A coordination mechanism with fair cost allocation for divergent multi-echelon inventory systems

In this paper we study the coordination of inventory control in divergent multi-echelon inventory systems under periodic review and decentralized control. Under decentralized control the installations decide upon replenishment policies that minimize their individual inventory costs. In general these policies do not coincide with the optimal policies of the system under centralized control. Hence, the total cost under decentralized control is larger than under centralized control. We present a simple coordination mechanism that removes this cost inefficiency. The upstream installations increases its base stock level while the downstream installations compensate their supplier for increased costs and provide it with additional side payments. We show that this mechanism coordinates the system; the global optimal policy of the system is the unique Nash equilibrium of the corresponding strategic game. Furthermore, the mechanism results in a fair allocation of the costs; all installations enjoy cost savings.     

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.     

An echelon inventory-based single-stage cost function for a two-station tandem system

We propose an alternative cost-accounting function for inventory control problems on a make-to-stock setting. Our proposal is based on observing that the traditional holding and backlog parameters introduce some odd short term distortions on the inventory state space. Our single-stage cost function accounts for echelon inventories and possesses a pair of cost parameters for each echelon inventory variable, depending on whether it is positive or negative. With the modified cost-accounting function, we study a twostation tandem system producing a single product, and investigate how it compares with the performances obtained with the usual single-stage cost function. The results available so far show that the optimal policies approach a multi-echelon base stock structure for each machine. Also, the service levels achieved are better under the modified function without increasing the levels of finished goods inventory.     

Inventory Positioning/Partitioning for Backorders Optimization for a Class of Multi-Echelon Inventory Problems*

Inventory management has undergone significant philosophical changes in recent decades such as the advent of the zero inventory concept. However, as attractive as the concept of minimal inventories may be, it is often unrealistic in application. Attention to basic features of inventory control systems such as order quantities, base stock levels, and reorder points remain crucial to ensure customer service at minimal cost. A nonlinear optimization model for determining base stock levels in a multi-echelon inventory network is presented. Lagrangian relaxation results in (1) newsboy-style relations that provide the optimal solutions, and (2) instantaneous shadow prices for the budget constraint. Sensitivity analysis of this model will facilitate making decisions concerning the desired investment in inventory for the entire system. This model may be solved on standard nonlinear programming software and is generalizable to problems in both production and distribution settings.     

Pricing decisions in a multi-criteria setting for product recovery facilities

Unpredictability in the arrival time and quantity of discarded products at product recovery facilities (PRFs) and varying demand for recovered components contribute to the volatility in their inventory levels. Achieving profit under such capricious inventory levels and stringent environmental legislations remains a challenge to many PRFs. This paper presents a multi-criteria decision model to determine a pricing policy that can simultaneously address two issues: stabilize inventory fluctuations and boost profits. The model considers that PRFs passively accepts discarded products as well as acquires them proactively if necessary. Under a multi-criteria setting, the current work determines prices of reusable and recyclable components to maximize revenue and minimize product recovery costs. A genetic algorithm is employed to solve the multi-criteria decision making problem. Sensitivity analysis is performed to investigate the effect of sorting yield, disassembly yield, and reusable component yield on the profits, prices, inventory levels, and disposal quantities.     

航空公司机上周转品多基地库存优化模型

在民航业日益激烈的市场竞争环境下,航空公司对成本控制的精细化管理显得尤为重要。本文基于航空公司的实际背景,针对为旅客提供的机上周转品,建立了一个多基地库存系统的库存优化模型。该模型以系统的总库存成本最小为目标,在考虑需求、回收、调运、安全库存等因素下,决策一个订货周期内的订货及调运方案。基于最优解的分析,在成本参数满足一定条件下,可以得到系统最优的期初订货量;在此基础上,可以将该模型转化为一个网络流模型,参考最小费用最大流算法,设计了一个多项式求解算法来求解该网络流模型,进而得到各基地之间的最优调运量,并证明该算法的最优性;此外,根据期初订货量可行解的范围,设计了一个求解原库存模型的启发式算法。通过实例分析,验证了该模型与两种算法的有效性。     

Joint production and subcontracting planning of unreliable multi-facility multi-product production systems

This article addresses the problem of joint optimization of production and subcontracting of unreliable production systems. The production system considered presents a common problem in the pharmaceutical industry. It is composed of multiple production facilities with different capacities, each of which is capable of producing two different classes of medications (brand name and generic). The resort to subcontracting is double: first, it involves the quantity of products received on a regular basis in order to compensate for insufficient production capacity in existing facilities, second, when needed, urgent orders are also launched in order to reduce the risk of shortages caused by breakdowns of manufacturing facilities. Failures, repairs and urgent delivery times may be represented by any probability distributions.The objective is to propose a general control policy for the system under consideration, and to obtain, in the case of two facilities, optimal control parameters that minimize the total incurred cost for a specific level of the customer service provided. Given the complexity of the problem considered, an experimental optimization approach is chosen in order to determine the optimal control parameters. This approach includes experimental design, analysis of variance, response surface methodology and simulation modeling. It allows the accurate representation of the dynamic and stochastic behaviors of the production system and the assessment of optimal control parameters. Other control parameters which represent the subcontracting are introduced and three joint production/subcontracting control policies (general, urgent, regular) are compared to one another. The proposed joint production/regular subcontracting control policy involves a cost decrease of up to 20%, as compared to results obtained by Dror et al. [1], who used a simplified control policy in addition to a heuristic solution approach for a real case study. This policy offers not only cost savings, but is also easier to manage, as compared to that proposed by Dror et al. [1]. Numerical examples and a sensitivity analysis are also performed to illustrate the robustness of the proposed control policy and the solution approach.     

短生命周期产品的三种库存模型的比较

讨论短生命周期产品库存模型,考虑无形变质因素,并假定无形变质率与需求率成反比关系.在线性需求和常数生产率的条件下,假设,若需求率为1,则视作产品的市场生命周期结束.并且,在产品生命周期的前期不存在缺货的情况下,给出了短生命周期产品分别在理想状态、允许缺货以及价格折扣导致需求率变化等3种状态下的库存模型,最后在相同参数条件下对这3种模型进行比较,找出了单位时间内平均总成本最小的最优库存模型,厂商可以根据自身的情况选择合适的库存策略.     

The Effects of Sharing Upstream Information on Product Rollover

The process of introducing new and phasing out old products is called product rollover. This paper considers a periodic‐review inventory system consisting of a manufacturer and a retailer, where the manufacturer introduces new and improved products over an infinite planning horizon using the solo‐roll strategy. We consider two scenarios: (1) the manufacturer does not share the upstream information about new‐product introduction with the retailer and (2) the manufacturer shares the information. For each scenario, we first derive the decentralized ordering policy and the system‐optimal ordering policy with given cost parameters. We then devise an optimal supply chain contract that coordinates the inventory system. We demonstrate that when the inventory system is coordinated, information sharing improves the performance of both supply chain entities. However, this may not be true if the inventory system is not coordinated. We also show that under the optimal contract, the manufacturer has no incentive to mislead the retailer about new‐product information in the information‐sharing model. When demand variability increases, information sharing adds more benefits to the coordinated supply chain. Our research provides insights about coordinating product, financial, and information flows in supply chains with product rollover.     

Generalization of multi-item,multi-retailer distribution system

The procedure developed by Muckstadt and Roundy is generalized. In a multi-echelon inventory system with a single warehouse and multi-retailers, some di erent items with constant demand rates are distributed. Considering set-up and holding costs as well as the cost of joint shipment of items from the warehouse to any retailer, the objective is to minimize the total costs of the system. In the proposed algorithm the assumption of nested policies is relaxed. The procedure introduced works for both nested and non-nested policies.     

Pool‐Point Distribution of Zero‐Inventory Products

We study zero‐inventory production‐distribution systems under pool‐point delivery. The zero‐inventory production and distribution paradigm is supported in a variety of industries in which a product cannot be inventoried because of its short shelf life. The advantages of pool‐point (or hub‐and‐spoke) distribution, explored extensively in the literature, include the efficient use of transportation resources and effective day‐to‐day management of operations. The setting of our analysis is as follows: A production facility (plant) with a finite production rate distributes its single product, which cannot be inventoried, to several pool points. Each pool point may require multiple truckloads to satisfy its customers' demand. A third‐party logistics provider then transports the product to individual customers surrounding each pool point. The production rate can be increased up to a certain limit by incurring additional cost. The delivery of the product is done by identical trucks, each having limited capacity and non‐negligible traveling time between the plant and the pool points. Our objective is to coordinate the production and transportation operations so that the total cost of production and distribution is minimized, while respecting the product lifetime and the delivery capacity constraints. This study attempts to develop intuition into zero‐inventory production‐distribution systems under pool‐point delivery by considering several variants of the above setting. These include multiple trucks, a modifiable production rate, and alternative objectives. Using a combination of theoretical analysis and computational experiments, we gain insights into optimizing the total cost of a production‐delivery plan by understanding the trade‐off between production and transportation.     

Storing Fresh Produce for Fast Retrieval in an Automated Compact Cross‐Dock System

We study temporary storage of fresh produce in a cross‐dock center. In order to minimize cooling cost, compact storage systems are used. A major disadvantage of these systems is that additional retrieval time is needed, caused by necessary reshuffles due to the improper storage sequence of unit loads. In practice therefore, a dedicated storage policy is used in which every storage lane in the system accommodates only one product. However, this policy does not use the planned arrival time information of the outbound trucks. To exploit this information, this study proposes a mathematical model for a shared storage policy that minimizes total retrieval time. The policy allows different products to share the same lane. In order to solve real‐sized problems, an effective and efficient heuristic is proposed, based on a greedy construction and an improvement part, which provides near optimal solutions. The gaps between the results of the heuristic and the lower bound are mostly less than 1%. The resulting shared storage policy is generally robust against disturbances in arrival or departure times. We compare our shared storage heuristic with dedicated storage to determine which policy performs best under which circumstances. For most practical cases, shared storage appears to outperform dedicated storage, with a shorter response time and better storage lane utilization.     

A Production–Inventory Model for a Push–Pull Manufacturing System with Capacity and Service Level Constraints

We study a hybrid push–pull production system with a two‐stage manufacturing process, which builds and stocks tested components for just‐in‐time configuration of the final product when a specific customer order is received. The first production stage (fabrication) is a push process where parts are replenished, tested, and assembled into components according to product‐level build plans. The component inventory is kept in stock ready for the final assembly of the end products. The second production stage (fulfillment) is a pull‐based assemble‐to‐order process where the final assembly process is initiated when a customer order is received and no finished goods inventory is kept for end products. One important planning issue is to find the right trade‐off between capacity utilization and inventory cost reduction that strives to meet the quarter‐end peak demand. We present a nonlinear optimization model to minimize the total inventory cost subject to the service level constraints and the production capacity constraints. This results in a convex program with linear constraints. An efficient algorithm using decomposition is developed for solving the nonlinear optimization problem. Numerical results are presented to show the performance improvements achieved by the optimized solutions along with managerial insights provided.     

易变质产品在带运输时间的二级供应链中的订购策略研究

研究了带运输时间的易变质产品的二级供应链库存模型。在有限计划期内,为补充下游分销商发出的订单,上游制造商以一定的生产速率进行生产。由于产品运输给分销商时需要花费时间与成本,在开始一段时间内分销商的订单得不到及时补充,只有当制造商的库存量达到最大时,才将产品运输给分销商。目标就是确定最优订购策略使得整个系统的总成本最小。通过分析成本函数的特点,证明了2种特殊情形下最优解的存在及唯一性。最后通过算例验证了最优策略的有效性。     

考虑策略性消费者的生鲜农产品定价和库存决策

消费者的策略性行为使零售商的生鲜农产品的定价和库存决策面临更大挑战。本文基于报童模型,综合考虑消费者的策略性行为,对生鲜农产品价值下降进行离散化处理。刻画策略性消费者的决策行为,构建零售商的单阶段和两阶段定价及库存决策模型,分析了产品价值剩余率对消费者行为、零售商最优定价、最优库存水平以及零售商利润的影响机理。研究发现,在单阶段模型中零售商最优价格和最优库存水平均随产品价值剩余率的递增而递增;而在两阶段模型中,第二阶段最优价格随价值剩余率的变化趋势可能存在阈值。     

Optimal price,warranty length and production rate for free replacement policy in the static demand market

In the present paper, a decision model is developed for producers in the static demand market to determine the optimal price, warranty length and production rate of a product to maximize profit based on the pre-determined life cycle. The free renewal warranty policy is considered under which failed products are renewed before the end of warranty length at no cost to consumers. The expected number of renewals based on warranty length is derived for Weibull life distributed products. The objective function includes both demand and cost functions, where production cost, warranty cost and inventory cost are involved. A solution approach using the maximum principle is described, and is applied to two specific cases of markets. The first case of market considers positive discount rate, and the second case of market considers zero discount rate. The economic sensitivity analysis is conducted to evaluate the effect of model parameters on the optimal solution. Some conclusions are drawn based on the sensitivity analysis.     

PRODUCTION SCHEDULING OF CONTINUOUS FLOW LINES: MULTIPLE PRODUCTS WITH SETUP TIMES AND COSTS

The problem of production planning and setup scheduling of multiple products on a single facility is studied in this paper. The facility can only produce one product at a time. A setup is required when the production switches from one type of product to another. Both setup times and setup costs are considered. The objective is to determine the setup schedule and production rate for each product that minimize the average total costs, which include the inventory, backlog, and setup costs. Under the assumption of a constant production rate, we obtain the optimal cyclic rotation schedule for the multiple products system. Besides the decision variables studied in the classical economic lot scheduling problem (ELSP), the production rate is also a decision variable in our model. We prove that our solutions improve the results of the classical ELSP.     

LR型模糊需求下连续盘点库存策略研究

本文研究了LR型模糊需求下缺货需补的连续盘点库存优化问题。基于可信性理论,建立了成本最小化的库存模型和两种服务水平下的库存分析模型,给出了其求解方法,并将成本和服务水平两方面进行综合获得最优库存策略。最后的算例分析,数值比较了不同模型下的库存策略。     

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.     

具有多元马氏需求的多产品多阶段库存优化模型

本文研究一类新的多产品库存控制策略,即具有多元马氏需求特征的多产品多阶段的订货点订货量(Q, R, SS)策略,该策略考虑市场需求在不同产品之间具有多元马氏转移特征,并考虑缺货因素设置安全库存。论文首先建立了多产品多阶段的多元马氏需求预测模型,并通过该模型确定了各种产品需求之间的关系。同时,在该模型的理论基础上,提出了多产品多阶段的总期望成本模型及其最优(Q, R, SS)策略,进而结合算例给出模型的最优策略的数值解。