EFFECTIVENESS OF STOCK TRANSSHIPMENT UNDER VARIOUS DEMAND DISTRIBUTIONS AND NONNEGLIGIBLE TRANSSHIPMENT TIMES*

This paper investigates the operational characteristics of a pooling group consisting of two stocking locations, supplied periodically by a central warehouse. The two locations may collaborate by moving inventory between them. The lateral transshipment times are shorter than the regular replenishment lead times, but they are not negligible. Several alternative types of ordering and transshipment policies are examined. Extensive experimentation by simulation leads to the conclusion that the benefits of risk pooling are substantial only when demand is highly variable. Moreover, the type and variability of the demand distributions are key determinants of the appropriate transshipment policy and pooling groups design.     

PRICE‐DEPENDENT INVENTORY MODELS WITH DISCOUNT OFFERS AT RANDOM TIMES*

We consider an inventory model with a supplier offering discounts to a reseller at random epochs. The offer is accepted when the inventory position is lower than a threshold level. We compare three different pricing policies in which demand is induced by the resellers price variation. Policy 1 is the EOQ policy without discount offers. Policy 2 is a uniform price, stock‐independent policy. Policy 3 is a stock level‐dependent, discriminated price policy. Assuming constant demand rates, expressions are obtained for the optimal order quantities, prices, and profits. The numerical experiments show that if it is better to accept a suppliers discount, then it benefits the reseller to transfer the discount to downstream customers.     

Managing Retail Shelf and Backroom Inventories When Demand Depends on the Shelf‐Stock Level

Inventory displayed on the retail sales floor not only performs the classical supply function but also plays a role in affecting consumers’ buying behavior and hence the total demand. Empirical evidence from the retail industry shows that for some types of products, higher levels of on‐shelf inventory have a demand‐increasing effect (“billboard effect”) while for some other types of products, higher levels of on‐shelf inventory have a demand‐decreasing effect (“scarcity effect”). This suggests that retailers may use the amount of shelf stock on display as a tool to influence demand and operate a store backroom to hold the inventory of items not displayed on the shelves, introducing the need for efficient management of the backroom and on‐shelf inventories. The purpose of this study is to address such an issue by considering a periodic‐review inventory system in which demand in each period is stochastic and depends on the amount of inventory displayed on the shelf. We first analyze the problem in a finite‐horizon setting and show under a general demand model that the system inventory is optimally replenished by a base‐stock policy and the shelf stock is controlled by two critical points representing the target levels to raise up/drop down the on‐shelf inventory level. In the infinite‐horizon setting, we find that the optimal policies simplify to stationary base‐stock type policies. Under the billboard effect, we further show that the optimal policy is monotone in the system states. Numerical experiments illustrate the value of smart backroom management strategy and show that significant profit gains can be obtained by jointly managing the backroom and on‐shelf inventories.     

ABC Classification: Service Levels and Inventory Costs

ABC inventory classifications are widely used in practice, with demand value and demand volume as the most common ranking criteria. The standard approach in ABC applications is to set the same service level for all stock keeping units (SKUs) in a class. In this paper, we show (for three large real life datasets) that the application of both demand value and demand volume as ABC ranking criteria, with fixed service levels per class, leads to solutions that are far from cost optimal. An alternative criterion proposed by Zhang et al. performs much better, but is still considerably outperformed by a new criterion proposed in this paper. The new criterion is also more general in that it can take criticality of SKUs into account. Managerial insights are obtained into what class should have the highest/lowest service level, a topic that has been disputed in the literature.     

Replenishment Policies for Multi‐Product Stochastic Inventory Systems with Correlated Demand and Joint‐Replenishment Costs

This study analyzes optimal replenishment policies that minimize expected discounted cost of multi‐product stochastic inventory systems. The distinguishing feature of the multi‐product inventory system that we analyze is the existence of correlated demand and joint‐replenishment costs across multiple products. Our objective is to understand the structure of the optimal policy and use this structure to construct a heuristic method that can solve problems set in real‐world sizes/dimensions. Using an MDP formulation we first compute the optimal policy. The optimal policy can only be computed for problems with a small number of product types due to the curse of dimensionality. Hence, using the insight gained from the optimal policy, we propose a class of policies that captures the impact of demand correlation on the structure of the optimal policy. We call this class (s, c, d, S)‐policies, and also develop an algorithm to compute good policies in this class, for large multi‐product problems. Finally using an exhaustive set of computational examples we show that policies in this class very closely approximate the optimal policy and can outperform policies analyzed in prior literature which assume independent demand. We have also included examples that illustrate performance under the average cost objective.     

Building Supply Chain Resilience through Virtual Stockpile Pooling

Stockpiling inventory is an essential strategy for building supply chain resilience. It enables firms to continue operating while finding a solution to an unexpected event that causes a supply disruption or demand surge. While extremely valuable when actually deployed, stockpiles incur large holding costs and usually provide no benefits until such a time. To help to reduce this cost, this study presents a new approach for managing stockpiles. We show that if leveraged intelligently, stockpiles can also help an organization better meet its own regular demand by enabling a type of virtual pooling we call virtual stockpile pooling (VSP). The idea of VSP is to first integrate the stockpile into several locations’ regular inventory buffers and then dynamically reallocate the stockpile among these locations in reaction to the demand realizations to achieve a kind of virtual transshipment. To study how to execute VSP and determine when it can provide the most value, we formulate a stylized multi‐location stochastic inventory model and solve for the optimal stockpile allocation and inventory order policies. We show that VSP can provide significant cost savings: in some cases nearly the full holding cost of the stockpile (i.e., VSP effectively maintains the stockpile for free), in other cases nearly the savings of traditional physical inventory pooling. Last, our results prescribe implementing VSP with many locations for large stockpiles, but only a few locations for small stockpiles.     

Lateral transshipment with partial request and random switching

A large body of inventory management research has been devoted to lateral transshipment. Most of the existent models assume that the unmet local demand will automatically request transshipment, and that the unmet local demand does not seek inventory at other locations within the same echelon. In contrast, we investigate a two-store retailer’s inventory replenishment and transshipment decisions when those two assumptions do not hold. Specifically, we use a fixed request rate to model partial demand for transshipment at the shortage store and a random switch rate to model the arrival of the unmet demand at the surplus store. We characterize the optimal transshipment and inventory replenishment policies. We find that it is not always in the best interest of the retailer to satisfy as much as possible the transshipment demand. In light of the switched demand flowing to the surplus store, the retailer may benefit from saving the leftover inventory at the surplus store for the switched demand. The optimal transshipment policy follows a double-threshold structure when the prospect of the switched demand is not large enough; and a transshipment quantity of zero becomes optimal otherwise. Through an extensive numerical analysis, we examine the impact of the request rate and the switch rate, together with other parameters. We also evaluate a few simple-to-use transshipment heuristics, including one that we devise based on the structure of the optimal transshipment policy. The consistent, near-optimal performance of the devised heuristic is a confirmation of the importance of our theoretical work on the optimal policy.     

Production lot sizing with process deterioration and machine breakdown under inspection schedule

The paper develops integrated production, inventory and maintenance models for a deteriorating production system in which the production facility may not only shift from an ‘in-control’ state to an ‘out-of-control’ state but also may break down at any random point in time during a production run. In case of machine breakdown, production of the interrupted lot is aborted and a new production lot is started when the on-hand inventory is depleted after corrective repair. The process is inspected during each production run to examine the state of the production process. If it is found in the ‘in-control’ state then either (a) no action is taken except at the time of last inspection where preventive maintenance is done (inspection policy-I) or (b) preventive maintenance is performed (inspection policy-II). If, however, the process is found to be in the ‘out-of-control’ state at any inspection then restoration is done. The proposed models are formulated under general shift, breakdown and repair time distributions. As it is, in general, difficult to find the optimal production policy under inspection policy-I, a suboptimal production policy is derived. Numerical examples are taken to determine numerically the optimal/suboptimal production policies of the proposed models, to examine the sensitivity of important model parameters and to compare the performance of inspection and no inspection policies.     

POWER APPROXIMATIONS FOR A TWO-ECHELON INVENTORY SYSTEM USING SERVICE LEVELS

We consider a two-echelon inventory system with one warehouse and several stores. The warehouse as well as the stores are controlled by periodic review (s, S) inventory policies. We study the interrelationship between the safety stocks at the warehouse and the stores. Stockouts at the warehouse will result in supply delays to the stores and cause the lead time to be stochastic. The stores may react by increasing their safety stock. However, there is a trade-off between the safety stock at the warehouse and the safety stock at the stores. We use a service level at the warehouse to quantify the effect of warehouse stockouts on the lead time to the stores. The service level at the warehouse is considered a decision variable to find the best compromise between the various safety stocks by minimizing the overall costs. Using power approximations for the (s, S) policies, we provide an iterative procedure for adjusting the lead time distribution to the stores; this can result in substantial savings, but it doesn't guarantee the overall optimality. Numerical studies are provided to test the accuracy of approximations. The effects of the different system parameters on the inventory policy give general guidelines for use of the policies.     

INVENTORY RATIONING AND SHIPMENT FLEXIBILITY ALTERNATIVES FOR DIRECT MARKET FIRMS

This paper investigates inventory‐rationing policies of interest to firms operating in a direct market channel. We model a single product with two demand classes, where one class requests a lower order fulfillment lead time but pays a higher price. Demand for each class follows a Poisson process. Inventory is fed by a production system with exponentially distributed build times. We study rationing policies in which the firm either blocks or backlogs orders for the lower priority customers when inventory drops below a certain level. We compare the performance of these rationing policies with a pure first‐come, first‐serve policy under various scenarios for customer response to delay: lost sales, backlog, and a combination of lost sales and backlog.     

Production planning problem in manufacturing systems with general failure and repair time distributions

We study the optimal flow control for a manufacturing system subject to random failures and repairs. In most previous work, it has been proved that, for constant demand rates and exponential failure and repair times distributions of machines, the hedging point policy is optimal. The aim of this study is to extend the hedging point policy to non-exponential failure and repair times distributions and random demand rates models. The performance measure is the cost related to the inventory and back order penalties. We find that the structure of the hedging point policy can be parametrized by a single factor representing the critical stock level or threshold. With the corresponding hedging point policy, simulation experiments are used to construct input-output data from which an estimation of the incurred cost function is obtained through a regression analysis. The best parameter value of the related hedging point policy is derived from a minimum search of the obtained cost function. The extended hedging point policy is validated and shown to be quite effective. We find that the hedging point policy is also applicable to a wide variety of complex problems (i.e. non-exponential failure and repair times distributions and random demand rates), where analytical solutions may not be easily obtained.     

A hybrid inventory management system responding to regular demand and surge demand

This paper proposes a hybrid policy for a stochastic inventory system facing regular demand and surge demand. The combination of two different demand patterns can be observed in many areas, such as healthcare inventory and humanitarian supply chain management. The surge demand has a lower arrival rate but higher demand volume per arrival. The solution approach proposed in this paper incorporates the level crossing method and mixed integer programming technique to optimize the hybrid inventory policy with both regular orders and emergency orders. The level crossing method is applied to obtain the equilibrium distributions of inventory levels under a given policy. The model is further transformed into a mixed integer program to identify an optimal hybrid policy. A sensitivity analysis is conducted to investigate the impact of parameters on the optimal inventory policy and minimum cost. Numerical results clearly show the benefit of using the proposed hybrid inventory model. The model and solution approach could help healthcare providers or humanitarian logistics providers in managing their emergency supplies in responding to surge demands.     

STOCK LEVELS AND DELIVERY RATES IN VENDORMANAGED INVENTORY PROGRAMS

Using the latest information technology, powerful retailers like Wal‐Mart have taken the lead in forging shorter replenishment‐cycles, automated supply systems with suppliers. With the objective to reduce cost, these retailers are directing suppliers to take full responsibility for managing stocks and deliveries. Suppliers' performance is measured according to how often inventory is shipped to the retailer, and how often customers are unable to purchase the product because it is out of stock. This emerging trend also implies that suppliers are absorbing a large part of the inventory and delivery costs and, therefore, must plan delivery programs including delivery frequency to ensure that the inherent costs are minimized. With the idea to incorporate this shift in focus, this paper looks at the problem facing the supplier who wants quicker replenishment at lower cost. In particular, we present a model that seeks the best trade‐off among inventory investment, delivery rates, and permitting shortages to occur, given some random demand pattern for the product. The process generating demand consists of two components: one is deterministic and the other is random. The random part is assumed to follow a compound Poisson process. Furthermore, we assume that the supplier may fail to meet uniform shipping schedules, and, therefore, uncertainty is present in delivery times. The solution to this transportationinventory problem requires determining jointly delivery rates and stock levels that will minimize transportation, inventory, and shortage costs. Several numerical results are presented to give a feel of the optimal policy's general behavior.     

Supply Performance in Multi‐Echelon Inventory Systems with Intermediate Product Demand: A Perspective on Allocation

In this article, we study the performance of multi‐echelon inventory systems with intermediate, external product demand in one or more upper echelons. This type of problem is of general interest in inventory theory and of particular importance in supply chain systems with both end‐product demand and spare parts (subassemblies) demand. The multi‐echelon inventory system considered here is a combination of assembly and serial stages with direct demand from more than one node. The aspect of multiple sources of demands leads to interesting inventory allocation problems. The demand and capacity at each node are considered stochastic in nature. A fixed supply and manufacturing lead time is used between the stages. We develop mathematical models for these multi‐echelon systems, which describe the inventory dynamics and allow simulation of the system. A simulation‐based inventory optimization approach is developed to search for the best base‐stock levels for these systems. The gradient estimation technique of perturbation analysis is used to derive sample‐path estimators. We consider four allocation schemes: lexicographic with priority to intermediate demand, lexiographic with priority to downstream demand, predetermined proportional allocation, and proportional allocation. Based on the numerical results we find that no single allocation policy is appropriate under all conditions. Depending on the combinations of variability and utilization we identify conditions under which use of certain allocation polices across the supply chain result in lower costs. Further, we determine how selection of an inappropriate allocation policy in the presence of scarce on‐hand inventory could result in downstream nodes facing acute shortages. Consequently we provide insight on why good allocation policies work well under differing sets of operating conditions.     

A Bayesian Inventory Model Using Real‐Time Condition Monitoring Information

Lack of coordination between machinery fault diagnosis and inventory management for spare parts can lead to increased inventory costs and disruptions in production activity. We develop a framework for incorporating real‐time condition monitoring information into inventory decisions for spare parts. We consider a manufacturer who periodically replenishes inventory for a machine part that is subject to deterioration. The deterioration is captured via condition monitoring and modeled using a Wiener process. The resulting degradation model is used to derive the life distribution of a functioning part and to estimate the demand distribution for spare parts. This estimation is periodically updated, in a Bayesian manner, as additional information on part deterioration is obtained. We develop an inventory model that incorporates this updated demand distribution and demonstrate that a dynamic base‐stock policy, in which the optimal base‐stock level is a function of some subset of the observed condition monitoring information, is optimal. We propose a myopic critical fractile policy that captures the essence of the optimal policy, but is easier to compute. Computational experiments indicate that this heuristic performs quite well relative to the optimal policy. Adaptive inventory policies such as these can help manufacturers to increase machine availability and reduce inventory costs.     

The cost of using stationary inventory policies when demand is non-stationary

Non-stationary stochastic demands are very common in industrial settings with seasonal patterns, trends, business cycles, and limited-life items. In such cases, the optimal inventory control policies are also non-stationary. However, due to high computational complexity, non-stationary inventory policies are not usually preferred in real-life applications. In this paper, we investigate the cost of using a stationary policy as an approximation to the optimal non-stationary one. Our numerical study points to two important results: (i) Using stationary policies can be very expensive depending on the magnitude of demand variability. (ii) Stationary policies may be efficient approximations to optimal non-stationary policies when demand information contains high uncertainty, setup costs are high and penalty costs are low.     

Optimal production,replenishment, delivery,routing and inventory management policies for products with perishable inventory

This paper presents a generalized production-inventory-routing model with perishable inventory. We analyze the optimal integrated decisions of when and how much to deliver and sell products with varying manufacturing periods. We discuss main inventory management policies to demonstrate the applicability of the model in real-world applications for production routing problems (PRPs) with perishable inventory. Furthermore, an exact branch-and-cut algorithm is developed and discussed. We introduce new families of logical, strengthened lot-sizing and lifted Miller–Tucker–Zemlin subtour elimination constraints for the PRP with perishable inventory. Finally, we test the performance of the algorithm. We also implement and compare 8 suboptimal delivery and selling priority policies with an optimized policy to develop managerial implications.     

应对突发事件的库存共享策略

以包含两个销售商的库存系统为例,构建了一个描述库存共享应对突发事件的非合作博弈模型,证明了其纳什均衡解是唯一存在的。研究结果显示库存共享策略总有可能使得销售商的期望利润得以改进。另外,比较静态分析反映了转载价格和转载成本显著影响库存共享销售商的最优订货量和最优期望利润。最后,提出了一个简单的求解模型纳什均衡解的启发式算法。     

面向批量订货和多需求类的生产与库存配给

针对一个面向两个需求类的生产企业,根据客户每次订货是否可分批交货,提出了当客户订货可分割和不可分割时供应商的最优生产和库存配给策略.分析表明,供应商的最优生产控制策略可用一个取决于系统状态的基准库存水平表示,最优的库存配给策略则用一个多层的取决于状态的配给水平向量表示.随后,该结论被推广至包含任意多个需求类的生产系统.数值分析验证了文中最优策略的有效性.     

Robust Stochastic Lot‐Sizing by Means of Histograms

Traditional approaches in inventory control first estimate the demand distribution among a predefined family of distributions based on data fitting of historical demand observations, and then optimize the inventory control using the estimated distributions. These approaches often lead to fragile solutions whenever the preselected family of distributions was inadequate. In this article, we propose a minimax robust model that integrates data fitting and inventory optimization for the single‐item multi‐period periodic review stochastic lot‐sizing problem. In contrast with the standard assumption of given distributions, we assume that histograms are part of the input. The robust model generalizes the Bayesian model, and it can be interpreted as minimizing history‐dependent risk measures. We prove that the optimal inventory control policies of the robust model share the same structure as the traditional stochastic dynamic programming counterpart. In particular, we analyze the robust model based on the chi‐square goodness‐of‐fit test. If demand samples are obtained from a known distribution, the robust model converges to the stochastic model with true distribution under generous conditions. Its effectiveness is also validated by numerical experiments.