Scheduling and due‐date quotation in a make‐to‐order supply chain

We consider a manufacturer, served by a single supplier, who has to quote due dates to arriving customers in a make‐to‐order production environment. The manufacturer is penalized for long lead times and for missing due dates. To meet due dates, the manufacturer has to obtain components from a supplier. We model this manufacturer and supplier as a two‐machine flow shop, consider several variations of this problem, and design effective due‐date quotation and scheduling algorithms for centralized and decentralized versions of the model. We perform extensive computational testing to assess the effectiveness of our algorithms and to compare the centralized and decentralized models to quantify the value of centralized control in a make‐to‐order supply chain. Since complete information exchange and centralized control is not always practical or cost‐effective, we explore the value of partial information exchange for this system. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

DEA models for two‐stage processes: Game approach and efficiency decomposition

Data envelopment analysis (DEA) is a method for measuring the efficiency of peer decision making units (DMUs). This tool has been utilized by a number of authors to examine two‐stage processes, where all the outputs from the first stage are the only inputs to the second stage. The current article examines and extends these models using game theory concepts. The resulting models are linear, and imply an efficiency decomposition where the overall efficiency of the two‐stage process is a product of the efficiencies of the two individual stages. When there is only one intermediate measure connecting the two stages, both the noncooperative and centralized models yield the same results as applying the standard DEA model to the two stages separately. As a result, the efficiency decomposition is unique. While the noncooperative approach yields a unique efficiency decomposition under multiple intermediate measures, the centralized approach is likely to yield multiple decompositions. Models are developed to test whether the efficiency decomposition arising from the centralized approach is unique. The relations among the noncooperative, centralized, and standard DEA approaches are investigated. Two real world data sets and a randomly generated data set are used to demonstrate the models and verify our findings. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

A new importance sampling Monte Carlo method for a flow network reliability problem

The exact evaluation of the probability that the maximum st‐flow is greater than or equal to a fixed demand in a stochastic flow network is an NP‐hard problem. This limitation leads one to consider Monte Carlo alternatives. In this paper, we propose a new importance sampling Monte Carlo method. It is based on a recursive use of the state space decomposition methodology of Doulliez and Jamoulle during the simulation process. We show theoretically that the resulting estimator belongs to the variance‐reduction family and we give an upper bound on its variance. As shown by experimental tests, the new sampling principle offers, in many cases, substantial speedups with respect to a previous importance sampling based on the same decomposition procedure and its best performances are obtained when highly reliable networks are analyzed. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 204–228, 2002; DOI 10.1002/nav.10004     

Contractual agreements for coordination and vendor‐managed delivery under explicit transportation considerations

We consider the coordination problem between a vendor and a buyer operating under generalized replenishment costs that include fixed costs as well as stepwise freight costs. We study the stochastic demand, single‐period setting where the buyer must decide on the order quantity to satisfy random demand for a single item with a short product life cycle. The full order for the cycle is placed before the cycle begins and no additional orders are accepted by the vendor. Due to the nonrecurring nature of the problem, the vendor's replenishment quantity is determined by the buyer's order quantity. Consequently, by using an appropriate pricing schedule to influence the buyer's ordering behavior, there is an opportunity for the vendor to achieve substantial savings from transportation expenses, which are represented in the generalized replenishment cost function. For the problem of interest, we prove that the vendor's expected profit is not increasing in buyer's order quantity. Therefore, unlike the earlier work in the area, it is not necessarily profitable for the vendor to encourage larger order quantities. Using this nontraditional result, we demonstrate that the concept of economies of scale may or may not work by identifying the cases where the vendor can increase his/her profits either by increasing or decreasing the buyer's order quantity. We prove useful properties of the expected profit functions in the centralized and decentralized models of the problem, and we utilize these properties to develop alternative incentive schemes for win–win solutions. Our analysis allows us to quantify the value of coordination and, hence, to identify additional opportunities for the vendor to improve his/her profits by potentially turning a nonprofitable transaction into a profitable one through the use of an appropriate tariff schedule or a vendor‐managed delivery contract. We demonstrate that financial gain associated with these opportunities is truly tangible under a vendor‐managed delivery arrangement that potentially improves the centralized solution. Although we take the viewpoint of supply chain coordination and our goal is to provide insights about the effect of transportation considerations on the channel coordination objective and contractual agreements, the paper also contributes to the literature by analyzing and developing efficient approaches for solving the centralized problem with stepwise freight costs in the single‐period setting. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Algorithms for the multi‐item multi‐vehicles dynamic lot sizing problem

We consider a two‐stage supply chain, in which multi‐items are shipped from a manufacturing facility or a central warehouse to a downstream retailer that faces deterministic external demand for each of the items over a finite planning horizon. The items are shipped through identical capacitated vehicles, each incurring a fixed cost per trip. In addition, there exist item‐dependent variable shipping costs and inventory holding costs at the retailer for items stored at the end of the period; these costs are constant over time. The sum of all costs must be minimized while satisfying the external demand without backlogging. In this paper we develop a search algorithm to solve the problem optimally. Our search algorithm, although exponential in the worst case, is very efficient empirically due to new properties of the optimal solution that we found, which allow us to restrict the number of solutions examined. Second, we perform a computational study that compares the empirical running time of our search methods to other available exact solution methods to the problem. Finally, we characterize the conditions under which each of the solution methods is likely to be faster than the others and suggest efficient heuristic solutions that we recommend using when the problem is large in all dimensions. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

Priority and dynamic scheduling in a make‐to‐stock queue with hyperexponential demand

We consider the scheduling problem in a make‐to‐stock queue with two demand classes that can be differentiated based on their variability. One class experiences Poisson arrivals and the other class experiences hyperexponential renewal arrivals. We provide an exact analysis of the case where the demand class with higher variability is given non‐preemptive priority. The results are then used to compare the inventory cost performance of three scheduling disciplines, first‐come first‐serve and priority to either class. We then build on an existing dynamic scheduling heuristic to propose a modification that works well for our system. Extensions of the heuristic to more than two classes and to the case where demand state is known are also discussed. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

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     

A branch‐and‐cut algorithm for the quay crane scheduling problem in a container terminal

The quay crane scheduling problem consists of determining a sequence of unloading and loading movements for cranes assigned to a vessel in order to minimize the vessel completion time as well as the crane idle times. Idle times originate from interferences between cranes since these roll on the same rails and a minimum safety distance must be maintained between them. The productivity of container terminals is often measured in terms of the time necessary to load and unload vessels by quay cranes, which are the most important and expensive equipment used in ports. We formulate the quay crane scheduling problem as a vehicle routing problem with side constraints, including precedence relationships between vertices. For small size instances our formulation can be solved by CPLEX. For larger ones we have developed a branch‐and‐cut algorithm incorporating several families of valid inequalities, which exploit the precedence constraints between vertices. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Determining optimal sizes of bounded batches with rejection via quadratic min‐cost flow

In this article, we consider a single machine scheduling problem, in which identical jobs are split into batches of bounded sizes. For each batch, it is allowed to produce less jobs than a given upper bound, that is, some jobs in a batch can be rejected, in which case a penalty is paid for each rejected job. The objective function is the sum of several components, including the sum of the completion times, total delivery cost, and total rejection cost. We reduce this problem to a min‐cost flow problem with a convex quadratic function and adapt Tamir's algorithm for its solution. © 2017 Wiley Periodicals, Inc. Naval Research Logistics 64: 217–224, 2017     

Optimizing usage and maintenance decisions for k‐out‐of‐n systems of moving assets

We consider an integrated usage and maintenance optimization problem for a k‐out‐of‐n system pertaining to a moving asset. The k‐out‐of‐n systems are commonly utilized in practice to increase availability, where n denotes the total number of parallel and identical units and k the number of units required to be active for a functional system. Moving assets such as aircraft, ships, and submarines are subject to different operating modes. Operating modes can dictate not only the number of system units that are needed to be active, but also where the moving asset physically is, and under which environmental conditions it operates. We use the intrinsic age concept to model the degradation process. The intrinsic age is analogous to an intrinsic clock which ticks on a different pace in different operating modes. In our problem setting, the number of active units, degradation rates of active and standby units, maintenance costs, and type of economic dependencies are functions of operating modes. In each operating mode, the decision maker should decide on the set of units to activate (usage decision) and the set of units to maintain (maintenance decision). Since the degradation rate differs for active and standby units, the units to be maintained depend on the units that have been activated, and vice versa. In order to minimize maintenance costs, usage and maintenance decisions should be jointly optimized. We formulate this problem as a Markov decision process and provide some structural properties of the optimal policy. Moreover, we assess the performance of usage policies that are commonly implemented for maritime systems. We show that the cost increase resulting from these policies is up to 27% for realistic settings. Our numerical experiments demonstrate the cases in which joint usage and maintenance optimization is more valuable. © 2017 Wiley Periodicals, Inc. Naval Research Logistics 64: 418–434, 2017