Multiperiod resource allocation with a smoothing objective

We consider a multiperiod resource allocation problem, where a single resource is allocated over a finite planning horizon of T periods. Resource allocated to one period can be used to satisfy demand of that period or of future periods, but backordering of demand is not allowed. The objective is to allocate the resource as smoothly as possible throughout the planning horizon. We present two models: the first assumes that the allocation decision variables are continuous, whereas the second considers only integer allocations. Applications for such models are found, for example, in subassembly production planning for complex products in a multistage production environment. Efficient algorithms are presented to find optimal allocations for these models at an effort of O(T²). Among all optimal policies for each model, these algorithms find the one that carries the least excess resources throughout the planning horizon. © 1995 John Wiley & Sons, Inc.     

Production planning for multi-resource network systems

Production planning for large-scale production systems requiring the allocation of numerous resources is considered. It is demonstrated how the dynamic activity analysis developed by Shephard leads to linear programming solutions of production planning problems. Three types of planning problems are formulated: maximization of output levels for a given time horizon; minimization of production duration for given output histories; and minimization of production costs for given output histories.     

Cyclical schedules for the joint replenishment problem with dynamic demands

The Joint Replenishment Problem (JRP) involves production planning for a family of items. The items have a coordinated cost structure whereby a major setup cost is incurred whenever any item in the family is produced, and an item-specific minor setup cost is incurred whenever that item is produced. This paper investigates the performance of two types of cyclical production schedules for the JRP with dynamic demands over a finite planning horizon. The cyclical schedules considered are: (1) general cyclical schedules—schedules where the number of periods between successive production runs for any item is constant over the planning horizon—and (2) power-of-two schedules—a subset of cyclical schedules for which the number of periods between successive setups must be a power of 2. The paper evaluates the additional cost incurred by requiring schedules to be cyclical, and identifies problem characteristics that have a significant effect on this additional cost. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 577–589, 1997.     

Scheduling maintenance and semiresumable jobs on a single machine

The majority of scheduling literature assumes that the machines are available at all times. In this paper, we study single machine scheduling problems where the machine maintenance must be performed within certain intervals and hence the machine is not available during the maintenance periods. We also assume that if a job is not processed to completion before the machine is stopped for maintenance, an additional setup is necessary when the processing is resumed. Our purpose is to schedule the maintenance and jobs to minimize some performance measures. The objective functions that we consider are minimizing the total weighted job completion times and minimizing the maximum lateness. In both cases, maintenance must be performed within a fixed period T, and the time for the maintenance is a decision variable. In this paper, we study two scenarios concerning the planning horizon. First, we show that, when the planning horizon is long in relation to T, the problem with either objective function is NP-complete, and we present pseudopolynomial time dynamic programming algorithms for both objective functions. In the second scenario, the planning horizon is short in relation to T. However, part of the period T may have elapsed before we schedule any jobs in this planning horizon, and the remaining time before the maintenance is shorter than the current planning horizon. Hence we must schedule one maintenance in this planning horizon. We show that the problem of minimizing the total weighted completion times in this scenario is NP-complete, while the shortest processing time (SPT) rule and the earliest due date (EDD) rule are optimal for the total completion time problem and the maximum lateness problem respectively. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 845–863, 1999     

Cost allocation of capacity investment games

Consider a manufacturer serving a set of retail stores each of which faces deterministic demands in a finite planning horizon. At the beginning of the planning horizon, the production capacity of the manufacturer is built, followed by production, outsourcing to third party manufacturers if necessary and distribution to the retail stores. Because the retail stores are usually managed by different managers who act as independent profit centers, it is desirable that the total cost is divided among the retail stores so that their incentives can be appropriately captured and thus efficient operations can be achieved. Under various conditions, we prove that there is a fair allocation of costs among the retail stores in the sense that no subset of retail stores subsidizes others, or equivalently, the resulting capacity investment game has a nonempty core, that is, the capacity investment game is a balanced game. In addition, our proof provides a mechanism to compute a fair cost allocation. © 2013 Wiley Periodicals, Inc. Naval Research Logistics 60: 512–523, 2013     

Minimal forecast horizon procedures for dynamic lot size models

This article presents new results which should be useful in finding production decisions while solving the dynamic lot sizing problem of Wagner–Whitin on a rolling horizon basis. In a rolling horizon environment, managers obtain decisions for the first period (or the first few periods) by looking at the forecasts for several periods. This article develops procedures to find optimal decisions for any specified number of initial periods (called planning horizon in the article) by using the forecast data for the minimum possible number of future periods. Computational results comparing these procedures with the other procedures reported in the literature are very encouraging.     

Planning horizon procedures for machine replacement models with several possible replacement alternatives

This paper develops a forward algorithm and planning horizon procedures for an important machine replacement model where it is assumed that the technological environment is improving over time and that the machine-in-use can be replaced by any of the several different kinds of machines available at that time. The set of replacement alternatives may include (i) new machines with different types of technologies such as labor- and capital- intensive, (ii) used machines, (iii) repairs and/or improvements which affect the performance characteristics of the existing machine, and so forth. The forward dynamic programming algorithm in the paper can be used to solve a finite horizon problem. The planning horizon results give a procedure to identify the forecast horizon T such that the optimal replacement decision for the first machine based on the forecast of machine technology until period T remains optimal for any problem with horizon longer than T and, for that matter, for the infinite horizon problem. A flow chart and a numerical example have been included to illustrate the algorithm.     

Risk‐sensitive sizing of responsive facilities

We develop a risk‐sensitive strategic facility sizing model that makes use of readily obtainable data and addresses both capacity and responsiveness considerations. We focus on facilities whose original size cannot be adjusted over time and limits the total production equipment they can hold, which is added sequentially during a finite planning horizon. The model is parsimonious by design for compatibility with the nature of available data during early planning stages. We model demand via a univariate random variable with arbitrary forecast profiles for equipment expansion, and assume the supporting equipment additions are continuous and decided ex‐post. Under constant absolute risk aversion, operating profits are the closed‐form solution to a nontrivial linear program, thus characterizing the sizing decision via a single first‐order condition. This solution has several desired features, including the optimal facility size being eventually decreasing in forecast uncertainty and decreasing in risk aversion, as well as being generally robust to demand forecast uncertainty and cost errors. We provide structural results and show that ignoring risk considerations can lead to poor facility sizing decisions that deteriorate with increased forecast uncertainty. Existing models ignore risk considerations and assume the facility size can be adjusted over time, effectively shortening the planning horizon. Our main contribution is in addressing the problem that arises when that assumption is relaxed and, as a result, risk sensitivity and the challenges introduced by longer planning horizons and higher uncertainty must be considered. Finally, we derive accurate spreadsheet‐implementable approximations to the optimal solution, which make this model a practical capacity planning tool.© 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Coping with shortages caused by disruptive events in automobile supply chains

Unpredictable disruptive events significantly increase the difficulty of the management of automobile supply chains. In this paper, we propose an automobile production planning problem with component chips substitution in a finite planning horizon. The shortage of one chip can be compensated by another chip of the same type with a higher-end feature at an additional cost. Therefore, the automobile manufacturer can divert the on-hand inventory of chips to product lines that are more profitable in the event of shortages caused by supply chain disruptions. To cope with this, we propose a max-min robust optimization model that captures the uncertain supplies of chips. We show that the robust model has a mixed-integer programming equivalence that can be solved by a commercial IP solver directly. We compare the max-min robust model with the corresponding deterministic and two-stage stochastic models for the same problem through extensive numerical experiments. The computational results show that the max-min robust model outperforms the other two models in terms of the average and worst-case profits.     

Heuristic procedure for a multiproduct dynamic lot-sizing problem with coordinated replenishments

In this article we develop a heuristic procedure for a multiproduct dynamic lot-sizing problem. In this problem a joint setup cost is incurred when at least one product is ordered in a period. In addition to the joint setup cost a separate setup cost for each product ordered is also incurred. The objective is to determine the product lot sizes, over a finite planning horizon, that will minimize the total relevant cost such that the demand in each period for each product is satisfied without backlogging. In this article we present an effective heuristic procedure for this problem. Computational results for the heuristic procedure are also reported. Our computational experience leads us to conclude that the heuristic procedure may be of considerable value as a decision-making aid to production planners in a real-world setting. © 1994 John Wiley & Sons, Inc.     

The capital supply curve in capacity expansion models: Some economic and algorithmic aspects

Capacity expansion models typically minimize the discounted cost of acquisition and operation over a given planning horizon. In this article we generalize this idea to one in which a capital supply curve replaces the usual discount rate. A capital supply curve is a means to model financial outlook, investment limits, and risk. We show that when such a curve is included in a capacity expansion model, it will, under certain conditions, provide a less capital intensive solution than one which incorporates a discount rate. In this article, we also provide an algorithm that solves capacity expansion models that incorporate a capital supply curve. The attractive feature of this algorithm is that it provides a means to utilize the “discount rate” models efficiently. Throughout, we give applications in power generation planning and computational experience for this application is also presented.     

Longitudinal manpower planning models

A manpower planning model is presented that exploits the longitudinal stability of manpower cohorts. The manpower planning process is described. An infinite horizon linear program for calculating minimum cost manpower input plans is presented and found to have a straightforward solution in a great many cases and to yield an easily implemented approximation technique in other cases.     

Competition under time‐varying demands and dynamic lot sizing costs

We develop a competitive pricing model which combines the complexity of time‐varying demand and cost functions and that of scale economies arising from dynamic lot sizing costs. Each firm can replenish inventory in each of the T periods into which the planning horizon is partitioned. Fixed as well as variable procurement costs are incurred for each procurement order, along with inventory carrying costs. Each firm adopts, at the beginning of the planning horizon, a (single) price to be employed throughout the horizon. On the basis of each period's system of demand equations, these prices determine a time series of demands for each firm, which needs to service them with an optimal corresponding dynamic lot sizing plan. We establish the existence of a price equilibrium and associated optimal dynamic lotsizing plans, under mild conditions. We also design efficient procedures to compute the equilibrium prices and dynamic lotsizing plans.© 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Capacity expansion and cost efficiency improvement in the warehouse problem

The warehouse problem with deterministic production cost, selling prices, and demand was introduced in the 1950s and there is a renewed interest recently due to its applications in energy storage and arbitrage. In this paper, we consider two extensions of the warehouse problem and develop efficient computational algorithms for finding their optimal solutions. First, we consider a model where the firm can invest in capacity expansion projects for the warehouse while simultaneously making production and sales decisions in each period. We show that this problem can be solved with a computational complexity that is linear in the product of the length of the planning horizon and the number of capacity expansion projects. We then consider a problem in which the firm can invest to improve production cost efficiency while simultaneously making production and sales decisions in each period. The resulting optimization problem is non‐convex with integer decision variables. We show that, under some mild conditions on the cost data, the problem can be solved in linear computational time. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 367–373, 2016     

Bounded flexibility in days‐on and days‐off scheduling

This article presents a flexible days‐on and days‐off scheduling problem and develops an exact branch and price (B&P) algorithm to find solutions. The main objective is to minimize the size of the total workforce required to cover time‐varying demand over a planning horizon that may extend up to 12 weeks. A new aspect of the problem is the general restriction that the number of consecutive days on and the number of consecutive days off must each fall within a predefined range. Moreover, the total assignment of working days in the planning horizon cannot exceed some maximum value. In the B&P framework, the master problem is stated as a set covering‐type problem whose columns are generated iteratively by solving one of three different subproblems. The first is an implicit model, the second is a resource constrained shortest path problem, and the third is a dynamic program. Computational experiments using both real‐word and randomly generated data show that workforce reductions up to 66% are possible with highly flexible days‐on and days‐off patterns. When evaluating the performance of the three subproblems, it was found that each yielded equivalent solutions but the dynamic program proved to be significantly more efficient. © 2013 Wiley Periodicals, Inc. Naval Research Logistics 60: 678–701, 2013     

Formulations for dynamic lot sizing with service levels

In this article, we study deterministic dynamic lot‐sizing problems with a service‐level constraint on the total number of periods in which backlogs can occur over a finite planning horizon. We give a natural mixed integer programming formulation for the single item problem (LS‐SL‐I) and study the structure of its solution. We show that an optimal solution to this problem can be found in \begin{align*}\mathcal O(n^2\kappa)\end{align*} time, where n is the planning horizon and \begin{align*}\kappa=\mathcal O(n)\end{align*} is the maximum number of periods in which demand can be backlogged. Using the proposed shortest path algorithms, we develop alternative tight extended formulations for LS‐SL‐I and one of its relaxations, which we refer to as uncapacitated lot sizing with setups for stocks and backlogs. {We show that this relaxation also appears as a substructure in a lot‐sizing problem which limits the total amount of a period's demand met from a later period, across all periods.} We report computational results that compare the natural and extended formulations on multi‐item service‐level constrained instances. © 2013 Wiley Periodicals, Inc. Naval Research Logistics, 2013     

A planning horizon algorithm for deterministic inventory management with piecewise linear concave costs

We consider a single-product, discrete-time production/inventory-control problem with nonstationary concave nondecreasing costs. Given a forecast horizon K, the problem is to find a decision horizon. We specialize to piecewise linear costs a general approach whereby a problem with horizon K + 1 and arbitrary final demand is parametrically solved. The resulting algorithm is polynomial in the input size.     

On the optimality of the bayes prediction policy in two-echelon multistation inventory models

The present paper provides a proof that the Bayes prediction ordering policy developed in [3] is an optimal policy, in the sense that it minimizes the total expected discounted cost of ordering for any finite planning horizon.     

Multiperiod capacity expansion and shipment planning with linear costs

In this paper we consider a multiperiod deterministic capacity expansion and shipment planning problem for a single product. The product can be manufactured in several producing regions and is required in a number of markets. The demands for each of the markets are non-decreasing over time and must be met exactly during each time period (i.e., no backlogging or inventorying for future periods is permitted). Each region is assumed to have an initial production capacity, which may be increased at a given cost in any period. The demand in a market can be satisfied by production and shipment from any of the regions. The problem is to find a schedule of capacity expansions for the regions and a schedule of shipments from the regions to the markets so as to minimize the discounted capacity expansion and shipment costs. The problem is formulated as a linear programming model, and solved by an efficient algorithm using the operator theory of parametric programming for the transporation problem. Extensions to the infinite horizon case are also provided.