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.     

Stepwise inspection in Bayesian multiattribute acceptance sampling

Bayesian models for multiattribute acceptance sampling have been developed under the assumption that sampling inspection is carried to completion. A Bayesian multiattribute model for stepwise sampling inspection is proposed, whereby sampling inspection is terminated as soon as the disposition of the inspection lot is determined. An iterative solution procedure is developed for obtaining optimal or near-optimal multiattribute acceptance sampling plans under stepwise sampling inspection. The effect of stepwise sampling inspection on the characteristics of an optimal sampling plan is investigated. It is shown that stepwise sampling inspection achieves a sampling plan with lower total expected cost than complete sampling inspection. In addition, it is shown that the sequence of attributes in a stepwise sampling inspection substantially affects the sampling plan and resultant expected cost. The proposed methodology is used to evaluate various heuristics which may be used to determine the sequence of attributes in a stepwise inspection procedure.     

Suboptimality of equal lot sizes for finite-horizon problems

We consider the problem of determining optimal lot sizes in continuous time for finite-horizon problems with stationary parameters. Using the average cost criterion, earlier researchers concluded that the optimal lot sizes should be equal. Using the conceptually rigorous discounted cash flow analysis, we show that equal lot sizes are optimal only when the finite horizon is an integral multiple of the optimal reorder interval for the infinite-horizon problem or, trivially, when the discount rate is zero. In all other cases, optimal lot sizes are either monotonically increasing or decreasing. Our characterization of the optimal policy is also useful in determining optimal lot sizes. © 1994 John Wiley & Sons, Inc.     

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     

Application of perturbation analysis to a class of periodic review (s,S) inventory systems

In this article we apply perturbation analysis (PA), combined with conditional Monte Carlo, to obtain derivative estimators of the expected cost per period with respect to s and S, for a class of periodic review (s, S) inventory systems with full backlogging, linear holding and shortage costs, and where the arrivals of demands follow a renewal process. We first develop the general form of four different estimators of the gradient for the finite-horizon case, and prove that they are unbiased. We next consider the problem of implementing our estimators, and develop efficient methodologies for the infinite-horizon case. For the case of exponentially distributed demand interarrival times, we implement our estimators using a single sample path. Generally distributed interarrival times are modeled as phase-type distributions, and the implementation of this more general case requires a number of additional off-line simulations. The resulting estimators are still efficient and practical, provided that the number of phases is not too large. We conclude by reporting the results of simulation experiments. The results provide further validity of our methodology and also indicate that our estimators have very low variance. © 1994 John Wiley & Sons, Inc.     

A multi-item EOQ model with inventory cycle balancing

This article concerns a multi-item, infinite-horizon, lot-sizing problem, where the objective is to minimize a total cost function made up of reordering cost, holding cost, and a cost determined by peak inventory levels. By spreading inventory replenishments over the reordering cycle, the peak inventory level can be reduced. The model permits the derivation of simultaneously optimal solutions for the length of the cycle and the individual item replenishment times within the cycle. An alternative formulation, in which total storage capacity is modeled as a constraint, is also solved.     

Global planning of accelerated degradation tests based on exponential dispersion degradation models

The accelerated degradation test (ADT) is an efficient tool for assessing the lifetime information of highly reliable products. However, conducting an ADT is very expensive. Therefore, how to conduct a cost-constrained ADT plan is a great challenging issue for reliability analysts. By taking the experimental cost into consideration, this paper proposes a semi-analytical procedure to determine the total sample size, testing stress levels, the measurement frequencies, and the number of measurements (within a degradation path) globally under a class of exponential dispersion degradation models. The proposed method is also extended to determine the global planning of a three-level compromise plan. The advantage of the proposed method not only provides better design insights for conducting an ADT plan, but also provides an efficient algorithm to obtain a cost-constrained ADT plan, compared with conventional optimal plans by grid search algorithms.     

Optimal search plan minimizing the expected risk of the search for a target with conditionally deterministic motion

This article deals with a search problem for a moving target with a rather simple type of motion called factorable conditionally deterministic. A search plan is characterized by (ϕ, T), the elements of which specify how to search and when to stop the search, respectively. The problem is to find the optimal search plan which minimizes the expected risk (the expected search cost minus the expected reward). We obtain conditions for the optimal search plan, and applying the theorems, we derive the optimal search plan in a closed form for the case in which the target moves straight from a fixed point selecting his course and speed randomly.     

Solving the multiperiod assignment problem with start-up costs using dual ascent

In this article we consider a multiperiod assignment problem where the assignment cost of assigning job i to machine j varies from one time period to the next. A start-up cost is incurred whenever the job processed by a machine in the current time period is different from the one processed in the previous time period. This problem is modeled as an integer programming problem for which a dual ascent approximate procedure is developed. Our computational results show that our procedure outperforms the more common Lagrangian-relaxation-based subgradient procedure by a significant margin. It is also found to be faster than MPSX/370 by many orders of magnitude. © 1993 John Wiley & Sons, Inc.     

Acceptance sampling,imperfect production,and the optimality of zero defects

Acceptance sampling is often used to monitor the quality of raw materials and components when product testing is destructive, time-consuming, or expensive. In this paper we consider the effect of a buyer-imposed acceptance sampling policy on the optimal batch size and optimal quality level delivered by an expected cost minimizing supplier. We define quality as the supplier's process capability, i.e., the probability that a unit conforms to all product specifications, and we assume that unit cost is an increasing function of the quality level. We also assume that the supplier faces a known and constant “pass-through” cost, i.e., a fixed cost per defective unit passed on to the buyer. We show that the acceptance sampling plan has a significant impact on the supplier's optimal quality level, and we derive the conditions under which zero defects (100% conformance) is the policy that minimizes the supplier's expected annual cost. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 515–530, 1997     

A risk function for the stochastic modeling of electric capacity expansion

We present a stochastic optimization model for planning capacity expansion under capacity deterioration and demand uncertainty. The paper focuses on the electric sector, although the methodology can be used in other applications. The goals of the model are deciding which energy types must be installed, and when. Another goal is providing an initial generation plan for short periods of the planning horizon that might be adequately modified in real time assuming penalties in the operation cost. Uncertainty is modeled under the assumption that the demand is a random vector. The cost of the risk associated with decisions that may need some tuning in the future is included in the objective function. The proposed scheme to solve the nonlinear stochastic optimization model is Generalized Benders' decomposition. We also exploit the Benders' subproblem structure to solve it efficiently. Computational results for moderate‐size problems are presented along with comparison to a general‐purpose nonlinear optimization package. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48:662–683, 2001     

Disruption management in production planning

We study the problem of recovering a production plan after a disruption, where the disruption may be caused by incidents such as power failure, market change, machine breakdown, supply shortage, worker no‐show, and others. The new recovery plan we seek after has to not only suit the changed environment brought about by the disruption, but also be close to the initial plan so as not to cause too much customer unsatisfaction or inconvenience for current‐stage and downstream operations. For the general‐cost case, we propose a dynamic programming method for the problem. For the convex‐cost case, a general problem which involves both cost and demand disruptions can be solved by considering the cost disruption first and then the demand disruption. We find that a pure demand disruption is easy to handle; and for a pure cost disruption, we propose a greedy method which is provably efficient. Our computational studies also reveal insights that will be helpful to managing disruptions in production planning. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Optimal job splitting on a multi‐slot machine with applications in the printing industry

In this article, we define a scheduling/packing problem called the Job Splitting Problem, motivated by the practices in the printing industry. There are n types of items to be produced on an m‐slot machine. A particular assignment of the types to the slots is called a “run” configuration and requires a setup cost. Once a run begins, the production continues according to that configuration and the “length” of the run represents the quantity produced in each slot during that run. For each unit of production in excess of demand, there is a waste cost. Our goal is to construct a production plan, i.e., a set of runs, such that the total setup and waste cost is minimized. We show that the problem is strongly NP‐hard and propose two integer programming formulations, several preprocessing steps, and two heuristics. We also provide a worst‐case bound for one of the heuristics. Extensive tests on real‐world and randomly generated instances show that the heuristics are both fast and effective, finding near‐optimal solutions. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Dynamic lot‐sizing model with production time windows

We consider a dynamic lot‐sizing model with production time windows where each of n demands has earliest and latest production due dates and it must be satisfied during the given time window. For the case of nonspeculative cost structure, an O(nlogn) time procedure is developed and it is shown to run in O(n) when demands come in the order of latest production due dates. When the cost structure is somewhat general fixed plus linear that allows speculative motive, an optimal procedure with O(T⁴) is proposed where T is the length of a planning horizon. Finally, for the most general concave production cost structure, an optimal procedure with O(T⁵) is designed. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

A note on parallel machine replacement

Jones, Zydiak, and Hopp [1] consider the parallel machine replacement problem (PMRP), in which there are both fixed and variable costs associated with replacing machines. Increasing maintenance cost motivates replacements, and a fixed replacement cost provides incentive for replacing machines of the same age in clusters. They prove two intuitive but important results for finite- or infinite-horizon PMRPs, which significantly reduce the size of the linear programming (LP) formulation of the problem and computing efforts required to obtain an optimal replacement policy. Their results are the no-splitting rule (NSR) and the older cluster replacement rule (OCRR). Under a slightly weaker set of assumptions, we prove a third rule, the all-or-none rule (AONR), which states that in any period, an optimal policy is to keep or to replace all the machines regardless of age. This result further reduces the size of the LP formulation of the PMRP. © 1993 John Wiley & Sons, Inc.     

Continuous-time markov decision processes with nonzero terminal reward

In this article we consider a continuous-time Markov decision process with a denumerable state space and nonzero terminal rewards. We first establish the necessary and sufficient optimality condition without any restriction on the cost functions. The necessary condition is derived through the Pontryagin maximum principle and the sufficient condition, by the inherent structure of the problem. We introduce a dynamic programming approximation algorithm for the finite-horizon problem. As the time between discrete points decreases, the optimal policy of the discretized problem converges to that of the continuous-time problem in the sense of weak convergence. For the infinite-horizon problem, a successive approximation method is introduced as an alternative to a policy iteration method.     

Estimating critical path and arc probabilities in stochastic activity networks

This article describes a new procedure for estimating parameters of a stochastic activity network of N arcs. The parameters include the probability that path m is the longest path, the probability that path m is the shortest path, the probability that arc i is on the longest path, and the probability that arc i is on the shortest path. The proposed procedure uses quasirandom points together with information on a cutset ? of the network to produce an upper bound of O[(log K)^N?|?|+1/K] on the absolute error of approximation, where K denotes the number of replications. This is a deterministic bound and is more favorable than the convergence rate of 1/K^1/2 that one obtains from the standard error for K independent replications using random sampling. It is also shown how series reduction can improve the convergence rate by reducing the exponent on log K. The technique is illustrated using a Monte Carlo sampling experiment for a network of 16 relevant arcs with a cutset of ? = 7 arcs. The illustration shows the superior performance of using quasirandom points with a cutset (plan A) and the even better performance of using quasirandom points with the cutset together with series reduction (plan B) with regard to mean square error. However, it also shows that computation time considerations favor plan A when K is small and plan B when K is large.     

A minmax search for the critical level of a system: The asymmetric case

We consider a system composed of k components, each of which is subject to failure if temperature is above a critical level. The failure of one component causes the failure of the system as a whole (a serially connected system). If z_i is the critical temperature of the ith component then z^* = min{z_i: i = 1,2,…, k} is the critical level of the system. The components may be tested individually at different temperature levels, if the temperature is below the critical level the cost is $1, otherwise the test is destructive and the cost is m > 1 dollars. The purpose of this article is to construct, under a budgetary constraint, an efficient (in a minmax sense) testing procedure which will locate the critical level of the system with maximal accuracy.     

Solution algorithms for the parallel replacement problem under economy of scale

We consider the parallel replacement problem in which machine investment costs exhibit economy of scale which is modeled through associating both fixed and variable costs with machine investment costs. Both finite- and infinite-horizon cases are investigated. Under the three assumptions made in the literature on the problem parameters, we show that the finite-horizon problem with time-varying parameters is equivalent to a shortest path problem and hence can be solved very efficiently, and give a very simple and fast algorithm for the infinite-horizon problem with time-invariant parameters. For the general finite-horizon problem without any assumption on the problem parameters, we formulate it as a zero-one integer program and propose an algorithm for solving it exactly based on Benders' decomposition. Computational results show that this solution algorithm is efficient, i.e., it is capable of solving large scale problems within a reasonable cpu time, and robust, i.e., the number of iterations needed to solve a problem does not increase quickly with the problem size. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 279–295, 1998     

Optimal pricing and inventory control policy in periodic‐review systems with fixed ordering cost and lost sales

This paper studies a periodic‐review pricing and inventory control problem for a retailer, which faces stochastic price‐sensitive demand, under quite general modeling assumptions. Any unsatisfied demand is lost, and any leftover inventory at the end of the finite selling horizon has a salvage value. The cost component for the retailer includes holding, shortage, and both variable and fixed ordering costs. The retailer's objective is to maximize its discounted expected profit over the selling horizon by dynamically deciding on the optimal pricing and replenishment policy for each period. We show that, under a mild assumption on the additive demand function, at the beginning of each period an (s,S) policy is optimal for replenishment, and the value of the optimal price depends on the inventory level after the replenishment decision has been done. Our numerical study also suggests that for a sufficiently long selling horizon, the optimal policy is almost stationary. Furthermore, the fixed ordering cost (K) plays a significant role in our modeling framework. Specifically, any increase in K results in lower s and higher S. On the other hand, the profit impact of dynamically changing the retail price, contrasted with a single fixed price throughout the selling horizon, also increases with K. We demonstrate that using the optimal policy values from a model with backordering of unmet demands as approximations in our model might result in significant profit penalty. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006