The initial provisioning decision for insurance type items

Initial provisioning decisions (inventory stocking requirements) for low demand items often have to be made without much knowledge of what future demand rates will be. When the nature of an item is such that little demand for it is expected, the problem of whether to stock initially or risk not stocking the item is most critical. This report discusses this problem and presents decision procedures which can be used to handle this aspect of initial provisioning. The procedures relate an item's provisioning desirability to its provisioning characteristics, such as expected cost, expected resupply time, current information on its likely demand rate, and to an overall operating policy or criterion. The criterion function measures the total system degredation as a function of the events of having items out of stock when demand occurs. Several different policy functions are discussed and the provisioning decision rules which apply to each are presented. Demand rate information is handled through a Bayesian type approach. The decision rules presented in this report can be utilized to either determine stocking requirements within a budgetary constraint, or determine the relative stocking desirability on an item-by-item basis.     

Optimization methods for large-scale multiechelon stockage problems

I examine the problem of determining inventory stockage levels and locations of different parts in a multiechelon system. This stockage problem is complicated by parts commonality—each part may be used by several different end items. Stockage levels and locations of each part affect the availability of end items that use the part, since an end item will be out of service if it requires a part that is not available. Of course, if the part is available at another nearby location, then the end item will be out of service for a shorter period of time. An essential feature of any model for this problem is constraints on operational availability of the end items. Because these constraints would involve nonconvex functions if the stockage levels were allowed to vary continuously, I formulate a 0–1 linear optimization model of the stockage problem. In this model, each part can be stocked at any of a number of prespecified levels at each echelon. The model is to minimize stockage cost of the selected items subject to the end-item availability constraints and limits on the total weight, volume, and number of different parts stocked at each echelon. Advantages and disadvantages of different Lagrangian relaxations and the simplex method with generalized upper-bounding capability are discussed for solving this stockage model.     

Optimal control of a production process subject to AOQL constraint

A production process which exhibits a decreasing pattern in the mean quality during the course of production is considered. A lower limit is specified for the quality characteristic of interest, and an item is classified as defective if its quality characteristic is below this lower limit. The major concern of the manufacturer is the average outgoing quality (AOQ). Hence, the process has to be adjusted after a time to avoid producing a large proportion of defective items due to deteriorating quality. To meet consumer specifications, an average outgoing quality limit (AOQL) is specified. A process-control scheme is developed in which decisions as to the upper and lower limit of the process mean are made based upon the choice of an AOQL. We discuss the decision problem of selecting the starting level of the process mean, and the level at which the process mean should be adjusted back to the starting level, so that the AOQ is not larger than AOQL. We consider a cost model which includes a fixed cost for adjustment, and a production cost which is assumed to be a function of the quality level. Due to the complexity of the model, a search procedure is used to find the optimal solution. In addition, an approximate solution which requires only simple calculations is developed, and is shown to be very effective in finding near-optimal solutions.     

Contract award analysis by mathematical programming

ABSTRACT A large manufacturer of telephone directories purchases about 100,000 tons of paper annually from several paper mills on the basis of competitive bids. The awards are subject to several constraints. The principal company constraint is that the paper must be purchased from at least three different suppliers. The principal external constraints are: 1) one large paper mill requires that if contracted to sell the company more than 50,000 tons of paper, it must be enabled to schedule production over the entire year; 2) the price of some bidders is based on the condition that their award must exceed a stipulated figure. The paper shows that an optimal purchasing program corresponds to the solution of a model which, but for a few constraints, is a linear programming formulation with special structure. The complete model is solved by first transforming it into an almost transportation type problem and then applying several well-known L.P. techniques.     

Multi-item service constrained (s,S) policies for spare parts logistics systems

Many organizations providing service support for products or families of products must allocate inventory investment among the parts (or, identically, items) that make up those products or families. The allocation decision is crucial in today's competitive environment in which rapid response and low levels of inventory are both required for providing competitive levels of customer service in marketing a firm's products. This is particularly important in high-tech industries, such as computers, military equipment, and consumer appliances. Such rapid response typically implies regional and local distribution points for final products and for spare parts for repairs. In this article we fix attention on a given product or product family at a single location. This single-location problem is the basic building block of multi-echelon inventory systems based on level-by-level decomposition, and our modeling approach is developed with this application in mind. The product consists of field-replaceable units (i.e., parts), which are to be stocked as spares for field service repair. We assume that each part will be stocked at each location according to an (s, S) stocking policy. Moreover, we distinguish two classes of demand at each location: customer (or emergency) demand and normal replenishment demand from lower levels in the multiechelon system. The basic problem of interest is to determine the appropriate policies (s_i S_i) for each part i in the product under consideration. We formulate an approximate cost function and service level constraint, and we present a greedy heuristic algorithm for solving the resulting approximate constrained optimization problem. We present experimental results showing that the heuristics developed have good cost performance relative to optimal. We also discuss extensions to the multiproduct component commonality problem.     

Customer delays in M/M/c repair systems with spares

A service center to which customers bring failed items for repair is considered. The items are exchangeable in the sense that a customer is ready to take in return for the failed item he brought to the center any good item of the same kind. This exchangeability feature makes it possible for the service center to possess spares. The focus of the article is on customer delay in the system—the time that elapses since the arrival of a customer with a failed item and his departure with a good one—when repaired items are given to waiting customers on a FIFO basis. An algorithm is developed for the computation of the delay distribution when the item repair system operates as an M/M/c queue.     

Coordinated replenishments of items under time-varying demand: Dynamic programming formulation

We consider a group (or family) of items having deterministic, but time-varying, demand patterns. The group is defined by a setup-cost structure that makes coordination attractive (a major setup cost for each group replenishment regardless of how many of the items are involved). The problem is to determine the timing and sizes of the replenishments of all of the items so as to satisfy the demand out to a given horizon in a cost-minimizing fashion. A dynamic programming formulation is illustrated for the case of a two-item family. It is demonstrated that the dynamic programming approach is computationally reasonable, in an operational sense, only for small family sizes. For large families heuristic solution methods appear necessary.     

基于Bayes理论的测试性数据融合评估技术

针对目前高可靠性产品测试性评估验证面临的样本量不足的问题,提出一种基于Bayes理论的内外场数据融合评估技术,并给出详细的内外场测试性数据收集方法及原则,利用某产品的试验数据对该方法进行了验证。该方法工程应用性强,可作为高可靠性产品测试性评估的依据。     

Renewal approximation to optimal order quantity for a class of continuous-review inventory systems

Using a wide range of demand distributions and parameter settings, we examine the performance of an easily computable order-quantity approximation for a class of continuous-review inventory systems under a compound-renewal demand process. The approximation is derived by using some asymptotic results from renewal theory. The emphasis is on the conditions for the accuracy of the approximation. We find that when the item is to be stocked, the approximation is practically the same as the optimal order quantity, provided that the batch-size coefficient of variation is ≦1. Otherwise, the ratio of setup (ordering) cost to mean interarrival time must be large enough, as prescribed by a simple condition derived in the article based on empirical considerations.     

A three-echelon,multi-item model for recoverable items

The main objective of this paper is to develop a mathematical model for a particular type of three-echelon inventory system. The proposed model is being used by the Air Force to evaluate inventory investment requirements for alternative logistic structures. The system we will model consists of a group of locations, called bases, and a central depot. The items of concern in our analysis are called recoverable items, that is, items that can be repaired when they fail. Furthermore, each item has a modular or hierarchical design. Briefly, the model is used to determine the stock levels at each location for each item so as to achieve optimum inventory-system performance for a given level of investment. An algorithm for the computation of stock levels for each item and location is developed and illustrated. Some of the ways the model can be used are illustrated with Air Force data.     

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.     

Locational tying of complementary retail items

We study a selling practice that we refer to as locational tying (LT), which seems to be gaining wide popularity among retailers. Under this strategy, a retailer “locationally ties” two complementary items that we denote by “primary” and “secondary.” The retailer sells the primary item in an appropriate “department” of his or her store. To stimulate demand, the secondary item is offered in the primary item's department, where it is displayed in very close proximity to the primary item. We consider two variations of LT: In the multilocation tying strategy (LT‐M), the secondary item is offered in its appropriate department in addition to the primary item's department, whereas in the single‐location tying strategy (LT‐S), it is offered only in the primary item's location. We compare these LT strategies to the traditional independent components (IC) strategy, in which the two items are sold independently (each in its own department), but the pricing/inventory decisions can be centralized (IC‐C) or decentralized (IC‐D). Assuming ample inventory, we compare and provide a ranking of the optimal prices of the four strategies. The main insight from this comparison is that relative to IC‐D, LT decreases the price of the primary item and adjusts the price of the secondary item up or down depending on its popularity in the primary item's department. We also perform a comparative statics analysis on the effect of demand and cost parameters on the optimal prices of various strategies, and identify the conditions that favor one strategy over others in terms of profitability. Then we study inventory decisions in LT under exogenous pricing by developing a model that accounts for the effect of the primary item's stock‐outs on the secondary item's demand. We find that, relative to IC‐D, LT increases the inventory level of the primary item. We also link the profitability of different strategies to the trade‐off between the increase in demand volume of the secondary item as a result of LT and the potential increase in inventory costs due to decentralizing the inventory of the secondary item. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

On the effectiveness of top‐down strategy for forecasting autoregressive demands

We investigate the relative effectiveness of top‐down versus bottom‐up strategies for forecasting the demand of an item that belongs to a product family. The demand for each item in the family is assumed to follow a first‐order univariate autoregressive process. Under the top‐down strategy, the aggregate demand is forecasted by using the historical data of the family demand. The demand forecast for the items is then derived by proportional allocation of the aggregate forecast. Under the bottom‐up strategy, the demand forecast for each item is directly obtained by using the historical demand data of the particular item. In both strategies, the forecasting technique used is exponential smoothing. We analytically evaluate the condition under which one forecasting strategy is preferred over the other when the lag‐1 autocorrelation of the demand time series for all the items is identical. We show that when the lag‐1 autocorrelation is smaller than or equal to 1/3, the maximum difference in the performance of the two forecasting strategies is only 1%. However, if the lag‐1 autocorrelation of the demand for at least one of the items is greater than 1/3, then the bottom‐up strategy consistently outperforms the top‐down strategy, irrespective of the items' proportion in the family and the coefficient of correlation between the item demands. A simulation study reveals that the analytical findings hold even when the lag‐1 autocorrelation of the demand processes is not identical. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007.     

The parallel replacement problem with demand and capital budgeting constraints

A generalized parallel replacement problem is considered with both fixed and variable replacement costs, capital budgeting, and demand constraints. The demand constraints specify that a number of assets, which may vary over time, are required each period over a finite horizon. A deterministic, integer programming formulation is presented as replacement decisions must be integer. However, the linear programming relaxation is shown to have integer extreme points if the economies of scale binary variables are fixed. This allows for the efficient computation of large parallel replacement problems as only a limited number of 0–1 variables are required. Examples are presented to provide insight into replacement rules, such as the “no‐splitting‐rule” from previous research, under various demand scenarios. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 40–56, 2000     

The stochastic joint replenishment problem: A new policy,analysis, and insights

In this study, we propose a new parsimonious policy for the stochastic joint replenishment problem in a single‐location, N‐item setting. The replenishment decisions are based on both group reorder point‐group order quantity and the time since the last decision epoch. We derive the expressions for the key operating characteristics of the inventory system for both unit and compound Poisson demands. In a comprehensive numerical study, we compare the performance of the proposed policy with that of existing ones over a standard test bed. Our numerical results indicate that the proposed policy dominates the existing ones in 100 of 139 instances with comparably significant savings for unit demands. With batch demands, the savings increase as the stochasticity of demand size gets larger. We also observe that it performs well in environments with low demand diversity across items. The inventory system herein also models a two‐echelon setting with a single item, multiple retailers, and cross docking at the upper echelon. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Queueing models for spares provisioning

A population of items which break down at random times and require repair is studied (the classic “machine repair problem with spares”). It is desired to determine the number of repair channels and spares required over a multiyear planning horizon in which population size and component reliability varies, and a service level constraint is imposed. When an item fails, a spare (if available) is immediately dispatched to replace the failed item. The failed item is removed, transported to the repair depot, repaired, and then placed in the spares pool (which is constrained to be empty not more than 10% of the time) unless there is a backlog of requests for spares, in which case it is dispatched immediately. The first model considered treats removal, transportation, and repair as one service operation. The second model is a series queue which allows for the separate treatment of removal, transportation, and repair. Breakdowns are assumed Poisson and repair times exponential.     

Group testing procedures with quantitative features and incomplete identification

We present a group testing model for items characterized by marker random variables. An item is defined to be good (defective) if its marker is below (above) a given threshold. The items can be tested in groups; the goal is to obtain a prespecified number of good items by testing them in optimally sized groups. Besides this group size, the controller has to select a threshold value for the group marker sums, and the target number of groups which by the tests are classified to consist only of good items. These decision variables have to be chosen so as to minimize a cost function, which is a linear combination of the expected number of group tests and an expected penalty for missing the desired number of good items, subject to constraints on the probabilities of misclassifications. We treat two models of this kind: the first one is based on an infinite population size, whereas the second one deals with the case of a finite number of available items. All performance measures are derived in closed form; approximations are also given. Furthermore, we prove monotonicity properties of the components of the objective function and of the constraints. In several examples, we study (i) the dependence of the cost function on the decision variables and (ii) the dependence of the optimal values of the decision variables (group size, group marker threshold, and stopping rule for groups classified as clean) and of the target functionals (optimal expected number of tests, optimal expected penalty, and minimal expected cost) on the system parameters.© 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

The inventory packing problem

We study the problem of finding the minimum number of identical storage areas required to hold n items for which demand is known and constant. The replenishments of the items within a single storage area may be time phased so as to minimize the maximum total storage capacity required at any time. This is the inventory-packing problem, which can be considered as a variant of the well-known bin-packing problem, where one constraint is nonlinear. We study the worst-case performance of six heuristics used for that earlier problem since the recognition version of the inventory-packing problem is shown to be NP complete. In addition, we describe several new heuristics developed specifically for the inventory-packing problem, and also study their worst-case performance. Any heuristic which only opens a bin when an item will not fit in any (respectively, the last) open bin needs, asymptotically, no more than 25/12 (resp., 9/4) times the optimal number of bins. Improved performance bounds are obtainable if the range from which item sizes are taken is known to be restricted. Extensive computational testing indicates that the solutions delivered by these heuristics are, for most problems, very close to optimal in value.     

The single and multi‐item transshipment problem with fixed transshipment costs

This article deals with supply chain systems in which lateral transshipments are allowed. For a system with two retailers facing stochastic demand, we relax the assumption of negligible fixed transshipment costs, thus, extending existing results for the single‐item case and introducing a new model with multiple items. The goal is to determine optimal transshipment and replenishment policies, such that the total centralized expected profit of both retailers is maximized. For the single‐item problem with fixed transshipment costs, we develop optimality conditions, analyze the expected profit function, and identify the optimal solution. We extend our analysis to multiple items with joint fixed transshipment costs, a problem that has not been investigated previously in the literature, and show how the optimality conditions may be extended for any number of items. Due to the complexity involved in solving these conditions, we suggest a simple heuristic based on the single‐item results. Finally, we conduct a numerical study that provides managerial insights on the solutions obtained in various settings and demonstrates that the suggested heuristic performs very well. © 2014 Wiley Periodicals, Inc. Naval Research Logistics, 61: 637–664, 2014     

Optimal design of a multi-item,multi-location,multi-repair type repair and supply system

The design of a system with many locations, each with many items which may fail while in use, is considered. When items fail, they require repair; the particular type of repair being governed by a probability distribution. As repairs may be lengthy, spares are kept on hand to replace failed items. System ineffectiveness is measured by expected weighted shortages over all items and locations, in steady state. This can be reduced by either having more spares or shorter expected repair times. Design consists of a provisioning of the number of spares for each item, by location; and specifying the expected repair times for each type of repair, by item and location. The optimal design minimizes expected shortages within a budget constraint, which covers both (i) procurement of spares and (ii) procurement of equipment and manning levels for the repair facilities. All costs are assumed to be separable so that a Lagrangian approach is fruitful, yielding an implementable algorithm with outputs useful for sensitivity analysis. A numerical example is presented.