Setup Reduction in the Economic Production Quantity Model

We present an analysis of setup cost reduction using the economic production quantity model. The objectives of the paper are to draw conclusions by investigating several classes of setup reduction functions and to provide a general solution procedure. We examine the trade-offs between reduced inventories and increased capital investment and show that given any hypothetical setup cost reduction function, we can determine whether the total relevant cost can be reduced and how the reduction is achieved.     

Joint Lot Sizing and Scheduling of Multiple Items with Sequence-Dependent Setup Costs

The objective of this research is to investigate the effects of setup-cost estimating methods on the lot sizing and scheduling of multiple products in multiple periods. These initial setup cost estimators (ISCEs) are used to estimate sequence-independent initial setup costs from sequence-dependent setup costs. A search of the literature reveals that, although sequence-dependent setup costs are frequently found in practice and ISCEs are frequently used, there is a dearth of research concerning the effect of using ISCEs. After a review of the literature, a mixed integer formulation of the joint problem of lot sizing and scheduling is presented, followed by a discussion of the difficulty in solving the formulation. Next, the six ISCEs evaluated are presented. These ISCEs range from simple (select the minimum setup cost) to complex (use the branch-and-bound solution to a traveling salesman-type problem). Each ISCE is evaluated using a full factorial design with five independent variables: demand distribution (three levels), demand trend (three levels), setup to inventory level (six levels), setup distribution (three levels), and setup variability (two levels). Two hypotheses are researched. Do the more computationally complex ISCEs produce lower overall costs than do the simpler ISCEs? Does the reduction in total cost justify the additional computation cost? The results of this study demonstrate that it may be incorrect to use “conventional wisdom'’when selecting an ISCE.     

EOQ FORMULA: IS IT VALID UNDER INFLATIONARY CONDITIONS?

The classical analysis of the economic order quantity (EOQ) problem ignores the effect of inflation. When a firm's cost factors are expected to rise at an annual rate of 10 percent or more, what adjustments in order quantities should the firm make to control its lot-size inventory (or cycle stock)? Using a model that includes both inflationary trends and time discounting, it is concluded that inflation brings no incentive either to increase or to decrease order quantities. In addition, order quantities can be computed using the classical EOQ formula under inflationary conditions, provided that the cost of capital invested in inventory is interpreted as an inflation-free cost. This interpretation implies that changes in the inflation rate should not affect the cost of capital that is utilized in the EOQ formula for determining order quantities.     

ECONOMIC ORDER QUANTITIES WITH QUANTITY DISCOUNTS: GRANDMA DOES IT BEST

We examine a new algorithm developed by Kuzdrall and Britney [5] for locating the optimal order quantity in the presence of quantity discounts. Their algorithm, based on a model for the supplier's formulation of the price schedule, involves a regression analysis to identify the supplier's variable cost per unit and the fixed cost that the supplier seeks to recover, followed by an iterative search for the optimum. The authors describe this method as a “convenient alternative to the aimless searching of traditional approaches” [5, p. 101]. We examine the allegation of superiority of their total setup lot-sizing model over the classical method and dispute their claim of superiority.     

TOTAL SETUP LOT SIZING WITH QUANTITY DISCOUNTS*

Often, order quantity decisions are made by purchasers facing a price schedule of quantity discounts. Traditional solution procedures have consisted of the evaluation of total cost at numerous price-break points in search of the lowest total cost. This approach is tedious and not particularly informative, especially when one is faced with lengthy schedules. This paper presents a total setup lot-sizing model that reduces the computations required to find the least-total-cost quantity, given parameters from a supplier's price schedule. The parameters are first obtained by simple regression (graphical or computer) and in themselves can provide valuable insight for the purchaser's decision making. A total setup lot-sizing model is next developed to define a “critical interval” that contains the solution. The model and algorithm are tested under a variety of conditions. Their application offers the decision maker a convenient alternative to determine the best quantity to order from a tendered price schedule.     

Some Comments on the Validity of EOQ Formula under Inflationary Conditions

In an earlier issue of Decision Sciences, Jesse, Mitra, and Cox [1] examined the impact of inflationary conditions on the economic order quantity (EOQ) formula. Specifically, the authors analyzed the effect of inflation on order quantity decisions by means of a model that takes into account both inflationary trends and time discounting (over an infinite time horizon). In their analysis, the authors utilized two models: Current-dollars model and Constant-dollars model. These models were derived, of course, by setting up a total cost equation in the usual manner then finding the optimum order quantity that minimizes the total cost. Jesse, Mitra, and Cox [1] found that EOQ is approximately the same under both conditions; with or without inflation. However, we disagree with the conclusion drawn by [2] and show that EOQ will be different under inflationary conditions, provided that the inflationary conditions are properly accounted for in the formulation of the total cost model.     

Economic Production Lot Sizing with Periodic Costs and Overtime*

Traditional approaches for modeling economic production lot‐sizing problems assume that a single, fixed equipment setup cost is incurred each time a product is run, regardless of the quantity manufactured. This permits multiple days of production from one production setup. In this paper, we extend the model to consider additional fixed charges, such as cleanup or inspection costs, that are associated with each time period's production. This manufacturing cost structure is common in the food, chemical, and pharmaceutical industries, where process equipment must be sanitized between item changeovers and at the end of each day's production. We propose two mathematical problem formulations and optimization algorithms. The models' unique features include regular time production constraints, a fixed charge for each time period's production, and the availability of overtime production capacity. Experimental results indicate the conditions under which our algorithms' performance is superior to traditional approaches. We also test the procedures on a set of lot‐sizing problems facing a national food processor and document their potential economic benefit.     

A Simple Heuristic for Lot Sizing with Setup Times

This paper presents an easily understood and computationally efficient heuristic algorithm for the capacitated lot sizing problem (CLSP), the single machine lot-sizing problem, with nonstationary costs, demands, and setup times. The algorithm solves problems with setup time or setup cost. A variation of the algorithm can solve problems when limited amounts of costly overtime are allowed. Results of experimentation indicate that the most significant effects on solution quality are due to the level of setup costs relative to holding costs and the size of the problems as determined by the number of items. Also affecting solution quality are tightness of the capacity constraint and variability of demand in a problem. When the capacity constraint is extremely tightly binding, it sometimes has difficulty finding solutions that do not require overtime.     

Optimal investment in setup reduction for finite horizon periodic review inventory system under deterministic time varying demand

This paper examines the impact of setup reduction on a finite horizon, periodic review inventory system, under deterministic time varying demand. A total relevant cost function is developed for such systems. Using this, the impact of setup reduction is examined under various forms of setup reduction cost functions that have been suggested in the literature. The operating characteristics and optimization of the various scenarios are discussed. Our analysis shows that the effects of setup reduction in a periodic review system are similar to those in a reorder point system. Our results are likely to help practitioners who use similar periodic review systems towards decreasing total inventory related costs by investing in setup reduction.     

Planning and Control in Multi-Cell Manufacturing

This research compares Material Requirements Planning (MRP), Kanban, and Period Batch Control (PBC) as alternative approaches to the planning and control of multi-cell manufacturing involving flow cells and assembly. Since previous research on performance of these systems in cellular manufacturing has been primarily conceptual, the experiments reported here provide new insights into their comparative performance. The results show that the production environment is a major factor in system choice. Three operating factors—Master Production Schedule (MPS) volume variation, MPS mix variation, and setup time/lot size—clearly affect system choice. All systems performed well under Justin-Time (JIT) conditions; there was no advantage to Kanban. Under the mixed conditions of high MPS variation, but small setup time/lot sizes, PBC produced superior performance compared to Kanban and MRP. Under non-JIT conditions, MRP was seen as clearly more effective. Finally, the results indicate that when conditions permit very small lot sizes relative to requirements, Kanban may perform best, even when MPS variation is high.     

Production and changeover control policies of a class of failure prone buffered flow-shops

This article deals with a stochastic optimal control problem for a class of buffered multi-parts flow-shops manufacturing system. The involved machines are subject to random breakdowns and repairs. The flow-shop under consideration is not completely flexible and hence requires setup time and cost in order to switch the production from a part type to another, this changeover is carried on the whole line. Our objective is to find the production plan and the sequence of setups that minimise the cost function, which penalises inventories/backlogs and setups. A continuous dynamic programming formulation of the problem is presented. Then, a numerical scheme is adopted to solve the obtained optimality conditions equations for a two buffered serial machines two parts case. A complete heuristic policy, based on the numerical observations which describe the optimal policies in system states, is developed. It will be shown that the obtained policy is a combination of a KANBAN/CONWIP and a modified hedging corridor policy. Moreover, based on our observations and existent research studies extension to cover more complex flow-shops is henceforth possible. The robustness of such a policy is illustrated through sensitivity analysis.     

Stochastic lot sizing problem with controllable processing times

In this study, we consider the stochastic capacitated lot sizing problem with controllable processing times where processing times can be reduced in return for extra compression cost. We assume that the compression cost function is a convex function as it may reflect increasing marginal costs of larger reductions and may be more appropriate when the resource life, energy consumption or carbon emission are taken into consideration. We consider this problem under static uncertainty strategy and α service level constraints. We first introduce a nonlinear mixed integer programming formulation of the problem, and use the recent advances in second order cone programming to strengthen it and then solve by a commercial solver. Our computational experiments show that taking the processing times as constant may lead to more costly production plans, and the value of controllable processing times becomes more evident for a stochastic environment with a limited capacity. Moreover, we observe that controllable processing times increase the solution flexibility and provide a better solution in most of the problem instances, although the largest improvements are obtained when setup costs are high and the system has medium sized capacities.     

Unsold Versus Unbought Commitment: Minimum Total Commitment Contracts with Nonzero Setup Costs

We study a minimum total commitment (MTC) contract embedded in a finite‐horizon periodic‐review inventory system. Under this contract, the buyer commits to purchase a minimum quantity of a single product from the supplier over the entire planning horizon. We consider nonstationary demand and per‐unit cost, discount factor, and nonzero setup cost. Because the formulations used in existing literature are unable to handle our setting, we develop a new formulation based on a state transformation technique using unsold commitment instead of unbought commitment as state variable. We first revisit the zero setup cost case and show that the optimal ordering policy is an unsold‐commitment‐dependent base‐stock policy. We also provide a simpler proof of the optimality of the dual base‐stock policy. We then study the nonzero setup cost case and prove a new result, that the optimal solution is an unsold‐commitment‐dependent (s, S) policy. We further propose two heuristic policies, which numerical tests show to perform very well. We also discuss two extensions to show the generality of our method's effectiveness. Finally, we use our results to examine the effect of different contract terms such as duration, lead time, and commitment on buyer's cost. We also compare total supply chain profits under periodic commitment, MTC, and no commitment.     

Integrative Cycle Scheduling Approach for a Capacitated Flexible Assembly System*

This study revisits the traditional single stage, multi-item, capacitated lot-sizing problem (CLSP) with a new integrative focus on problem structuring. Unlike past research, we develop integrative cycle scheduling approaches which simultaneously address lot-sizing, capacity, and sequencing issues. Our purposes are to (1) explore the effect of sequencing on inventory levels, (2) examine the problem of infeasibility in the economic lot scheduling problem (ELSP), and (3) provide a simple methodology of generating low-cost cycle schedules in an environment with discrete shipping, dynamic demands, limited capacity, zero setup cost, and sequence-independent setup times. Our procedures are compared to benchmark cycle scheduling approaches in terms of both inventory cost and computation time under different demand scenarios, using the operating data from a flexible assembly system (FAS) at the Ford Motor Company's Sandusky, Ohio plant.     

SETUP REDUCTION AND MACHINE AVAILABILITY

This paper is an extension of Billington, who used the framework of the economic production quantity (EPQ) to model setup cost reduction. In the present paper, we use the EPQ model as a starting point to investigate the nature of setup costs and the effect of setup time reduction on the increase in available capacity. Reducing setup is vital to a company's success because a lengthy changeover of machinery is expensive: it demands long production runs to justify its cost, and these, in turn, lead to excessive inventory and to a slow response to customer needs. As in Billington, setup reduction is modeled as a function of an annual amortized investment. The paper examines the behavior of the setup time, the inventory cost, the lot size, and the freeing up of machine time in the face of a capacity constraint. A solution algorithm is provided to find setup times that minimize the sum of setup and holding cost, subject to a constraint on machine availability. The analysis sheds light on the true nature of setup cost and on the opportunity cost of not reducing setups. In the constrained optimization, the Lagrangian multiplier gives an estimate of the marginal value of adding one time unit of machine capacity, or, alternatively, of reducing one unit of setup time.     

企业人力资本管理研究

在知识经济时代,企业之间的竞争更多地表现为企业所拥有的人力资本间的竞争。那么,企业怎样才能有效地管理好内部的人力资本呢?本文运用新制度经济学的研究工具,首先从人力资本专用程度、人力资本信息分布状况和人力资本管理的成本与收益三个方面提出了分析框架。然后,按转移成本和对企业依赖程度的不同,把人力资本分为通用性人力资本、专用性人力资本和准专用性人力资本三类,并对每一类人力资本的管理进行了研究。     

盈余质量对资本配置效率的影响及作用机理

本文以2004-2007年沪深两市的上市公司为研究样本,在Richardson、verdi研究的基础上,对中国现实制度背景下盈余质量和资本配置效率两者的关系进行了探讨.不同于国内外的现有研究,本文不仅检验了盈余质量是否影响上市公司的资本配置效率,还对盈余质量如何影响上市公司资本配置效率进行了检验.检验结果表明,盈余质量的改善一方面能直接提高上市公司的资本配置效率,另一方面则能够通过降低代理成本间接促进上市公司资本配置效率的提高.这一研究结论对理解盈余质量在上市公司资本配置效率中的作用,以及了解盈余质量与上市公司资本配置效率之间的中介传导机制和路径模式均具有较强的现实意义.     

A Knowledge Based Decision Support System for Setup Reduction

The issue of setup reduction is important for firms seeking to incorporate advanced procedures and concepts such as flexible manufacturing systems (FMS) and just-in-time (JIT) manufacturing to improve manufacturing productivity. Investing adequate amounts in setup reduction is a complex decision affected by many factors including the existing level of automation, worker characteristics, product features, and the manufacturing environment. The consequences of improper investment (i.e., over- and underinvestment) includes possible disruption of manufacturing operations as well as wasted resources. Much of the knowledge involved in the investment decision is heuristic and experience-based, and takes on greater significance when the form of the setup reduction function is not known a priori. This paper describes the development of a knowledge-based decision support system (KBDSS) that combines both heuristic and procedural knowledge to provide support for the setup reduction investment decision. The system uses codified manufacturing expertise to improve both the accuracy and effectiveness of setup-reduction decision making. Use of the KBDSS is illustrated by two examples based on disparate manufacturing contexts.     

THE INDUCE VERSUS PURCHASE DECISION: AN EMPIRICAL ANALYSIS OF INDUSTRIAL R&D*

With the recent slowdown in productivity growth within the economy, R&D has come under scrutiny as a policy target variable. If such targeting is to be effective, it must be realized that not all innovations employed within a firm are induced by the firm through its own R&D: many innovations are purchased through technological licensing or in the form of new capital equipment. Here, interfirm differences in this “make” versus “buy” strategy are analyzed within the context of the Utterback-Abernathy production process lifecycle. Our findings suggest that (1) alternative sources to a firm's R&D for stimulating innovation may prove a viable strategy for federal targeting and (2) extrapolating the Utterback-Abernathy model to an industry formulation has empirical validity.     

Setup cost reduction a multi-stage order quantity model

In this paper, a single item, multi-stage serial order quantity (MSOQ) model with constant demand is discussed. The objective of the model is to minimize the total cost which includes the setup cost and the inventory holding cost. This paper examines and analyses the investment in a one-time cost to reduce the (current) setup level and adds a per unit item amortization of this cost to the other costs associated with the MSOQ model. We consider the setup cost to be decreased on each stage with the same rate and the cost of the joint setup cost reduction is a logarithmic cost function.