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.     

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.     

A time dependent continuous review inventory model with compound poisson demand

We discuss a time dependent optimal ordering policy for a finite horizon inventory system for which the provision of service is essential and thus no stockout is allowed. It is assumed that the system can place an order at any point in time during the horizon when it cannot meet the customer's demand and that lead time is negligible. The demand is considered to be distributed as a compound Poisson process with known parameters and the functional equation approach of dynamic programming is used to formulate the objective function. An algorithm has been developed to obtain the solution for all the cases. In addition, analytical solutions of the basic equation under two limiting conditions are presented.     

The effect of prior assumptions on the expected cost of m/m/1 queueing systems with unknown arrival rate

In this study we deal with the determination of optimal service rate in an M/M/1 queue. The arrival rate is unknown and assumed to be a random variable with a known distribution function. Holding and operating costs are considered and service rate is determined to minimize total expected discounted costs for infinite horizon. The effects of the arrival rate's distribution properties on the characteristics of the system are examined.     

Strong turnpike policies in the single-item capacitated lot-sizing problem with periodical dynamic parameter

This article considers optimization problems in a discrete capacitated lot sizing model for a single product with limited backlogging. The demand as well as the holding and backlogging costs are assumed to be periodical in time. Nothing is assumed about types of the cost functions. It is shown that there exists an optimal infinite inverse policy and a strong turnpike policy. A forward algorithm for computing optimal policies relative to the class of batch ordering type policies is derived. Some backward procedure is adopted to determine a strong turnpike policy. The algorithm is simple, and it terminates after the a number of steps equal to the turnpike horizon. Some remarks on the existence of rolling horizontal plans and forecast horizons are also given. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 775–790, 1997     

Scheduling peacetime rotation of Pakistan army units

Because Pakistan has varying climates and terrains, the Pakistan Army rotates its units between peacetime locations so that no unit endures inequitable hardship or enjoys unfair advantage. Army policy specifies strict constraints on unit rotations, such as the length of a unit's stay in any location, the number of units moving at any time, and the allowable replacements for any moving unit. Scheduling rotations manually in accordance with these rules, as is currently practiced, is extremely difficult and time consuming. This article presents an integer programming model that finds feasible, minimum-cost schedules for the Pakistan Army's desired planning horizons. The model also ensures that the units are positioned at the end of the planning horizon so that feasible schedules exist for future planners. The model is implemented with commercially available optimization software. Schedules are obtained for realistic test problems in less than an hour on a personal computer. © 1995 John Wiley & Sons, Inc.     

Optimal switchover times between two activities utilizing the same resource

The “gold‐mining” decision problem is concerned with the efficient utilization of a delicate mining equipment working in a number of different mines. Richard Bellman was the first to consider this type of a problem. The solution found by Bellman for the finite‐horizon, continuous‐time version of the problem with two mines is not overly realistic since he assumed that fractional parts of the same mining equipment could be used in different mines and this fraction could change instantaneously. In this paper, we provide some extensions to this model in order to produce more operational and realistic solutions. Our first model is concerned with developing an operational policy where the equipment may be switched from one mine to the other at most once during a finite horizon. In the next extension we incorporate a cost component in the objective function and assume that the horizon length is not fixed but it is the second decision variable. Structural properties of the optimal solutions are obtained using nonlinear programming. Each model and its solution is illustrated with a numerical example. The models developed here may have potential applications in other areas including production of items requiring the same machine or choosing a sequence of activities requiring the same resource. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 186–203, 2002; DOI 10.1002/nav.10008     

Concentrated firing in many-versus-many duels

A simple stochastic-duel model, based on alternate firing, is proposed. This model is shown to be asymptotically equivalent, for small hit probabilities, to other known models, such as simple and square duels. Alternate firing introduces an interaction between opponents and allows one to consider multiple duels. Conditions under which concentrated firing is better or worse than parallel firing are found by calculation and sometimes by simulation. The only parameters considered are the combat group sizes (all units within a group are assumed identical), the hit probabilities and the number of hits necessary to destroy an opposing unit.     

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.     

Optimal replacement of parts having observable correlated stages of deterioration

A single component system is assumed to progress through a finite number of increasingly bad levels of deterioration. The system with level i (0 ≤ i ≤ n) starts in state 0 when new, and is definitely replaced upon reaching the worthless state n. It is assumed that the transition times are directly monitored and the admissible class of strategies allows substitution of a new component only at such transition times. The durations in various deterioration levels are dependent random variables with exponential marginal distributions and a particularly convenient joint distribution. Strategies are chosen to maximize the average rewards per unit time. For some reward functions (with the reward rate depending on the state and the duration in this state) the knowledge of previous state duration provides useful information about the rate of deterioration.     

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.     

A comparative study of three tool replacement/operation sequencing strategies in a flexible manufacturing system

This paper studies three tool replacement/operation sequencing strategies for a flexible manufacturing system over a finite time horizon: (1) failure replacement—replace the tool only upon failure, (2) optimal preventive tool replacement for a fixed sequence of operations, and (3) joint scheduling of the optimal preventive tool replacement times and the optimal sequence of operations. Stochastic dynamic decision models are used for strategies 2 and 3. The optimization criterion for strategies 2 and 3 is the minimization of the total expected cost over the finite time horizon. We will show through numerical studies that, with the same amount of information, the total expected costs can be reduced considerably by choosing an optimal strategy. Our conclusion is that in flexible manufacturing, optimal tool replacement and optimal operations sequencing are not separate issues. They should be considered jointly to minimize the expected total cost. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 479–499, 2000     

Maintaining systems with heterogeneous spare parts

We consider the problem of optimally maintaining a stochastically degrading, single‐unit system using heterogeneous spares of varying quality. The system's failures are unannounced; therefore, it is inspected periodically to determine its status (functioning or failed). The system continues in operation until it is either preventively or correctively maintained. The available maintenance options include perfect repair, which restores the system to an as‐good‐as‐new condition, and replacement with a randomly selected unit from the supply of heterogeneous spares. The objective is to minimize the total expected discounted maintenance costs over an infinite time horizon. We formulate the problem using a mixed observability Markov decision process (MOMDP) model in which the system's age is observable but its quality must be inferred. We show, under suitable conditions, the monotonicity of the optimal value function in the belief about the system quality and establish conditions under which finite preventive maintenance thresholds exist. A detailed computational study reveals that the optimal policy encourages exploration when the system's quality is uncertain; the policy is more exploitive when the quality is highly certain. The study also demonstrates that substantial cost savings are achieved by utilizing our MOMDP‐based method as compared to more naïve methods of accounting for heterogeneous spares.     

Optimal resource extraction with uncertain reserves

We consider the problem of finding a plan that maximizes the expected discounted return when extracting a nonrenewable resource having uncertain reserves. An extraction plan specifies the rate at which the resource is extracted as a function of time until the resource is exhausted or the time horizon is reached. The return per unit of resource extracted may depend on the rate of extraction, time, and the amount of resource previously extracted. We apply a new method called the generalized search optimization technique to find qualitative features of optimal plans and to devise algorithms for the numerical calculation of optimal plans.     

Facility location when demand is time dependent

In this article we investigate the problem of locating a facility among a given set of demand points when the weights associated with each demand point change in time in a known way. It is assumed that the location of the facility can be changed one or more times during the time horizon. We need to find the time “breaks” when the location of the facility is to be changed, and the location of the facility during each time segment between breaks. We investigate the minisum Weber problem and also minimax facility location. For the former we show how to calculate the objective function for given time breaks and optimally solve the rectilinear distance problem with one time break and linear change of weights over time. Location of multiple time breaks is also discussed. For minimax location problems we devise two algorithms that solve the problem optimally for any number of time breaks and any distance metric. These algorithms are also applicable to network location problems.     

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.     

Stationary (s,s) policies for a finite horizon

In the finite-horizon stochastic (s, S) inventory model with periodic review the parameters of the optimal policy generally vary with the length of the horizon. A stationary policy, however, is easier to implement and may be easier to calculate. This paper studies optimal stationary policies for a finite horizon and relates them to optimal policies through their relation to optimal stationary policies for an infinite horizon.     

Control of entry to a nonstationary queuing system

In this article the control of entry of customers to a queuing system with s servers is considered. It is assumed that the arrivals form a nonstationary Poisson process with a periodic rate. The service times are assumed to be exponentially distributed with a parameter independent of time. The cost structure considered is the same as that of Naor. It is demonstrated numerically that, like the stationary cases, the average expected benefit of customers per unit of time is a unimodal function of the critical point. And, also, the social critical point is smaller than the individual critical point. These suggest the use of a search technique for finding the social critical point. The results show successful application of the discrete version of the Fibonacci search.     

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     

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.