Joint modified block replacement and production/inventory control policy for a failure-prone manufacturing cell

This paper considers a joint preventive maintenance (PM) and production/inventory control policy of an unreliable single machine, mono-product manufacturing cell with stochastic non-negligible corrective and preventive delays. The production/inventory control policy, which is based on the hedging point policy (HPP), consists in building and maintaining a safety stock of finished products in order to respond to demand and to avoid shortages during maintenance actions. Without considering the impact of preventive and corrective actions on the overall performance of the production system, most authors working in the reliability and maintainability domains confirm that the age-based preventive maintenance policy (ARP) outperforms the classical block-replacement policy (BRP). In order to reduce wastage incurred by the classical BRP, we consider a modified block replacement policy (MBRP), which consists in canceling a preventive maintenance action if the time elapsed since the last maintenance action exceeds a specified time threshold. The main objective of this paper is to determine the joint optimal policy that minimizes the overall cost, which is composed of corrective and preventive maintenance costs as well as inventory holding and backlog costs. A simulation model mimicking the dynamic and stochastic behavior of the manufacturing cell, based on more realistic considerations of the real behavior of industrial manufacturing cells, is proposed. Based on simulation results, the joint optimal MBRP/HPP parameters are obtained through a numerical approach that combines design of experiment, analysis of variance and response surface methodologies. The joint optimal MBRP/HPP policy is compared to classical joint ARP/HPP and BRP/HPP optimal policies, and the results show that the proposed MBRP/HPP outperforms the latter. Sensitivity analyses are also carried out in order to confirm the superiority of the proposed MBRP/HPP, and it is observed that for practitioners, the proposed joint MBRP/HPP offers not only cost savings, but is also easy to manage, as compared to the ARP/HPP policy.     

Near-optimal control policy for loss networks

In this paper, the phenomenon of the optimal management of requests of service in general networks is formulated as a control problem for a finite number of multiserver loss queues with Markovian routing. This type of problem may arise in a wide range of fields, e.g., manufacturing industries, storage facilities, computer networks, and communication systems. Using inductive approach of dynamic programming, the optimal admission control can be induced to be the functions of the number of requested service in progress. However, for large-scale network, the computational burden to find optimal control policy may be infeasible due to its involvement of the states for all stations in the networks. Hence, the idea of bottleneck modeling is borrowed to compute the near-optimal admission control policy. We reduced the scale of loss network and decreased the difference between the original and reduced models by making compensation for system parameters. A novel method is proposed in this paper to compute the compensation. Numerical results show that the near-optimal control policy demonstrates close performance to the optimal policy.     

A simple integrated production policy of an imperfect item for vendor and buyer

This article develops a simple approach for determining an optimal integrated vendor–buyer inventory policy for an item with imperfect quality. The objective is to minimize the total joint annual costs incurred by the vendor and the buyer. This model is assumed to produce a certain number of defective items during the production process. Items of poor quality detected in the screening process of a lot are sold at a discounted price. The expected annual integrated total cost function is derived and a solution procedure is proposed to determine the optimal policy. Finally, a numerical example is also given to illustrate the solution procedure presented in this article.     

Coordinating pricing and production decisions for multiple products

We consider a dynamic problem of joint pricing and production decisions for a profit-maximizing firm that produces multiple products. We model the problem as a mixed integer nonlinear program, incorporating capacity constraints, setup costs, and dynamic demand. We assume demand functions to be convex, continuous, differentiable, and strictly decreasing in price. We present a solution approach which is more general than previous approaches that require the assumption of a specific demand function. Using real-world data from a manufacturer, we study problem instances for different demand scenarios and capacities and solve for optimal prices and production plans. We present analytical results that provide managerial insights on how the optimal prices change for different production plans and capacities. We extend some of the earlier works that consider single product problems to the case of multiple products and time variant production capacities. We also benchmark performance of proposed algorithm with a commercial solver and show that it outperforms the solver both in terms of solution quality and computational times.     

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.     

OPTIMAL AND NEAR OPTIMAL CONTROL OF A TWO-PART-TYPE STOCHASTIC MANUFACTURING SYSTEM WITH DYNAMIC SETUPS

This paper deals with a manufacturing system consisting of a single machine subject to random failures and repairs. The machine can produce two types of parts. When the production is switched from one part type to the other, a random setup time is incurred at a constant cost rate. The objective is to track the demand, while keeping the work-in-process as close as possible to zero for both products. The problem is formulated as an optimal stochastic control problem. The optimal policy is obtained numerically by discretizing the continuous time continuous state opti-mality conditions using a Markov chain approximation technique. The discretized optimality conditions are shown to correspond to an infinite horizon, discrete time, discrete state dynamic programming problem. The optimal setup policy is shown to have two different structures depending on the parameters of the system. A heuristic policy is proposed to approximate the optimal setup policy. Simulation results show that the heuristic policy is a very good approximation for sufficiently reliable systems.     

An Application of Master Schedule Smoothing and Planned Lead Time Control

Make‐to‐order (MTO) manufacturers must ensure concurrent availability of all parts required for production, as any unavailability may cause a delay in completion time. A major challenge for MTO manufacturers operating under high demand variability is to produce customized parts in time to meet internal production schedules. We present a case study of a producer of MTO offshore oil rigs that highlights the key aspects of the problem. The producer was faced with an increase in both demand and demand variability. Consequently, it had to rely heavily on subcontracting to handle production requirements that were in excess of its capacity. We focused on the manufacture of customized steel panels, which represent the main sub‐assemblies for building an oil rig. We considered two key tactical parameters: the planning window of the master production schedule and the planned lead time of each workstation. Under the constraint of a fixed internal delivery lead time, we determined the optimal planning parameters. This improvement effort reduced the subcontracting cost by implementing several actions: the creation of a master schedule for each sub‐assembly family of the steel panels, the smoothing of the master schedule over its planning window, and the controlling of production at each workstation by its planned lead time. We report our experience in applying the analytical model, the managerial insights gained, and how the application benefits the oil‐rig producer.     

A reinforcement-learning approach for admission control in distributed network service systems

In the distributed network service systems such as streaming-media systems and resource-sharing systems with multiple service nodes, admission control (AC) technology is an essential way to enhance performance. Model-based optimization approaches are good ways to be applied to analyze and solve the optimal AC policy. However, due to “the curse of dimensionality”, computing such policy for practical systems is a rather difficult task. In this paper, we consider a general model of the distributed network service systems, and address the problem of designing an optimal AC policy. An analytical model is presented for the system with fixed parameters based on semi-Markov decision process (SMDP). We design an event-driven AC policy, and the stationary randomized policy is taken as the policy structure. To solve the SMDP, both the state aggregation approach and the reinforcement-learning (RL) method with online policy optimization algorithm are applied. Then, we extend the problem by considering the system with time-varying parameters, where the arrival rates of requests at each service node may change over time. In view of this situation, an AC policy switching mechanism is presented. This mechanism allows the system to decide whether to adjust its AC policy according to the policy switching rule. And in order to maximize the gain of system, that is, to obtain the optimal AC policy switching rule, another RL-based algorithm is applied. To assess the effectiveness of SMDP-based AC policy and policy switching mechanism for the system, numerical experiments are presented. We compare the performance of optimal policies obtained by the solutions of proposed methods with other classical AC policies. The simulation results illustrate that higher performance and computational efficiency could be achieved by using the SMDP model and RL-based algorithms proposed in this paper.     

An inventory control policy for liquefied natural gas as a transportation fuel

In this paper, we study a novel stochastic inventory management problem that arises in storage and refueling facilities for Liquefied Natural Gas (LNG) as a transportation fuel. In this inventory problem, the physio-chemical properties of LNG play a key role in the design of inventory policies. These properties are: (1) LNG suffers from both quantity decay and quality deterioration and (2) the quality of on-hand LNG can be upgraded by mixing it with higher-quality LNG. Given that LNG quality can be upgraded, an inventory control policy for this problem needs to consider the removal of LNG as a decision variable. We model and solve the problem by means of a Markov Decision Process (MDP) and study the structural characteristics of the optimal policy. The insights obtained in the analysis of the optimal policy are translated into a simple, though effective, inventory control policy in which actions (i.e., replenishment and/or removal) are driven by both the quality and the quantity of the inventories. We assess the performance of our policy by means of a numerical study and show that it performs close to optimal in many numerical instances. The main conclusion of our study is that it is important to take quality into consideration when design inventory control policies for LNG, and that the most effective way to cope with quality issues in an LNG inventory system involves both the removal and the replenishment of inventories.     

Simultaneous Determination of Joint Product Cost Allocations and Cost-Plus Prices*

Use of the net realizable value approach for joint manufacturing cost allocations requires knowledge of selling prices of joint products. However, joint product selling prices themselves are functions of the allocated costs under a cost-plus pricing policy. In this case, it is necessary to determine joint cost allocations and joint product prices simultaneously. This paper applies a nonlinear programming (NLP) approach to simultaneously determine the optimal joint production decision, joint product cost-plus prices, and joint cost allocations using the net realizable value method. The NLP solution provides not only the optimal joint production and pricing decisions, but also the necessary conditions for such optimal decisions.     

Decision support for multi-family aggregate production planning

Aggregate production planning decisions are inter mediate range decisions that can have a significant impact on both productivity and profitability. In this paper, we examine an interactive computer-based method that provides decision support for the aggregate planner. The proposed approach combines the judgement of the planner with the optimization of subproblems to arrive at an effective solution for multi-family aggregate production planning problems. In the interactive approach, the planner exercises direct control over sensitive workforce levels and production capacities. A network flow sub-problem solver is used to generate optimal production plans and inventory levels given the user-specified production capacities. Decision aids are provided to help the planner achieve a cost-effective solution that is consistent with judgement concerning workforce levels. Computational testing on five test problems indicates that very cost-effective solutions can be obtained. The results of applying the interactive method to a real-world problem are also reported.     

Subcontracting price schemes for order acceptance and scheduling

In this paper we study subcontracting price schemes between a subcontractor and a firm that are engaged in subcontracting of heterogeneous orders with distinct due dates, revenues, and processing times. We assume that the subcontractor proposes the subcontracting pricing and the firm follows by determining the subcontracted orders by solving its order acceptance and scheduling problem. When the subcontractor adopts a linear pricing scheme, we find the firm׳s optimal decisions and develop an algorithm to derive the subcontractor׳s own optimal pricing. We then design a fixed pricing with transfer payment scheme and a quantity discount pricing scheme to coordinate the firm׳s and subcontractor׳s decisions. We examine if the subcontractor can make a higher profit using either of these schemes than the linear pricing scheme, and if they will induce the firm to make decisions that lead to system-wide optimal outcomes.     

公共服务平台下虚拟联盟成员选择机制及联盟企业间协同制造问题研究

本文主要研究了公共服务平台下虚拟联盟成员选择和联盟企业间协同生产的联合优化问题。该问题主要涉及到虚拟联盟战略层面和运营层面两个层面,旨在实现虚拟联盟成员选择、订单分配和生产排序等三个阶段的协同优化。在分析单一联盟企业的生产排序最优化性质的基础上,本文给出了涉及到顾客订单分配和联盟成员选择的结构化性质。考虑到联合优化问题的复杂性,引入并拓展了用于求解连续优化问题的树种算法,开发了嵌入二维离散编码策略和离散种子生成规则的离散树种算法,给出了结合前述结构化性质的适应度计算方法,并开展了一系列仿真对比试验,实验结果表明所提算法相较于离散萤火虫算法和集合蛙跳算法等离散智能优化算法而言,在求解质量和鲁棒性上具有一定的优越性。本文的主要创新点在于提出了横跨战略层面和运营层面的虚拟联盟协同模型,开发了新颖的离散树种算法,能够为虚拟制造联盟的组建和运行提供一定的指导意义。     

Managing appointments with waiting time targets and random walk-ins

The random arrivals of walk-in patients significantly affect the daily operations of healthcare facilities. To improve the performance of outpatient departments, this paper attempts to make an appointment schedule by considering walk-ins and the waiting time target (WTT) for appointment patients. A stochastic programming model is proposed to solve this problem with the objective of minimizing the weighted patient waiting and makespan cost. A non-decreasing waiting cost function is used to capture the WTT fulfillment of appointment patients, whereas walk-ins incur a linear waiting cost. A finite-horizon Markov Decision Process model is formulated to establish the optimal real-time scheduling policy under a given appointment schedule. The appointment schedule is determined by a two-stage stochastic programming approximation and a local search improvement. Structural properties of the optimal appointment scheduling and real-time scheduling policies are established. In particular, it is shown that appointment overbooking is allowed only at the end of the regular session, and the optimal real-time scheduling policy is an easy-to-implement threshold policy with bounded sensitivity. Numerical experiments based on real data are performed to investigate the influence of different parameters and to compare different schedules. The optimal schedule demonstrates superior performance by allowing reasonable waiting times for appointment patients depending on their WTTs. Managerial insights are also provided to hospital managers. Finally, the basic model is extended by incorporating random service times and random arrivals of appointment patients. The latter includes the random number of patients that show up for service or call for appointments, and the random arrival time (unpunctuality). Appointment overbooking strategies are shown to have different structures under some stochastic factors.     

Dynamic Pricing and Inventory Management with Dual Suppliers of Different Lead Times and Disruption Risks

It is common for a firm to make use of multiple suppliers of different delivery lead times, reliabilities, and costs. In this study, we are concerned with the joint pricing and inventory control problem for such a firm that has a quick‐response supplier and a regular supplier that both suffer random disruptions, and faces price‐sensitive random demands. We aim at characterizing the optimal ordering and pricing policies in each period over a planning horizon, and analyzing the impacts of supply source diversification. We show that, when both suppliers are unreliable, the optimal inventory policy in each period is a reorder point policy and the optimal price is decreasing in the starting inventory level in that period. In addition, we show that having supply source diversification or higher supplier reliability increases the firm's optimal profit and lowers the optimal selling price. We also demonstrate that, with the selling price as a decision, a supplier may receive even more orders from the firm after an additional supplier is introduced. For the special case where the quick‐response supplier is perfectly reliable, we further show that the optimal inventory policy is of a base‐stock type and the optimal pricing policy is a list‐price policy with markdowns.     

A robust optimization model for stochastic aggregate production planning

The aggregate production planning (APP) problem considers the medium-term production loading plans subject to certain restrictions such as production capacity and workforce level. It is not uncommon for management to often encounter uncertainty and noisy data, in which the variables or parameters are stochastic. In this paper, a robust optimization model is developed to solve the aggregate production planning problems in an environment of uncertainty in which the production cost, labour cost, inventory cost, and hiring and layoff cost are minimized. By adjusting penalty parameters, decision-makers can determine an optimal medium-term production strategy including production loading plan and workforce level while considering different economic growth scenarios. Numerical results demonstrate the robustness and effectiveness of the proposed model. The proposed model is realistic for dealing with uncertain economic conditions. The analysis of the tradeoff between solution robustness and model robustness is also presented.     

Inventory Rationing in a Make‐to‐Stock System with Batch Production and Lost Sales

We address an inventory rationing problem in a lost sales make‐to‐stock (MTS) production system with batch ordering and multiple demand classes. Each production order contains a single batch of a fixed lot size and the processing time of each batch is random. Assuming that there is at most one order outstanding at any point in time, we first address the case with the general production time distribution. We show that the optimal order policy is characterized by a reorder point and the optimal rationing policy is characterized by time‐dependent rationing levels. We then approximate the production time distribution with a phase‐type distribution and show that the optimal policy can be characterized by a reorder point and state‐dependent rationing levels. Using the Erlang production time distribution, we generalize the model to a tandem MTS system in which there may be multiple outstanding orders. We introduce a state‐transformation approach to perform the structural analysis and show that both the reorder point and rationing levels are state dependent. We show the monotonicity of the optimal reorder point and rationing levels for the outstanding orders, and generate new theoretical and managerial insights from the research findings.     

The permutation flow shop problem with just in time production considerations

This research presents a variation to the permutation flow shop problem where Just In Time (JIT) production requirements are taken into account. The model developed in this research employs dual objectives. In addition to the traditional objective of minimizing the production makespan, minimization of Miltenburg's material usage rate is also incorporated. In this model, multiple units of any product are permitted in the production sequence. However, the minimization of material usage rates attempts to prevent batch scheduling of products and allows unit flow of products as required in demand flow manufacturing. A solution method is proposed for determining an optimal production sequence via an efficient frontier approach and Simulated Annealing (SA). Test problems and specific performance criteria are used to assess the solutions generated by the proposed method. Experimental results presented in this paper show that the use of the efficient frontier and SA provide solutions that approach the optimal solution for the performance measures used in this research.     

An interactive decision support system for an aggregate production planning model based on multiple criteria mixed integer linear programming

In this paper, we present an aggregate production planning (APP) model applied to a Portuguese firm that produces construction materials. A multiple criteria mixed integer linear programming (MCMILP) model is developed with the following performance criteria: (1) maximize profit, (2) minimize late orders, and (3) minimize work force level changes. It includes certain operational features such as partial inflexibility of the work force, legal restrictions on workload, work force size (workers to be hired and downsized), workers in training, and production and inventory capacity. The purpose is to determine the number of workers for each worker type, the number of overtime hours, the inventory level for each product category, and the level of subcontracting in order to meet the forecasted demand for a planning period of 12 months. Additionally, a decision support system (DSS) based on the MCMILP model is proposed. It will help practitioners find the “best” solution for an APP problem without having to familiarize themselves with the mathematical complexities associated with the model. An example to illustrate the use of the DSS is also included.     

Joint Inventory and Pricing Coordination with Incomplete Demand Information

In retailing operations, retailers face the challenge of incomplete demand information. We develop a new concept named K‐approximate convexity, which is shown to be a generalization of K‐convexity, to address this challenge. This idea is applied to obtain a base‐stock list‐price policy for the joint inventory and pricing control problem with incomplete demand information and even non‐concave revenue function. A worst‐case performance bound of the policy is established. In a numerical study where demand is driven from real sales data, we find that the average gap between the profits of our proposed policy and the optimal policy is 0.27%, and the maximum gap is 4.6%.