An Advanced Heuristic for Multiple‐Option Spare Parts Procurement after End‐of‐Production

After‐sales service is a major source of profit for many original equipment manufacturers in industries with durable products. Successful engagement in after‐sales service improves customer loyalty and allows for competitive differentiation through superior service like an extended service period during which customers are guaranteed to be provided with service parts. Inventory management during this period is challenging due to the substantial uncertainty concerning demand over a long time horizon. The traditional mechanism of spare parts acquisition is to place a large final order at the end of regular production of the parent product, causing major holding costs and a high level of obsolescence risk. With an increasing length of the service period, more flexibility is needed and can be provided by adding options like extra production and remanufacturing. However, coordinating all three options yields a complicated stochastic dynamic decision problem. For that problem type, we show that a quite simple decision rule with order‐up‐to levels for extra production and remanufacturing is very effective. We propose a heuristic procedure for parameter determination which accounts for the main stochastic and dynamic interactions in decision making, but still consists of relatively simple calculations that can be applied to practical problem sizes. A numerical study reveals that the heuristic performs extremely well under a wide range of conditions, and therefore can be strongly recommended as a decision support tool for the multi‐option spare parts procurement problem. A comparison with decision rules adapted from practice demonstrates that our approach offers an opportunity for major cost reductions.     

Coordinated Capacitated Lot‐Sizing Problem with Dynamic Demand: A Lagrangian Heuristic

Coordinated replenishment problems are common in manufacturing and distribution when a family of items shares a common production line, supplier, or a mode of transportation. In these situations the coordination of shared, and often limited, resources across items is economically attractive. This paper describes a mixed‐integer programming formulation and Lagrangian relaxation solution procedure for the single‐family coordinated capacitated lot‐sizing problem with dynamic demand. The problem extends both the multi‐item capacitated dynamic demand lot‐sizing problem and the uncapacitated coordinated dynamic demand lot‐sizing problem. We provide the results of computational experiments investigating the mathematical properties of the formulation and the performance of the Lagrangian procedures. The results indicate the superiority of the dual‐based heuristic over linear programming‐based approaches to the problem. The quality of the Lagrangian heuristic solution improved in most instances with increases in problem size. Heuristic solutions averaged 2.52% above optimal. The procedures were applied to an industry test problem yielding a 22.5% reduction in total costs.     

An Expected Consequence Approach to Route Choice in the Maritime Transportation of Crude Oil

Maritime transportation is the major conduit of international trade, and the primary link for global crude oil movement. Given the volume of oil transported on international maritime links, it is not surprising that oil spills of both minor and major types result, although most of the risk‐related work has been confined to the local settings. We propose an expected consequence approach for assessing oil‐spill risk from intercontinental transportation of crude oil that not only adheres to the safety guidelines specified by the International Maritime Organization but also outlines a novel technique that makes use of coarse global data to estimate accident probabilities. The proposed estimation technique, together with four of the most popular cost‐of‐spill models from the literature, were applied to study and analyze a realistic size problem instance. Numerical analyses showed that: a shorter route may not necessarily be less risky; an understanding of the inherent oil‐spill risk of different routes could potentially facilitate tanker routing decisions; and the associated negotiations over insurance premium between the transport company and the not‐for‐profit prevention and indemnity clubs. Finally, we note that only the linear model should be used with one of the three nonlinear cost‐of‐spill models for evaluating tanker routes.     

Distributed Decision‐Making in Supply Chains and Private E‐Marketplaces

This paper develops a distributed decision‐making framework for the players in a supply chain or a private e‐marketplace to collaboratively arrive at a global Pareto‐optimal solution. In this model, no player has complete knowledge about all the costs and constraints of the other players. The decision‐making framework employs an iterative procedure, based on the Integer L‐shaped method, in which a master problem is solved to propose global solutions, and each player uses his local problems to construct feasibility and optimality cuts on the master problem. The master problem is modeled as a mixed‐integer program, and the players' local problems are formulated as linear programs. Collaborative planning scenarios in private e‐marketplaces and in supply chains were formulated and solved for test data. The results show that this distributed model is able to achieve near‐optimal solutions considerably faster than the traditional centralized approach.     

Facility Location: A Robust Optimization Approach

In this research, we apply robust optimization (RO) to the problem of locating facilities in a network facing uncertain demand over multiple periods. We consider a multi‐period fixed‐charge network location problem for which we find (1) the number of facilities, their location and capacities, (2) the production in each period, and (3) allocation of demand to facilities. Using the RO approach we formulate the problem to include alternate levels of uncertainty over the periods. We consider two models of demand uncertainty: demand within a bounded and symmetric multi‐dimensional box, and demand within a multi‐dimensional ellipsoid. We evaluate the potential benefits of applying the RO approach in our setting using an extensive numerical study. We show that the alternate models of uncertainty lead to very different solution network topologies, with the model with box uncertainty set opening fewer, larger facilities. Through sample path testing, we show that both the box and ellipsoidal uncertainty cases can provide small but significant improvements over the solution to the problem when demand is deterministic and set at its nominal value. For changes in several environmental parameters, we explore the effects on the solution performance.     

Scheduling of Multi‐skilled Staff Across Multiple Locations

We address the problem of assigning airline customer service agents (CSAs) to tasks related to departing flights, such as selling tickets and collecting boarding cards, at an international terminal of a large airport. The airline specifies minimum and target levels of staff and required (or desired) types and levels of skills for each location in each time period. The assignment problem is complicated by staff heterogeneity, time required for moves between locations, and lunch and rest‐break requirements. We present a mixed‐integer formulation that considers both staffing shortages and skills mismatches and show that the problem is NP‐hard. We derive valid inequalities that tighten the bounds within a branch‐and‐cut procedure, enabling us to obtain near‐optimal solutions for problems of realistic size very quickly. We also present a generalization to simultaneously optimize shift starting times and task assignments, which can aid in longer term workforce planning. Finally, we utilize our procedure to obtain managerial insights regarding the benefits of flexibility derived from more highly skilled staff, allowing more frequent moves, and choices of shift starting times. We also demonstrate the benefits of our procedure vs. a heuristic that mimics what an experienced scheduler might choose.     

Pay‐Back‐Revenue‐Sharing Contract in Coordinating Supply Chains with Random Yield

We consider coordination issues in supply chains where supplier's production process is subject to random yield losses. For a simple supply chain with a single supplier and retailer facing deterministic demand, a pay back contract which has the retailer paying a discount price for the supplier's excess units can provide the right incentive for the supplier to increase his production size and achieve coordination. Building upon this result, we consider coordination issues for two other supply chains: one with competing retailers, the other with stochastic demand. When retailers compete for both demand and supply, they tend to over‐order. We show that a combination of a pay back and revenue sharing mechanism can coordinate the supply chain, with the pay back mechanism correcting the supplier's under‐producing problem and the revenue sharing mechanism correcting the retailers' over‐ordering problem. When demand is stochastic, we consider a modified pay‐back‐revenue‐sharing contract under which the retailer agrees to not only purchase the supplier's excess output (beyond the retailer's order), but also share with the supplier a portion of the revenue made from the sales of the excess output. We show that this contract, by giving the supplier additional incentives in the form of revenue share, can achieve coordination.     

Scheduling Truck Arrivals at an Air Cargo Terminal

We consider the scheduling of truck arrivals at an air cargo terminal. By coordinating arrivals of cargo delivery trucks with outbound flight departure schedules, some of the shipments can be transferred directly to the departing flights, while others will be stored at the terminal's storage facility and incur extra handling and storage costs. The objective is to obtain a feasible schedule so as to minimize the total cost of operations. We formulate the problem as a time‐indexed integer program and show that, even with limited number of unloading docks at the terminal, the problem is non‐trivial (NP‐hard in the strong sense). Our solution method includes an exact solution procedure to determine an optimal unloading sequence for the shipments carried by each truck, together with a Lagrangian relaxation‐based heuristic for assigning trucks to truck docks and determining truck arrival times. We conducted computational experiments to test the performance of our solution method. Computational results show that our method can generate near‐optimal solutions efficiently. Our simulation results indicate that the scheduling approach proposed in this paper has the potential to generate significant cost savings over a first‐come, first‐served approach currently used at the air cargo terminal that we observed.     

A Framework for Facilitating Sourcing and Allocation Decisions for Make‐to‐Order Items

This paper provides a fundamental building block to facilitate sourcing and allocation decisions for make‐to‐order items. We specifically address the buyer's vendor selection problem for make‐to‐order items where the goal is to minimize sourcing and purchasing costs in the presence of fixed costs, shared capacity constraints, and volume‐based discounts for bundles of items. The potential suppliers for make‐to‐order items provide quotes in the form of single sealed bids or participate in a dynamic auction involving open bids. A solution to our problem can be used to determine winning bids amongst the single sealed bids or winners at each stage of a dynamic auction. Due to the computational complexity of this problem, we develop a heuristic procedure based on Lagrangian relaxation technique to solve the problem. The computational results show that the procedure is effective under a variety of scenarios. The average gap across 2,250 problem instances is 4.65%.     

Robust Resource Allocation Decisions in Resource‐Constrained Projects*

The well‐known deterministic resource‐constrained project scheduling problem involves the determination of a predictive schedule (baseline schedule or pre‐schedule) of the project activities that satisfies the finish–start precedence relations and the renewable resource constraints under the objective of minimizing the project duration. This baseline schedule serves as a baseline for the execution of the project. During execution, however, the project can be subject to several types of disruptions that may disturb the baseline schedule. Management must then rely on a reactive scheduling procedure for revising or reoptimizing the baseline schedule. The objective of our research is to develop procedures for allocating resources to the activities of a given baseline schedule in order to maximize its stability in the presence of activity duration variability. We propose three integer programming–based heuristics and one constructive procedure for resource allocation. We derive lower bounds for schedule stability and report on computational results obtained on a set of benchmark problems.     

Optimal Sourcing and Lead‐Time Reduction under Evolutionary Demand Risk

We develop a real‐options model for optimizing production and sourcing choices under evolutionary supply‐chain risk. We model lead time as an endogenous decision and calculate the cost differential required to compensate for the risk exposure coming from lead time. The shape of the resulting cost‐differential frontier reveals the term structure of supply‐chain risk premiums and provides guidance as to the potential value of lead‐time reduction. Under constant demand volatility, the break‐even cost differential increases in volatility and lead time at a decreasing rate, making incremental lead‐time reduction less valuable than full lead‐time reduction. Stochastic demand volatility increases the relative value of incremental lead‐time reduction. When demand has a heavy right tail, the value of lead‐time reduction depends on how extreme values of demand are incorporated into the forecasting process. The cost‐differential frontier is invariant to discount rates, making the cost of capital irrelevant for choosing between lead times. We demonstrate the managerial implications of the model by applying it first to the classic Sport‐Obermeyer case and then to a supplier‐selection problem faced by a global manufacturer.     

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.     

DYNAMIC LOT SIZING FOR A SINGLE-FACILITY MULTIPRODUCT PROBLEM IN A ROLLING-HORIZON ENVIRONMENT

This paper considers a production planning model for a single-facility multiproduct problem where backlogging is not allowed. A planning-horizon theorem is derived. From that theorem, a forward algorithm for finding an optimal solution over a finite horizon and a procedure for selecting the first-period production in a rolling-horizon environment are developed. Computational results from a set of simulation experiments designed to investigate the cost effectiveness of the procedure demonstrate its effectiveness.     

The Retail Planning Problem Under Demand Uncertainty

We consider the retail planning problem in which the retailer chooses suppliers and determines the production, distribution, and inventory planning for products with uncertain demand to minimize total expected costs. This problem is often faced by large retail chains that carry private‐label products. We formulate this problem as a convex‐mixed integer program and show that it is strongly NP‐hard. We determine a lower bound by applying a Lagrangian relaxation and show that this bound outperforms the standard convex programming relaxation while being computationally efficient. We also establish a worst‐case error bound for the Lagrangian relaxation. We then develop heuristics to generate feasible solutions. Our computational results indicate that our convex programming heuristic yields feasible solutions that are close to optimal with an average suboptimality gap at 3.4%. We also develop managerial insights for practitioners who choose suppliers and make production, distribution, and inventory decisions in the supply chain.     

Allocation of Returned Products among Different Recovery Options through an Opportunity Cost–Based Dynamic Approach*

In a make‐to‐order product recovery environment, we consider the allocation decision for returned products decision under stochastic demand of a firm with three options: refurbishing to resell, parts harvesting, and recycling. We formulate the problem as a multiperiod Markov decision process (MDP) and present a linear programming (LP) approximation that provides an upper bound on the optimal objective function value of the MDP model. We then present two solution approaches to the MDP using the LP solution: a static approach that uses the LP solution directly and a dynamic approach that adopts a revenue management perspective and employs bid‐price controls technique where the LP is resolved after each demand arrival. We calculate the bid prices based on the shadow price interpretation of the dual variables for the inventory constraints and accept a demand if the marginal value is higher than the bid price. Since the need for solving the LP at each demand arrival requires a very efficient solution procedure, we present a transportation problem formulation of the LP via variable redefinitions and develop a one‐pass optimal solution procedure for it. We carry out an extensive numerical analysis to compare the two approaches and find that the dynamic approach provides better performance in all of the tested scenarios. Furthermore, the solutions obtained are within 2% of the upper bound on the optimal objective function value of the MDP model.     

Managing Production and Distribution for Supply Chains in the Processed Food Industry

We develop and evaluate a modeling approach for making periodic review production and distribution decisions for a supply chain in the processed food industry. The supply chain faces several factors, including multiple products, multiple warehouses, production constraints, high transportation costs, and limited storage at the production facility. This problem is motivated by the supply chain structure at Amy's Kitchen, one of the leading producers of natural and organic foods in the United States. We develop an enhanced myopic two‐stage approach for this problem. The first stage determines the production plan and uses a heuristic, and the second stage determines the warehouse allocation plan and uses a non‐linear optimization model. This two‐stage approach is repeated every period and incorporates look‐ahead features to improve its performance in future periods. We validate our model using actual data from one factory at Amy's Kitchen and compare the performance of our model to that of the actual operation. We find that our model significantly reduces both inventory levels and stockouts relative to those of the actual operation. In addition, we identify a lower bound on the total costs for all feasible solutions to the problem and measure the effectiveness of our model against this lower bound. We perform sensitivity analysis on some key parameters and assumptions of our modeling approach.     

A Practical Two‐Step Method for Testing Moment Inequalities

This paper considers the problem of testing a finite number of moment inequalities. We propose a two‐step approach. In the first step, a confidence region for the moments is constructed. In the second step, this set is used to provide information about which moments are “negative.” A Bonferonni‐type correction is used to account for the fact that, with some probability, the moments may not lie in the confidence region. It is shown that the test controls size uniformly over a large class of distributions for the observed data. An important feature of the proposal is that it remains computationally feasible, even when the number of moments is large. The finite‐sample properties of the procedure are examined via a simulation study, which demonstrates, among other things, that the proposal remains competitive with existing procedures while being computationally more attractive.     

Inventory Control with a Fixed Cost and a Piecewise Linear Convex Cost

This paper studies the optimal policy for a periodic‐review inventory system in which the production costs consist of a fixed cost and a piecewise linear convex variable cost. Such a cost function can arise from alternate sources of supply or from the use of overtime production. We fully characterize the structure of the optimal policy for the single‐period problem. For the multi‐period problem, the optimal policy can have disconnected production regions and complicated optimal produce‐up‐to levels, which implies that implementation of the optimal policy may not be practical. Fortunately, careful investigation shows that the optimal policy has some interesting properties. The structure of the optimal policy outlined by these properties leads to a practical and close‐to‐optimal heuristic policy. In an extensive numerical study, the average gap is only 0.02% and the worst gap is 1.37%.     

Long‐Term Contracting: The Role of Private Information in Dynamic Supply Risk Management

We examine the critical role of evolving private information in managing supply risk. The problem features a dyadic channel where a dominant buyer operates a multiperiod inventory system with lost sales and fixed cost. He replenishes from a supplier, whose private state of production is vulnerable to random shocks and evolves dynamically over time. We characterize the optimal inventory policy with a simple semi‐stationary structure; it distorts order quantity for limiting information rent only in the initial period; the optimal payment compensates for production cost in every period but concedes real information rent only in the initial period. These properties allow us to derive an easy‐to‐implement revenue‐sharing contract that facilitates ex ante strategic planning and ex post dynamic execution. This work advances our understanding on when and how to use private information in dynamic risk management.     

Multistage Stochastic Optimization for Production‐Inventory Planning with Intermittent Renewable Energy

A growing number of companies install wind and solar generators in their energy‐intensive facilities to attain low‐carbon manufacturing operations. However, there is a lack of methodological studies on operating large manufacturing facilities with intermittent power. This study presents a multi‐period, production‐inventory planning model in a multi‐plant manufacturing system powered with onsite and grid renewable energy. Our goal is to determine the production quantity, the stock level, and the renewable energy supply in each period such that the aggregate production cost (including energy) is minimized. We tackle this complex decision problem in three steps. First, we present a deterministic planning model to attain the desired green energy penetration level. Next, the deterministic model is extended to a multistage stochastic optimization model taking into account the uncertainties of renewables. Finally, we develop an efficient modified Benders decomposition algorithm to search for the optimal production schedule using a scenario tree. Numerical experiments are carried out to verify and validate the model integrity, and the potential of realizing high‐level renewables penetration in large manufacturing system is discussed and justified.