A heuristic for capacity expansion planning with multiple facility types

A capacity expansion model with multiple facility types is examined, where different facility types represent different quality levels. Applications for the model can be found in communications networks and production facilities. The model assumes a finite number of discrete time periods. The facilities are expanded over time. Capacity of a high-quality facility can be converted to satisfy demand for a lower-quality facility. The costs considered include capacity expansion costs and excess capacity holding costs. All cost functions are nondecreasing and concave. An algorithm that finds optimal expansion policies requires extensive computations and is practical only for small scale problems. Here, we develop a heuristic that employs so-called distributed expansion policies. It also attempts to decompose the problem into several smaller problems solved independently. The heuristic is computationally efficient. Further, it has consistently found near-optimal solutions.     

A network flow approach for capacity expansion problems with two facility types

A deterministic capacity expansion model for two facility types with a finite number of discrete time periods is described. The model generalizes previous work by allowing for capacity disposals, in addition to capacity expansions and conversions from one facility type to the other. Furthermore, shortages of capacity are allowed and upper bounds on both shortages and idle capacities can be imposed. The demand increments for additional capacity of any type in any time period can be negative. All cost functions are assumed to be piecewise, concave and nondecreasing away from zero. The model is formulated as a shortest path problem for an acyclic network, and an efficient search procedure is developed to determine the costs associated with the links of this network.     

Locating facilities in three-dimensional space by convex programming

We consider the problem of simultaneously locating any number of facilities in three-dimensional Euclidean space. The criterion to be satisfied is that of minimizing the total cost of some activity between the facilities to be located and any number of fixed locations. Any amount of activity may be present between any pair of the facilities themselves. The total cost is assumed to be a linear function of the inter-facility and facility-to-fixed locations distances. Since the total cost function for this problem is convex, a unique optimal solution exists. Certain discontinuities are shown to exist in the derivatives of the total cost function which previously has prevented the successful use of gradient computing methods for locating optimal solutions. This article demonstrates the use of a created function which possesses all the necessary properties for ensuring the convergence of first order gradient techniques and is itself uniformly convergent to the actual objective function. Use of the fitted function and the dual problem in the case of constrained problems enables solutions to be determined within any predetermined degree of accuracy. Some computation results are given for both constrained and unconstrained problems.     

Optimal cutoff strategies in capacity expansion problems

Capacity expansion refers to the process of adding facilities or manpower to meet increasing demand. Typical capacity expansion decisions are characterized by uncertain demand forecasts and uncertainty in the eventual cost of expansion projects. This article models capacity expansion within the framework of piecewise deterministic Markov processes and investigates the problem of controlling investment in a succession of same type projects in order to meet increasing demand with minimum cost. In particular, we investigate the optimality of a class of investment strategies called cutoff strategies. These strategies have the property that there exists some undercapacity level M such that the strategy invests at the maximum available rate at all levels above M and does not invest at any level below M. Cutoff strategies are appealing because they are straightforward to implement. We determine conditions on the undercapacity penalty function that ensure the existence of optimal cutoff strategies when the cost of completing a project is exponentially distributed. A by-product of the proof is an algorithm for determining the optimal strategy and its cost. © 1995 John Wiley & Sons, Inc.     

The network redesign problem for access telecommunications networks

The network redesign problem attempts to design an optimal network that serves both existing and new demands. In addition to using spare capacity on existing network facilities and deploying new facilities, the model allows for rearrangement of existing demand units. As rearrangements mean reassigning existing demand units, at a cost, to different facilities, they may lead to disconnecting of uneconomical existing facilities, resulting in significant savings. The model is applied to an access network, where the demands from many sources need to be routed to a single destination, using either low‐capacity or high‐capacity facilities. Demand from any location can be routed to the destination either directly or through one other demand location. Low‐capacity facilities can be used between any pair of locations, whereas high‐capacity facilities are used only between demand locations and the destination. We present a new modeling approach to such problems. The model is described as a network flow problem, where each demand location is represented by multiple nodes associated with demands, low‐capacity and high‐capacity facilities, and rearrangements. Each link has a capacity and a cost per unit flow parameters. Some of the links also have a fixed‐charge cost. The resulting network flow model is formulated as a mixed integer program, and solved by a heuristic and a commercially available software. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 487–506, 1999     

The continuous‐time single‐sourcing problem with capacity expansion opportunities

This paper develops a new model for allocating demand from retailers (or customers) to a set of production/storage facilities. A producer manufactures a product in multiple production facilities, and faces demand from a set of retailers. The objective is to decide which of the production facilities should satisfy each retailer's demand, in order minimize total production, inventory holding, and assignment costs (where the latter may include, for instance, variable production costs and transportation costs). Demand occurs continuously in time at a deterministic rate at each retailer, while each production facility faces fixed‐charge production costs and linear holding costs. We first consider an uncapacitated model, which we generalize to allow for production or storage capacities. We then explore situations with capacity expansion opportunities. Our solution approach employs a column generation procedure, as well as greedy and local improvement heuristic approaches. A broad class of randomly generated test problems demonstrates that these heuristics find high quality solutions for this large‐scale cross‐facility planning problem using a modest amount of computation time. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

A dual-based optimization procedure for the two-echelon uncapacitated facility location problem

The two-echelon uncapacitated facility location problem (TUFLP) is a generalization of the uncapacitated facility location problem (UFLP) and multiactivity facility location problem (MAFLP). In TUFLP there are two echelons of facilities through which products may flow in route to final customers. The objective is to determine the least-cost number and locations of facilities at each echelon in the system, the flow of product between facilities, and the assignment of customers to supplying facilities. We propose a new dual-based solution procedure for TUFLP that can be used as a heuristic or incorporated into branch-and-bound procedures to obtain optimal solutions to TUFLP. The algorithm is an extension of the dual ascent and adjustment procedures developed by Erlenkotter for UFLP. We report computational experience gained by solving over 420 test problems. The largest problems solved have 25 possible facility locations at each echelon and 35 customer zones, implying 650 integer variables and 21,875 continuous variables.     

A facility reliability problem: Formulation,properties, and algorithm

Having a robustly designed supply chain network is one of the most effective ways to hedge against network disruptions because contingency plans in the event of a disruption are often significantly limited. In this article, we study the facility reliability problem: how to design a reliable supply chain network in the presence of random facility disruptions with the option of hardening selected facilities. We consider a facility location problem incorporating two types of facilities, one that is unreliable and another that is reliable (which is not subject to disruption, but is more expensive). We formulate this as a mixed integer programming model and develop a Lagrangian Relaxation‐based solution algorithm. We derive structural properties of the problem and show that for some values of the disruption probability, the problem reduces to the classical uncapacitated fixed charge location problem. In addition, we show that the proposed solution algorithm is not only capable of solving large‐scale problems, but is also computationally effective. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

A capacity-expansion model for two facility types

This paper describes a deterministic capacity-expansion model for two facility types with a finite number of discrete time periods. Capacity expansions are initialed either by new construction or by the conversion of idle capacity from one facility type to the other. Once converted, the capacity becomes an integral part of the new facility type. The costs incurred include construction, conversion, and holding costs. All cost functions are assumed to be nondecreasing and concave. Using a network flow approach, the paper develops an efficient dynamic-programming algorithm to minimize the total costs when the demands for additional capacity are nonnegative in each period. Thereafter, the algorithm is extended for arbitrary demands. The model is applied to a cable-sizing problem that occurs in communication networks, and numerical examples are discussed.     

A localization property for facility-location problems with arbitrary norms

In an earlier article we showed that, for facilities-location problems characterized by generalized distance norms and any even number of existing facilities, the optimal location of the new facility is at the intersection of the lines joining the pairs of facilities if these lines intersect at a single point. In this article we extend this concept to show that, for a more general class of problems, the optimal location is one of a set of points which is specified by the existing facilities.     

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     

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     

Natural gas storage valuation and optimization: A real options application

In this article, we present an algorithm for the valuation and optimal operation of natural gas storage facilities. Real options theory is used to derive nonlinear partial‐integro‐differential equations (PIDEs), the solution of which give both valuation and optimal operating strategies for these facilities. The equations are designed to incorporate a wide class of spot price models that can exhibit the same time‐dependent, mean‐reverting dynamics, and price spikes as those observed in most energy markets. Particular attention is paid to the operational characteristics of real storage units. These characteristics include working gas capacities, variable deliverability and injection rates, and cycling limitations. We illustrate the model with a numerical example of a salt cavern storage facility that clearly shows how a gas storage facility is like a financial straddle with both put and call properties. Depending on the amount of gas in storage the relative influence of the put and call components vary. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Determination of efficient points in multiple-objective location problems

This article is devoted to an MCDM problem connected with locational analysis. The MCDM problem can be formulated so as to minimize the distance between a facility and a given set of points. The efficient points of this problem are candidates for optimal solutions to many location problems. We propose an algorithm to find all efficient points when distance is measured by any polyhedral norm.     

Optimal machine capacity expansions with nested limitations under stochastic demand

This paper studies capacity expansions for a production facility that faces uncertain customer demand for a single product family. The capacity of the facility is modeled in three tiers, as follows. The first tier consists of a set of upper bounds on production that correspond to different resource types (e.g., machine types, categories of manpower, etc.). These upper bounds are augmented in increments of fixed size (e.g., by purchasing machines of standard types). There is a second‐tier resource that constrains the first‐tier bounds (e.g., clean room floor space). The third‐tier resource bounds the availability of the second‐tier resource (e.g., the total floor space enclosed by the building, land, etc.). The second and third‐tier resources are expanded at various times in various amounts. The cost of capacity expansion at each tier has both fixed and proportional elements. The lost sales cost is used as a measure for the level of customer service. The paper presents a polynomial time algorithm (FIFEX) to minimize the total cost by computing optimal expansion times and amounts for all three types of capacity jointly. It accommodates positive lead times for each type. Demand is assumed to be nondecreasing in a “weak” sense. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Multiple-facility loading under capacity-based economies of scope

Multiple-facility loading (MFL) involves the allocation of products among a set of finite-capacity facilities. Applications of MFL arise naturally in a variety of production scheduling environments. MFL models typically assume that capacity is consumed as a linear function of products assigned to a facility. Product similarities and differences, however, result in capacity-based economies or diseconomies of scope, and thus the effective capacity of the facility is often a (nonlinear) function of the set of tasks assigned to the facility. This article addresses the multiple-facility loading problem under capacity-based economies (and diseconomies) of scope (MFLS). We formulate MFLS as a nonlinear 0–1 mixed-integer programming problem, and we discuss some useful properties. MFLS generalizes many well-known combinatorial optimization problems, such as the capacitated facility location problem and the generalized assignment problem. We also define a tabu-search heuristic and a branch-and-bound algorithm for MFLS. The tabu-search heuristic alternates between two search phases, a regional search and a diversification search, and offers a novel approach to solution diversification. We also report computational experience with the procedures. In addition to demonstrating MFLS problem tractability, the computational results indicate that the heuristic is an effective tool for obtaining high-quality solutions to MFLS. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 229–256, 1997     

Optimal capacity expansion

We consider the problem of temporal expansion of the capacity of, say, a plant or road given estimates of its desired usage (demand). The basic problem is: given a sequence of predicted demands for N time periods, determine the optimal investment decision in each period to minimize a linear investment cost and a strictly convex cost of capacity. The relationship between capacity and the investment decisions is assumed to be linear, but time varying. Constraints on both the individual decisions and on the sum of the decisions are considered. An algorithm for solving this problem is derived.     

Split delivery routing

This article examines a relaxed version of the generic vehicle routing problem. In this version, a delivery to a demand point can be split between any number of vehicles. In spite of this relaxation the problem remains computationally hard. Since only small instances of the vehicle routing problem are known to be solved using exact methods, the vehicle route construction for this problem version is approached using heuristic rules. The main contribution of this article to the existing body of literature on vehicle routing issues in (a) is presenting a new vehicle routing problem amenable to practical applications, and (b) demonstrating the potential for cost savings over similar “traditional” vehicle routing when implementing the model and solutions presented here. The solution scheme allowing for split deliveries is compared with a solution in which no split deliveries are allowed. The comparison is conducted on six sets of 30 problems each for problems of size 75, 115, and 150 demand points (all together 540 problems). For very small demands (up to 10% of vehicle's capacity) no significant difference in solutions is evident for both solution schemes. For the other five problem sets for which point demand exceeds 10% of vehicle's capacity, very significant cost savings are realized when allowing split deliveries. The savings are significant both in the total distance and the number of vehicles required. The vehicles' routes constructed by our procedure tend to cover cohesive geographical zones and retain some properties of optimal solutions.     

Facility location and capacity acquisition: An integrated approach

The facility location and capacity acquisition decisions are intertwined, especially within the international context where capacity acquisition costs are location dependent. A review of the relevant literature however, reveals that the facility location and the capacity acquisition problems have been dealt with separately. Thus, an integrated approach for simultaneous optimization of these strategic decisions is presented. Analytical properties of the arising model are investigated and an algorithm for solving the problem is devised. Encouraging computational results are reported. © 1995 John Wiley & Sons, Inc.     

An approach to modeling electric utility capacity expansion planning

This article describes an algorithm for solving the static electric utility capacity expansion problem. The advantages of this algorithm are twofold. First, it is simpler and yet more efficient than previous algorithms for the same problem. Second, by making simplifying but realistic assumptions on plant sizes it is possible to use this algorithm for the case where one does not allow fractional plant additions. While the model has n variables, it has a clear two-dimensional geometric representation for understanding its properties, developing an algorithm, and interpreting the optimal solution. This algorithm has been implemented in the Intermediate Future Forecasting (IFFS) capacity expansion model at the Department of Energy.