Learning and costs in airframe production: A multiple-output production function approach

This article examines the influence of both production rate and learning on airframe program costs. A dynamic multiple-output production model is developed and is used to observe the cost impact of changes in production rate and learning. Several simulations are performed to demonstrate the sensitivity of the optimal time path of cost to changes in the model parameters. The model is applied by estimating parameters from the F102 airframe program.     

Selection of the optimal setup policy

A model is developed taking into consideration all the costs (namely cost of sampling, cost of not detecting a change in the process, cost of a false indication of change, and the cost of readjusting detected changes) incurred when a production process, using an unscheduled setup policy, utilizes fraction-defective control charts to control current production. The model is based on the concept of the expected time between detection of changes calling for setups. It is shown that the combination of unscheduled setups and control charts can be utilized in an optimal way if those combinations of sample size, sampling interval, and extent of control limits from process average are used that provide the minimum expected total cost per unit of time. The costs of a production process that uses unscheduled setups in conjunction with the appropriate optimal control charts are compared to the costs of a production process that uses scheduled setups at optimum intervals in conjunction with its appropriate control charts. This comparison indicates the criteria for selecting production processes with scheduled setups using optimal setup intervals over unscheduled setups. Suggestions are made to evaluate the optimal process setup strategy and the accompanying optimal decision parameters, for any specific cost data, by use of computer enumeration. A numerical example for assumed cost and process data is provided.     

A two-machine repair model with variable repair rate

A two-unit cold standby production system with one repairman is considered. After inspection of a failed unit the repairman chooses either a slow or a fast repair rate to carry out the corresponding amount of work. At system breakdown the repairman has an additional opportunity to switch to the fast rate. If there are no fixed costs associated with system breakdowns, then the policy which minimizes longrun average costs is shown to be a two-dimensional control limit rule. If fixed costs are incurred every time the system breaks down, then the optimal policy is not necessarily of control limit type. This is illustrated by a counterexample. Furthermore, we present several performance measures for this maintenance system controlled by a two-dimensional control limit rule. © 1993 John Wiley & Sons, Inc.     

TTT transforms and age replacements with discounted costs

The ordinary age replacement problem consists of finding an optimal age at which a unit, needed in a continuous production process, should be replaced in order to minimize the average long-run cost per unit time. Bergman introduced a graphical procedure based on the total-time-on-test (TTT) concept for the analysis of the age replacement problem. In this article, that idea is generalized to the situation of discounted costs. We also study a more general age replacement problem in which we have a form of imperfect repair.     

Analysis of the turbulent regime of the progress curve when new learning additions have variable slopes

Learning curves have been used extensively for predictive purposes in the airframe and other industries. In many instances this has led to erroneous results because analysts failed to extend learning curve theory and develop adequate analytical techniques in the turbulent regime of the cost history characterizing these industries. It is this area where a series of design changes induces a series of perturbations whose turbulence intensity is a function of the frequency of occurrence and magnitudes of the design changes under consideration. In Ref. 1, a series of formulations amenable to machine programming was developed for the accurate determination of perturbed unit costs. This development was based on additions of new learning having a constant slope. In this discussion, the development of Ref. 1 will be generalized by developing formulas for the addition of new effort having variable slopes. Consideration will also be given to the expressions involving elementary unit cost expressions so that cumulative average and cumulative total values can readily be obtained from existing experience curve tables. Conversely, the problem of determining the magnitudes of design changes and the slopes of new effort from graphical data will also be considered.     

Resource efficiency in aircraft production

This article examines measures of economic efficiency in aircraft production. In particular, a type of nonlinear frontier estimation is contrasted with more traditional methods for estimating a dynamic cost function. This cost function is grounded in economic theory, and it is consistent with knowledge of the aircraft-production process. The model includes the effects of both learning and production rate on total program costs. The usefulness of the model is demonstrated with an example that relates to the acquisition of military equipment. It is shown through various sensitivity analyses that an alternative procurement policy for an aircraft program could have resulted in increased efficiency and hence a lower total program cost to the government.     

The Organization of the Defense Support System: An Economic Geography Perspective

In the context of restricted budgetary resources and the growing cost of maintenance, repair, and overhaul (MRO) activities, a major issue for modern armed forces is to sustain defense platforms. A possible method consists of realizing economies of scale through the concentration of maintenance activities, which involves the spatial reorganization of existing industrial sites dedicated to MRO. This article provides a formalized framework to discuss the optimal organization for the MRO of defense platforms in space. The public planner organizes the maintenance of defense platforms with only two possible spatial configurations. In the dispersed configuration, two industrial production units in charge of the maintenance optimally cover space, whereas in the concentrated configuration, a unique industrial unit covers space. Focusing on the tipping point between the two configurations, the balance of forces between agglomeration and dispersion in defense support activities is described and discussed. On the one hand, economies of scale provide an opportunity to optimize defense support costs, favoring concentration in a unique industrial unit. On the other hand, space causes dispersion to reduce both transport costs and operational social costs. This trade-off illustrates a general principle in spatial economics with an application to MRO production in the French case.     

A misclassification cost‐minimizing evolutionary–neural classification approach

Machine learning algorithms that incorporate misclassification costs have recently received considerable attention. In this paper, we use the principles of evolution to develop and test an evolutionary/genetic algorithm (GA)‐based neural approach that incorporates asymmetric Type I and Type II error costs. Using simulated, real‐world medical and financial data sets, we compare the results of the proposed approach with other statistical, mathematical, and machine learning approaches, which include statistical linear discriminant analysis, back‐propagation artificial neural network, integrated cost preference‐based linear mathematical programming‐based minimize squared deviations, linear integrated cost preference‐based GA, decision trees (C 5.0, and CART), and inexpensive classification with expensive tests algorithm. Our results indicate that the proposed approach incorporating asymmetric error costs results in equal or lower holdout sample misclassification cost when compared with the other statistical, mathematical, and machine learning misclassification cost‐minimizing approaches. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

Subcontracting versus capacity expansion and the impact on pricing of services

The strategic trade-offs between acquiring new capacity and subcontracting (or leasing) capacity are explored for service environments characterized by rapid technological improvement or highly seasonal demand. Reflecting the focus on service-sector organizations, it is assumed that demand cannot be met from inventory. Furthermore, the critical impact that subcontracting has on a firm's competitive pricing policy is examined. The analysis presented is of particular relevance for firms in price-competitive industries such as telecommunications, information services, or health care, because subcontracting capacity represents an alternative to acquiring costly new capacity which may soon become obsolete or unnecessary. It is shown that the optimal price charged is based on the higher of the two operating costs incurred (internal unit cost or unit cost of subcontracting). It is also shown that as a consequence of subcontracting to maximize profit, the optimal price charged is never reduced and may increase. © 1994 John Wiley & Sons, Inc.     

Optimal control policies for an inventory system with commitment lead time

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

Nash bargaining over allocations in inventory pooling contracts

When facing uncertain demand, several firms may consider pooling their inventories leading to the emergence of two key contractual issues. How much should each produce or purchase for inventory purposes? How should inventory be allocated when shortages occur to some of the firms? Previously, if the allocations issue was considered, it was undertaken through evaluation of the consequences of an arbitrary priority scheme. We consider both these issues within a Nash bargaining solution (NBS) cooperative framework. The firms may not be risk neutral, hence a nontransferable utility bargaining game is defined. Thus the physical pooling mechanism itself must benefit the firms, even without any monetary transfers. The firms may be asymmetric in the sense of having different unit production costs and unit revenues. Our assumption with respect to shortage allocation is that a firm not suffering from a shortfall, will not be affected by any of the other firms' shortages. For two risk neutral firms, the NBS is shown to award priority on all inventory produced to the firm with higher ratio of unit revenue to unit production cost. Nevertheless, the arrangement is also beneficial for the other firm contributing to the total production. We provide examples of Uniform and Bernoulli demand distributions, for which the problem can be solved analytically. For firms with constant absolute risk aversion, the agreement may not award priority to any firm. Analytically solvable examples allow additional insights, e.g. that higher risk aversion can, for some problem parameters, cause an increase in the sum of quantities produced, which is not the case in a single newsvendor setting. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

An operator theory of parametric programming for the generalized transportation problem—IV—global operators

This paper investigates the effect of the optimal solution of a (capacitated) generalized transportation problem when the data of the problem (the rim conditions—i.e., the available time of machine types and demands of product types, the per unit production costs, the per unit production time and the upper bounds) are continuously varied as a linear function of a single parameter. Operators that effect the transformation of optimal solution associated with such data changes, are shown to be a product of basis preserving operators (described in our earlier papers) that operate on a sequence of adjacent basis structures. Algorithms are furnished for the three types of operators—rim, cost, and weight. The paper concludes with a discussion of the production and managerial interpretations of the operators and a comment on the “production paradox”.     

Periodic replacement with minimal repair at failure and adjustment costs

We investigate periodic replacement policies with minimal repair at failure, thereby, minimizing the average expected cost per unit time over an infinite time span. The standard cost structure is modified by the introduction of a term which takes adjustment costs into account.     

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.     

Allocation of quality improvement targets based on investments in learning

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

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     

Periodic inspection policy with preventive maintenance

This article considers a modified inspection policy with periodic check intervals, where the unit after check has the same age as before with probability p and is as good as new with probability q. The mean time to failure and the expected number of checks before failure are derived, forming renewal-type equations. The total expected cost and the expected cost per unit of time until detection of failure are obtained. Optimum inspection policies which minimize the expected costs are given as a numerical example.     

Three ways of obtaining the average cost expression in a problem related to joint replenishment inventory control

This paper does not present a new result, rather it is meant to illustrate the choice of modelling procedures available to an analyst in a typical inventory control problem. The same “average cost per unit time” expression is developed by three quite different procedures. This variety of approaches, as well as the recounting of the author's chronological efforts to solve the problem, should be of interest to the reader. The specific inventory problem studied is one where the controller of an item is faced with random opportunities for replenishment at a reduced setup cost; the problem is an integral component of the broader problem of inventory control of a group of items whose replenishments are coordinated to reduce the costs of production, procurement, and/or transportation.     

An operator theory of parametric programming for the transportation problem-I

This paper investigates the effect on the optimum solution of a (capacitated) transportation problem when the data of the problem (the rim conditions-i. e., the warehouse supplies and market demands-the per unit transportation costs and the upper bounds) are continuously varied as a (linear) function of a single parameter. An operator theory is developed and algorithms provided for applying rim and cost operators that effect the transformation of optimum solution associated with changes in rim conditions and unit costs. Bound operators that effect changes in upper bounds are shown to be equivalent to rim operators. The discussion in this paper is limited to basis preserving operators for which the changes in the data are such that the optimum basis structures are preserved.     

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