Lot sizing when yields increase during the production run

We investigate the problem of determining lot sizes for multiple items when the expected percentage of acceptable output increases with the duration of the production run, usually due to adjustments made during the early part of the production run. Such problems arise in metal stamping, textile finishing processes, and a variety of other industries. The goal is to minimize the total cost of production, inventory holding costs, and setup costs (where applicable). We develop a heuristic procedure based on a Lagrangian relaxation that differs from relaxations used in earlier studies. We use various properties of the objective function to guide the adjustment of the initial solution from the relaxation toward feasibility. Computational results indicate that, on the average, the heuristic produces solutions within 4.9% of the lower bound obtained from the Lagrangian relaxation. © 1996 John Wiley & Sons, Inc.     

The economic lot scheduling problem with finite backorder costs

We are concerned with the problem of scheduling m items, facing constant demand rates, on a single facility to minimize the long-run average holding, backorder, and setup costs. The inventory holding and backlogging costs are charged at a linear time weighted rate. We develop a lower bound on the cost of all feasible schedules and extend recent developments in the economic lot scheduling problem, via time-varying lot sizes, to find optimal or near-optimal cyclic schedules. The resulting schedules are used elsewhere as target schedules when demands are random. © 1992 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.     

Production lot sizing under setup and worker learning

Previous lot-sizing models incorporating learning effects focus exclusively on worker learning. We extend these models to include the presence of setup learning, which occurs when setup costs exhibit a learning curve effect as a function of the number of lots produced. The joint worker/setup learning problem can be solved to optimality by dynamic programming. Computational experience indicates, however, that solution times are sensitive to certain problem parameters, such as the planning horizon and/or the presence of a lower bound on worker learning. We define a two-phase EOQ-based heuristic for the problem when total transmission of worker learning occurs. Numerical results show that the heuristic consistently generates solutions well within 1% of optimality.     

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.     

On a rational stopping rule for facilities location algorithms

In the multifacility location problem, a number of new facilities are to be located so as to minimize a sum of weighted distances. Recently, a lower bound on the optimal value was developed, for use in deciding when to stop an iterative solution procedure. We develop a stronger bound that allows some computational savings.     

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     

Resource allocation with lumpy demand: To speed or not to speed?

In the classical EPQ model with continuous and constant demand, holding and setup costs are minimized when the production rate is no larger than the demand rate. However, the situation may change when demand is lumpy. We consider a firm that produces multiple products, each having a unique lumpy demand pattern. The decision involves determining both the lot size for each product and the allocation of resources for production rate improvements among the products. We find that each product's optimal production policy will take on only one of two forms: either continuous production or lot‐for‐lot production. The problem is then formulated as a nonlinear nonsmooth knapsack problem among products determined to be candidates for resource allocation. A heuristic procedure is developed to determine allocation amounts. The procedure decomposes the problem into a mixed integer program and a nonlinear convex resource allocation problem. Numerical tests suggest that the heuristic performs very well on average compared to the optimal solution. Both the model and the heuristic procedure can be extended to allow the company to simultaneously alter both the production rates and the incoming demand lot sizes through quantity discounts. Extensions can also be made to address the case where a single investment increases the production rate of multiple products. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

An optimal procedure for the coordinated replenishment dynamic lot‐sizing problem with quantity discounts

We consider in this paper the coordinated replenishment dynamic lot‐sizing problem when quantity discounts are offered. In addition to the coordination required due to the presence of major and minor setup costs, a separate element of coordination made possible by the offer of quantity discounts needs to be considered as well. The mathematical programming formulation for the incremental discount version of the extended problem and a tighter reformulation of the problem based on variable redefinition are provided. These then serve as the basis for the development of a primal‐dual based approach that yields a strong lower bound for our problem. This lower bound is then used in a branch and bound scheme to find an optimal solution to the problem. Computational results for this optimal solution procedure are reported in the paper. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 686–695, 2000     

The dynamic transshipment problem

We investigate the strategy of transshipments in a dynamic deterministic demand environment over a finite planning horizon. This is the first time that transshipments are examined in a dynamic or deterministic setting. We consider a system of two locations which replenish their stock from a single supplier, and where transshipments between the locations are possible. Our model includes fixed (possibly joint) and variable replenishment costs, fixed and variable transshipment costs, as well as holding costs for each location and transshipment costs between locations. The problem is to determine how much to replenish and how much to transship each period; thus this work can be viewed as a synthesis of transshipment problems in a static stochastic setting and multilocation dynamic deterministic lot sizing problems. We provide interesting structural properties of optimal policies which enhance our understanding of the important issues which motivate transshipments and allow us to develop an efficient polynomial time algorithm for obtaining the optimal strategy. By exploring the reasons for using transshipments, we enable practitioners to envision the sources of savings from using this strategy and therefore motivate them to incorporate it into their replenishment strategies. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48:386–408, 2001     

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     

A robust policy for serial agile production systems

One of the major problems in modeling production systems is how to treat the job arrival process. Restrictive assumptions such as Markovian arrivals do not represent real world systems, especially if the arrival process is generated by job departures from upstream workstations. Under these circumstances, cost‐effective policies that are robust with respect to the nature of the arrival process become of interest. In this paper, we focus on minimizing the expected total holding and setup costs in a two‐stage produce‐to‐order production system operated by a cross‐trained worker. We will show that if setup times are insignificant in comparison with processing times, then near‐optimal policies can be generated with very robust performances with respect to the arrival process. We also present conditions under which these near‐optimal policies can be obtained by using only the arrival and service rates. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Cost analysis of pro rata and free-replacement warranties

This article examines the short run total costs and long run average costs of products under warranty. Formulae for both consumer cost under warranty and producer profit are derived. The results in the case of the pro rata warranty correct a mistake appearing in Blischke and Scheuer [5]. We also show that expected average cost to both the producer and the consumer of a product under warranty depends on both the mean of the product lifetime distribution and on its failure rate.     

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.     

Optimizing the quality control station configuration

We study unreliable serial production lines with known failure probabilities for each operation. Such a production line consists of a series of stations, existing machines, and optional quality control stations (QCSs). Our aim is to decide on the allocation of the QCSs within the assembly line, so as to maximize the expected profit of the system. In such a problem, the designer has to determine the QCS configuration and the production rate simultaneously. The profit maximization problem is approximated assuming exponentially distributed processing times, Poisson arrival process of jobs into the system, and the existing of holding costs. The novel feature of our model is the incorporation of holding costs that significantly complicated the problem. Our approximation approach uses a branch and bound strategy that employs our fast dynamic programming algorithm for minimizing the expected operational costs for a given production rate as a subroutine. Extensive numerical experiments are conducted to demonstrate the efficiency of the branch and bound procedure for solving large scale instances of the problem and for obtaining some qualitative insights.

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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 single-machine replacement model with learning

The replacement or upgrade of productive resources over time is an important decision for a manufacturing organization. The type of technology used in the productive resources determines how effectively the manufacturing operations can support the product and marketing strategy of the organization. Increasing operating costs (cost of maintenance, labor, and depreciation) over time force manufacturing organizations to periodically consider replacement or upgrade of their existing productive resources. We assume that there is a setup cost associated with the replacement of a machine, and that the setup cost is a nonincreasing function of the number of replacements made so far due to learning in setups. The operating cost of a newer machine is assumed to be lower than the operating cost of an older machine in any given period, except perhaps in the first period of operation of the new machine when the cost could be unusually high due to higher initial depreciation. A forward dynamic programming algorithm is developed which can be used to solve finite-horizon problems. We develop procedures to find decision and forecast horizons such that choices made during the decision horizon based only on information over the forecast horizon are also optimal for any longer horizon problem. Thus, we are able to obtain optimal results for what is effectively an infinite-horizon problem while only requiring data over a finite period of time. We present a numerical example to illustrate the decision/forecast horizon procedure, as well as a study of the effects of considering learning in making a series of machine replacement decisions. © 1993 John Wiley & Sons. Inc.     

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.     

One- and two-stage scheduling of two products with distributed inserted idle time: The benefits of a controllable production rate

Consider the problem of scheduling two products on a single machine or through two machines in series when demand is constant and there is a changeover cost between runs of different products on the same machine. As well as setting batch sizes, it is assumed that the production scheduler can choose the production rate for each product, provided an upper bound is not exceeded. This is equivalent to permitting distributed inserted idle time over the production run. It is shown that characteristic of the optimum schedule is that there is no idle time concentrated between runs; it is all distributed over the run. If the inventory charge is based on average inventory then one product is always produced at maximum rate on the bottleneck stage; however, if there is an inventory constraint based on maximum inventory then in the single-stage case it can occur that neither product is produced at maximum rate.     

Operations sequencing for a multi‐stage production inventory system

This article studies operations sequencing for a multi‐stage production inventory system with lead times under predictable (deterministic) yield losses and random demand. We consider various cases with either full or partial release of work‐in‐process inventories, for either pre‐operation or post‐operation cost structures, and under either the total discounted or average cost criteria. We derive necessary and sufficient criteria for the optimal sequence of operations in all cases. While the criteria differ in their specific forms, they all lead to the same principal: those operations with (1) lower yields, (2) lower processing costs, (3) longer lead times, and (4) lower inventory holding costs should be placed higher upstream in the system.Copyright © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 144–154, 2014