The optimal operation planning of a Kanban system with variable lead times

In the majority of the previous research on Kanban systems delivery lead time is treated as a fixed value. In many practical situations, however, the lead time is variable. In this paper, optimal operation planning of a fixed interval withdrawal Kanban with variable lead times is proposed. A cost is incurred for inventory level less than the safety inventory level, since the risk of shortage of inventory must be considered. Behaviour of the optimal number of Kanbans and the withdrawal interval of Kanbans are investigated in terms of various parameters such as standard deviation and mean lead time.     

An algorithm to dynamically adjust the number of Kanbans in stochastic processing times and variable demand environment

In a real-life environment, the just-in-time JIT system is subjected to various types of uncertainties such as stochastic processing times and variable demand. Since, JIT was only meant to operate in a deterministic environment, its performance is seriously affected by variations in processing times and demand. In this paper, a newly developed Kanban system is presented which uses an algorithm to dynamically and systematically manipulate the number of Kanbans in order to offset the blocking and starvation caused by the said uncertainties during a production cycle. The new system is termed a flexible Kanban system FKS . The steps of the algorithm are detailed and the effectiveness of FKS is demonstrated using an example model. For the example model, the solution procedure, results and a discussion are presented.     

Optimal dispatching control of an AGV in a JIT production system

This paper deals with an FMS (Flexible Manufacturing System) in a JIT (Just-In-Time) production system. The FMS consists of m workstations, one dispatching station and a single AGV (Automated Guided Vehicle). Each workstation has an input buffer of limited capacity and its processing times are distributed stochastically. When the processing of a new component starts at the workstation, a withdrawal Kanban attached to it is sent to the dispatching station. The AGV chooses one from workstations whose withdrawal Kanbans are accumulated at the dispatching station, and conveys a component with a withdrawal Kanban from the dispatching station to the workstation. The main purpose of this paper is to find an optimal dispatching policy of the AGV that maximizes the long-run expected average reward per unit time. The problem is formulated as a semi-Markov decision process and an optimal dispatching policy is computed. Numerical experiments are performed to make several comparisons.     

协作车辆路径成本分摊问题的 B-T Shapley 方法

多个企业协作配送能显著地降低物流配送成本和减少尾气排放, 研究协作配送模型与成本分摊方法是亟需解决的关键问题.传统经典成本分摊方法需要计算所有子联盟的协作成本, 在本问题中等价于需要求解2N-1个 (N为企业数量) 复杂的车辆路径问题.本文建立了多方协作车辆路径问题模型, 分析了协作配送成本分摊问题的属性.基于经典的Shapley成本分摊方法, 提出了B-T (Binary Tree) Shapley近似方法, 不仅将成本分摊本身计算复杂度由O (N22N) 降为O (N2log2N) , 而且将需要求解的车辆路径问题数量由2N-1个锐减至2N-1个, 从而能够在合理时间内完成协作配送问题的成本分摊.通过求解算例和实际案例, 计算结果表明, B-T Shapley的耗时与Shapley方法相比几乎可以忽略不计, 更重要的是B-T Shapley与Shapley的成本分摊结果之间仅有细微的偏差, 其平均准确度可以达到95%左右.     

Optimal Food Safety Sampling Under a Budget Constraint

Much of the literature regarding food safety sampling plans implicitly assumes that all lots entering commerce are tested. In practice, however, only a fraction of lots may be tested due to a budget constraint. In such a case, there is a tradeoff between the number of lots tested and the number of samples per lot. To illustrate this tradeoff, a simple model is presented in which the optimal number of samples per lot depends on the prevalence of sample units that do not conform to microbiological specifications and the relative costs of sampling a lot and of drawing and testing a sample unit from a lot. The assumed objective is to maximize the number of nonconforming lots that are rejected subject to a food safety sampling budget constraint. If the ratio of the cost per lot to the cost per sample unit is substantial, the optimal number of samples per lot increases as prevalence decreases. However, if the ratio of the cost per lot to the cost per sample unit is sufficiently small, the optimal number of samples per lot reduces to one (i.e., simple random sampling), regardless of prevalence. In practice, the cost per sample unit may be large relative to the cost per lot due to the expense of laboratory testing and other factors. Designing effective compliance assurance measures depends on economic, legal, and other factors in addition to microbiology and statistics.     

Algorithms and time complexity of the request-service problem

Given a number of users each of which provides a set of services with a cost for each service and has a set of requests to be satisfied, the goal of the request-service problem is to find a feasible solution that satisfies all requests of each user with minimum cost. In addition, a feasible solution must satisfy an additional constraint. Specifically, if user A provides a service to user B, B should provide a service back to A either directly or indirectly through other users. In this paper, we studied the complexity of this problem. We show that there exists a polynomial time algorithm that can compute a feasible solution with minimum cost if such a solution exists. However, if a feasible solution does not exist, the problem of maximizing the number of satisfied users (i.e., all requests of the users are satisfied) is NP-hard.     

Lead Time Management through Expediting in a Continuous Review Inventory System

We consider a continuous review inventory system where delivery lead times can be managed by expediting in‐transit orders shipped from the supplier. First, we propose an ordering/expediting policy and derive expressions for evaluating the operating characteristics of such systems. Second, using extensive numerical experiments, we quantify the benefits of such an expediting policy. Third, we investigate a number of managerial issues. Specifically, we analyze the impact of the number of expediting hubs and their locations along the shipment network on the performance of such systems and offer insights into the design of the shipment network. We show (i) a single expediting hub that is optimally located in a shipment network can capture the majority of cost savings achieved by a multi‐hub system, especially when expediting cost is not low or demand variability is not high; (ii) when expediting time is proportional to the time to destination, for small‐enough or large‐enough demand variations, a single expediting hub located in the middle of the shipment network can capture the majority of cost savings of an optimally located hub; and (iii) in general, hubs close to the retailer significantly drive down costs, whereas hubs close to the supplier may not offer much cost savings.     

基于碳排放的废弃产品回收站点分布研究

基于碳税价格对废弃产品回收运营决策的影响考虑,本文从整个社会的视角,把顾客、回收站点、回收总站作为一个整体进行考虑,并分析碳税价格对回收站点数量和成本的影响。首先,将顾客、回收站点和回收处理中心作为整体,考虑能源成本、运营成本和碳排放费用,建立废弃产品回收站点分布的社会总成本模型。接着,对碳税价格为零和碳税价格无穷大两种极端情况,分析了回收站点的数量、碳税价格、社会总成本等因素之间的关系。最后对模型进行数值计算。结果表明：当前碳税价格下,同时考虑碳税成本和运营费用或仅考虑运营费用这两种情况计算出来的回收站点数量相等,单位总成本区别不显著,即碳税价格对运营影响不大;若仅考虑碳税成本,则回收站点数量变化较大,即合理的碳税价格对运营影响显著;碳税价格理想的定价应该在40.03至66.46之间;回收站点数量为66时,碳排放量最优。     

Lowering Inventory Systems Costs by Using Regression-Derived Estimators of Demand Variability*

Scientific techniques for inventory management typically are applied to systems containing many items. Such techniques require an estimation of the demand variance (and mean) of each item from historical data. This research demonstrates a significant potential for improvement in system cost performance from using least-squares regression fits of a variance-to-mean functional relation instead of the standard statistical variance estimate. Even when there is a moderate degree of heterogeneity among items and when the form of the variance-to-mean relation is misspecified, substantial cost savings may be realized. The cost of statistical uncertainty may be reduced by half. The research also provides evidence that system cost is fairly insensitive to the number of items used to fit the regression. This paper provides the underlying reason why a regression-derived variance estimator yields lower cost: it is less variable than the usual individual item variance estimator.     

考虑组织成本的两阶段竞赛机制研究

在企业招聘实践中,招聘成本是企业管理者在制定招聘策略时所考虑的重要因素之一。为保证招聘效果并控制成本,企业管理者将选择不同成本的人才测评方法,分阶段地筛选应聘者,选择测评方法和确定各阶段应聘者人数成为企业管理者主要的决策问题。在此管理背景下,进行两阶段竞赛机制的研究,并将节约组织成本作为竞赛设计者目标的一部分。分别修改竞赛者总努力最大化和最高努力最大化这两个传统目标,得到两个修正后的优化目标。当竞赛者能力分布函数为幂函数时,通过模型分析和数值模拟。研究结果表明,两个优化目标下的最优竞赛机制具有共同性质,即针对确定的奖励选择竞赛筛选方法时,单位组织成本不能过大;在确定筛选方法后,如果奖励与单位组织成本的比值过小,或低能力者占竞赛者的大部分,那么应仅允许两名竞赛者进入复试。另外,对于以竞赛者最高努力最大化为目标的竞赛,如果高能力者相对较多时,第二阶段的最优竞赛人数也为2。     

Effects of Product Structure Complexity on Multi-level Lot Sizing*

As an input to the materials requirement planning (MRP) process, the product structure interacts with the lot-sizing rules to affect inventories, materials flow, and production costs. Despite engineering constraints, considerable latitude is still available to construct alternate product structures for the same product. An important concern of MRP managers and designers is the impact of product structure complexity on the cost performance of the lot-sizing rules. To date, there exists no detailed research that provides managers with guidelines that relate the lot-sizing rules to individual product structure parameters. We report on an extensive experiment to test the effects of individual product structure parameters on the relative cost performance of 11 lot-sizing rules. Three parameters—the number of items, number of levels, and commonality index—are proposed to characterise product structure complexity and used as factors in an experiment involving a large variety of product structures. The results indicate that all three parameters affect the relative cost differences but not the ranking of the rules. The overall best lot-sizing rule is Bookbinder and Koch's [11] rule.     

蓄冷式多温集配路径优化模型

现实中,由于配送中心选址对占地面积、土地成本等要求较高,加之物流企业资金有限或交通拥堵等限制,配送中心的设置通常会远离市中心。为了减少集货与配送车辆往返配送中心的次数以及车辆行驶距离,本文以总成本最小化,包括车辆派遣成本、行驶成本、碳排放成本、违背时间窗的惩罚成本、保温柜/箱成本、非整箱货物的配送成本,构建了1个配送中心由大型车辆为m个供应商采用蓄冷柜/蓄冷箱集货,由1个虚拟接驳点(中型车辆)结合小型车辆为n个零售门店采用蓄冷箱多温共配的路径优化模型,并设计了基于蚁群算法的混合更新信息素策略。以20个零售门店与6个海鲜供应商的三种品温海鲜品为仿真算例,验证了模型的有效性。实例分析发现：引入虚拟接驳点的配送线路数低于单纯的配送线路数;时间窗限制越宽松,引入虚拟接驳点的优越性越突出;具有虚拟接驳点的多温集配总成本低于自配送中心的集配总成本;具有虚拟接驳点的蓄冷式多温集配尤其利于低碳环保的冷链系统构建。     

Analyzing the Cost of Screening Selectee and Non-Selectee Baggage

Determining how to effectively operate security devices is as important to overall system performance as developing more sensitive security devices. In light of recent federal mandates for 100% screening of all checked baggage, this research studies the trade-offs between screening only selectee checked baggage and screening both selectee and non-selectee checked baggage for a single baggage screening security device deployed at an airport. This trade-off is represented using a cost model that incorporates the cost of the baggage screening security device, the volume of checked baggage processed through the device, and the outcomes that occur when the device is used. The cost model captures the cost of deploying, maintaining, and operating a single baggage screening security device over a one-year period. The study concludes that as excess baggage screening capacity is used to screen non-selectee checked bags, the expected annual cost increases, the expected annual cost per checked bag screened decreases, and the expected annual cost per expected number of threats detected in the checked bags screened increases. These results indicate that the marginal increase in security per dollar spent is significantly lower when non-selectee checked bags are screened than when only selectee checked bags are screened.     

DECENTRALIZED MULTIECHELON INVENTORY CONTROL

This paper considers a model for decentralized control of an inventory system consisting of 1 central warehouse and a number of retailers. The cost structure includes holding costs at both echelons and shortage costs proportional to the time until delivery at the retailers. We analyze a procedure for coordinated but still decentralized control of the system. The procedure is based on a simple approximation, in which the stochastic lead times perceived by the retailers are replaced by their correct averages. The approximation enables us to decompose the considered multiechelon inventory problem into a number of single echelon problems, 1 for each installation. The information about how a certain decision at the warehouse affects the retailers is conveyed through the marginal cost increase with respect to a change of the expected lead time. This information about the retailer costs is used as a shortage cost at the warehouse. We show that a coordination procedure based on this information can be used for finding near-optimal reorder points for the system and provide bounds for the approximation errors.     

Efficient formation of storage classes for warehouse storage location assignment: A simulated annealing approach

Class-based storage policy distributes products among a number of classes and for each class it reserves a region within the storage area. The procedures reported in the literature for formation of storage classes primarily consider order-picking cost ignoring storage-space cost. Moreover, in these procedures items are ordered on the basis of their cube per order index (COI), and items are then partitioned into classes maintaining this ordering. This excludes many possible product combinations in forming classes which may result in inferior solutions. In this paper, a simulated annealing algorithm (SAA) is developed to solve an integer programming model for class formation and storage assignment that considers all possible product combinations, storage-space cost and order-picking cost. Computational experience on randomly generated data sets and an industrial case shows that SAA gives superior results than the benchmark dynamic programming algorithm for class formation with COI ordering restriction.     

一种能力外包且费用时变批量问题的启发式算法

当企业自身能力不能满足需求时考虑外包,可以有效提高企业的竞争力。一种带能力外包的多产品动态经济批量问题得以提出,并设定外包能力使用价格较高且费用时变。建立混合整数规划模型,通过约束松弛与模型分解,设计出一个基于拉格朗日松弛理论的启发式算法进行模型求解。大量随机实验表明,无论解的质量还是求解时间都表现较好。     

The optimal number of suppliers considering the costs of individual supplier failures

This paper utilizes the decision tree approach to determine the optimal number of suppliers in the presence of supplier failure risks. Previous proposed models have considered only two states of nature: all suppliers fail to deliver and not all suppliers fail to deliver. In practice, however, there is clearly a partial loss associated with the failure of any individual supplier. We present models that allow a more realistic decision-making process by taking into consideration the independent risks of individual supplier failures when the probability of failure for each of the suppliers is equal as well as the case where the probability of failure from each of the suppliers is not equal. We also consider various levels of supplier failure probability and possible procurement or operating cost savings gained from using less reliable suppliers. The results indicate that when suppliers are highly reliable, sole sourcing is the lowest cost approach under all experimental conditions. However, as the suppliers become less reliable, additional suppliers may be required to obtain the lowest cost. Finally, it was shown that only in the extreme conditions of unreliable suppliers, high loss to operational cost per supplier, and low ability to mitigate the failure from a partial set of suppliers, having a large number of suppliers is an effective strategy.     

A genetic algorithm approach to developing the multi-echelon reverse logistics network for product returns

Traditionally, product returns have been viewed as an unavoidable cost of doing business, forfeiting any chance of cost savings. As cost pressures continue to mount in this era of economic downturns, a growing number of firms have begun to explore the possibility of managing product returns in a more cost-efficient manner. However, few studies have addressed the problem of determining the number and location of centralized return centers (i.e., reverse consolidation points) where returned products from retailers or end-customers were collected, sorted, and consolidated into a large shipment destined for manufacturers’ or distributors’ repair facilities. To fill the void in such a line of research, this paper proposes a nonlinear mixed-integer programming model and a genetic algorithm that can solve the reverse logistics problem involving product returns. The usefulness of the proposed model and algorithm was validated by its application to an illustrative example dealing with products returned from online sales.     

Coalition Formation and Cost Allocation for Joint Replenishment Systems

This paper focuses on the issues of coalition formation and cost allocation in a joint replenishment system involving a set of independent and freely interacting retailers purchasing an item from one supplier to meet a deterministic demand. The papers dealing with this problem are mainly focused on supperadditive games, where the cost savings associated with a coalition increase with the number of players in the coalition. The most relevant question addressed then is how to allocate the savings to the players. In this paper, we propose to go further by dealing with a non‐supperadditive game, where a set of independent retailers have the common understanding to share the cost savings according to the cost‐based proportional rule. In this setting, the global cost optimization is no longer a relevant approach to identify appealing coalitions for any retailer. Here, we provide an iterative procedure to form the so‐called efficient coalition structure and we show that this coalition structure has the nice properties of being (i) weakly stable in the sense of the coalition structure core and (ii) strongly stable under a given assumption. An exact fractional programming based solution is also given to generate such efficient coalitions.     

A Hint of Risk: Tradeoffs Between Quantitative and Qualitative Risk Factors

Risk-perception research plays an active role in discussions of risk-management alternatives. However, little guidance is provided regarding how public concerns should be weighed against other sources of cost and benefits. This paper reports the results of two experiments that measure tradeoffs among cost (in dollars), a quantitative risk measure (number of deaths or injuries), and several qualitative characteristics associated with perceived risk. Most subjects were willing to make the requested trade. However, the perceived risk information led others to reject the proposed technology.