will occur at the same time as the maximum of the inventory. The model has a linear inventory ordering cost and instantaneous delivery of stocks; many results, however, are extended to models with a convex ordering cost or a delivery time lag.     

The one‐warehouse multiretailer problem with an order‐up‐to level inventory policy

We consider a two‐level system in which a warehouse manages the inventories of multiple retailers. Each retailer employs an order‐up‐to level inventory policy over T periods and faces an external demand which is dynamic and known. A retailer's inventory should be raised to its maximum limit when replenished. The problem is to jointly decide on replenishment times and quantities of warehouse and retailers so as to minimize the total costs in the system. Unlike the case in the single level lot‐sizing problem, we cannot assume that the initial inventory will be zero without loss of generality. We propose a strong mixed integer program formulation for the problem with zero and nonzero initial inventories at the warehouse. The strong formulation for the zero initial inventory case has only T binary variables and represents the convex hull of the feasible region of the problem when there is only one retailer. Computational results with a state‐of‐the art solver reveal that our formulations are very effective in solving large‐size instances to optimality. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Note on “An Optimal Recursive Method for Various Inventory Replenishment Models with Increasing Demand and Shortages” by Teng et al.

In a recent paper, Teng, Chern, and Yang consider four possible inventory replenishment models and determine the optimal replenishment policies for them. They compare these models to identify the best alternative on the basis of minimum total relevant inventory costs. The total cost functions for Model 1 and Model 4 as derived by them are not exact for the comparison. As a result, their conclusion on the least expensive replenishment policy is incorrect. The present article provides the actual total costs for Model 1 and Model 4 to make a correct comparison of the four models. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 602–606, 2000     

Models for multi-item continuous review inventory policies subject to constraints

Models are formulated for determining continuous review (Q, r) policies for a multiitem inventory subject to constraints. The objective function is the minimization of total time-weighted shortages. The constraints apply to inventory investment and reorder workload. The formulations are thus independent of the normal ordering, holding, and shortage costs. Two models are presented, each representing a convex programming problem. Lagrangian techniques are employed with the first, simplified model in which only the reorder points are optimized. In the second model both the reorder points and the reorder quantities are optimized utilizing penalty function methods. An example problem is solved for each model. The final section deals with the implementation of these models in very large inventory systems.     

Degeneracy in inventory models

In order‐quantity reorder‐point formulations for inventory items where backordering is allowed, some of the more common ways to prevent excessive stockouts in an optimal solution are to impose either a cost per unit short, a cost per stockout occasion, or a target fill rate. We show that these popular formulations, both exact and approximate, can become “degenerate” even with quite plausible parameters. By degeneracy we mean any situation in which the formulation either cannot be solved, leads to nonsensical “optimal” solutions, or becomes equivalent to something substantially simpler. We explain the reasons for the degeneracies, yielding new insight into these models, and we provide practical advice for inventory managers. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 686–705, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10037     

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     

More ado about economic order quantities (EOQ)

This paper is concerned with the determination of explicit expressions for economic order quantities and reorder levels, such that the cost of ordering and holding inventory is minimized for specific backorder constraints. Holding costs are applied either to inventory position or on-hand inventory, and the backorder constraint is considered in terms of the total number of backorders per year or the average number of backorders at any point in time. Through the substitution of a new probability density function in place of the normal p.d.f., explicit expressions are determined for the economic order quantities and the reorder points. The resulting economic order quantities are independent of all backorder constraints. It is also concluded that under certain conditions, the minimization of ordering costs and inventory holding costs (applied to inventory position), subject to a backorder constraint, is equivalent in terms of reorder levels to minimization of the safety level dollar investment subject to the same backorder constraint.     

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.     

Optimal advertising and inventory control of perishable goods

The primary goal of this article is to extend the results of a previous article to the case where the effect of advertisement on sales lasts more than one period. Monotonicity of the optimal advertising and inventory policies in the various factors is investigated. Also, attention will be focused on the relationship between the fluctuations over time of the optimal policies and the variations over time of the factors involved, such as demand distributions and holding costs. For example, if over a finite interval the demand decreases from one period to the next, reaches a minimum, and then increases, then the optimal advertising policy will produce the opposite effect. The period of minimum demand never precedes that of maximum goodwill; moreover, the optimal inventory level decreases while the demand decreases. Finally, when demand distributions are just translates of one another, the results of this article can be extended to nonperishable goods.     

Optimal policies under the shortage probability criterion for an inventory model with unknown dependent demands

The principal innovation in this paper is the consideration of a new objective function for inventory models which we call the shortage probability criterion. Under this criterion we seek to minimize the total expected discounted cost of ordering subject to the probability that the stock level at the end of the period being less than some fixed quantity not exceed some prescribed number. For three different models we show that the minimum order policy is optimal. This result is then applied to a particular inventory model in which the demand distribution is not completely known. A Bayesian procedure is discussed for obtaining optimal policies.     

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.     

Optimal ordering policies when anticipating parameter changes in EOQ systems

The classical Economic Order Quantity Model requires the parameters of the model to be constant. Some EOQ models allow a single parameter to change with time. We consider EOQ systems in which one or more of the cost or demand parameters will change at some time in the future. The system we examine has two distinct advantages over previous models. One obvious advantage is that a change in any of the costs is likely to affect the demand rate and we allow for this. The second advantage is that often, the times that prices will rise are fairly well known by announcement or previous experience. We present the optimal ordering policy for these inventory systems with anticipated changes and a simple method for computing the optimal policy. For cases where the changes are in the distant future we present a myopic policy that yields costs which are near-optimal. In cases where the changes will occur in the relatively near future the optimal policy is significantly better than the myopic policy.     

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.     

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.     

When is a base stock policy optimal in recovering disrupted cyclic schedules?

The extended economic lot scheduling problem (EELSP) is concerned with scheduling the production of a set of items in a single facility to minimize the long-run average holding, backlogging, and setup costs. Given an efficient cyclic production schedule for the EELSP, called the target schedule, we consider the problem of how to schedule production after a single schedule disruption. We propose a base stock policy, characterized by a base stock vector, that prescribes producing an item until its inventory level reaches the peak inventory of the target schedule corresponding to the item's position in the production sequence. We show that the base stock policy is always successful in recovering the target schedule. Moreover, the base stock policy recovers the target schedule at minimal excess over average cost whenever the backorder costs are proportional to the processing times. This condition holds, for example, when the value of the items is proportional to their processing times, and a common inventory carrying cost and a common service level is used for all the items. Alternatively, the proportionality condition holds if the inventory manager is willing to select the service levels from a certain set that is large enough to guarantee any minimal level of service, and then uses the imputed values for the backorder costs. When the proportionality condition holds we provide a closed-form expression for the total relevant excess over average cost of recovering the target schedule. We assess the performance of the base stock policy when the proportionality condition does not hold through a numerical study, and suggest some heuristic uses of the base stock policy. © 1994 John Wiley & Sons, Inc.     

Distribution free bounds for service constrained (Q,r) inventory systems

A classical and important problem in stochastic inventory theory is to determine the order quantity (Q) and the reorder level (r) to minimize inventory holding and backorder costs subject to a service constraint that the fill rate, i.e., the fraction of demand satisfied by inventory in stock, is at least equal to a desired value. This problem is often hard to solve because the fill rate constraint is not convex in (Q, r) unless additional assumptions are made about the distribution of demand during the lead‐time. As a consequence, there are no known algorithms, other than exhaustive search, that are available for solving this problem in its full generality. Our paper derives the first known bounds to the fill‐rate constrained (Q, r) inventory problem. We derive upper and lower bounds for the optimal values of the order quantity and the reorder level for this problem that are independent of the distribution of demand during the lead time and its variance. We show that the classical economic order quantity is a lower bound on the optimal ordering quantity. We present an efficient solution procedure that exploits these bounds and has a guaranteed bound on the error. When the Lagrangian of the fill rate constraint is convex or when the fill rate constraint does not exist, our bounds can be used to enhance the efficiency of existing algorithms. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 635–656, 2000     

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.     

A generalized recursive algorithm for a class of non-stationary regeneration (scheduling) problems

Recent efforts in the field of dynamic programming have explored the feasibility of solving certain classes of integer programming problems by recursive algorithms. Special recursive algorithms have been shown to be particularly effective for problems possessing a 0–1 attribute matrix displaying the “nesting property” studied by, Ignall and Veinott in inventory theory and by Glover in network flows. This paper extends the class of problem structures that has been shown amenable to recursive exploitation by providing an efficient dynamic programming approach for a general transportation scheduling problem. In particular, we provide alternative formulations lor the scheduling problem and show how the most general of these formulations can be readily solved vis a vis recursive techniques.     

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