Multi-item inventory model with quantity-dependent inventory costs and demand-dependent unit cost under imprecise objective and restrictions: A geometric programming approach

A multi-item inventory model with constant demand and infinite replenishment is developed under the restrictions on storage area, total average shortage cost and total average inventory investment cost. These restrictions may be precise or imprecise. Here, it is assumed that inventory costs are directly proportional to the respective quantities, and unit purchase/production cost is inversely related to the demand. Restricted shortages are allowed but fully backlogged. First, the problem is formulated in crisp environment taking the deterministic and precise inventory parameters. It is solved by both geometric programming (GP) and gradient-based non-linear programming (NLP) methods. Later, the problem is formulated with fuzzy goals on constraints and objectives where impreciseness is introduced through linear membership functions. It is solved using the fuzzy geometric programming (FGP) method. The inventory models are illustrated with numerical values and compared with the crisp results. A sensitivity analysis on the optimum order quantity and average cost is also presented due to the variation in the tolerance of total average inventory investment cost and total average shortage cost following Dutta et al., 1993, Fuzzy Sets and Systems, 55, 133-142.     

A mixed inventory model with variable lead time and random supplier capacity

In this paper, we have studied analytically the implication of a controllable lead-time and a random supplier capacity on the continuous review inventory policy, in which the order quantity, reorder point and lead-time are decision variables. Two models are considered: the normal lead-time demand and lead-time demand is distributed free. For both cases, after formulating the general model, some properties of the optimal ordering policy have been developed. Particularly, we have shown that the expected annual total cost is a unimodal function and quasi-convex in the order quantity. When the variable capacity distribution is exponential, we develop effective procedures for finding the optimal solutions. Furthermore, the effects of parameters are also performed.     

On variance amplification in a three-echelon supply chain with minimum mean square error forecasting

We analyse a three echelon supply chain model. First-order autoregressive end consumer demand is assumed. We obtain exact analytical expressions for bullwhip and net inventory variance at each echelon in the supply chain. All of the three supply chain participants employ the order-up-to policy with the minimum mean square error forecasting scheme. After demonstrating that the character of the stochastic ordering process observed at each level of the supply chain is mathematically tractable, we show that the upper stream participants have complete information of the market demand process. Then we quantify the bullwhip produced by the system, together with the amplification ratios of the variance of the net inventory levels. Our analysis reveals that the level of the supply chain has no impact upon the bullwhip effect, rather bullwhip is determined by the accumulated lead-time from the customer and the local replenishment lead-time. We also find that the conditional variance of the forecast error over the lead-time is identical to the variance of the net inventory levels and that the net inventory variance is dominated by the local replenishment lead-time.     

Inventory management with variable lead-time dependent procurement cost

A reduction in the inventory replenishment lead-time allows reducing safety stock requirements and improving customer service. However, it might be accompanied by increased procurement costs because of premium charges imposed by suppliers, or higher transportation costs. This paper studies a single-stage variable lead-time inventory system with lead-time dependent procurement cost. Selection of the lead-time value represents finding the trade-off between benefits of lead-time reduction and increase in the procurement cost. A model for joint optimization of inventory and procurement costs is developed. Numerical studies are conducted to identify conditions under which lead-time reduction is favorable compared to procuring at the lowest cost.     

Multi-item production lot-size inventory model with varying order cost under a restriction: A geometric programming approach

In this paper we present a geometric programming approach for determining the inventory policy for multiple items having varying order cost, which is a continuous function of the order quantity, and a limit on the total average inventory of all items. Our model is a generalization of that of Gupta and Gupta for unrestricted single-item order quantity model with varying order cost and assumes the same order cost function. This cost function relates well to real-life situations since it increases as the order quantity increases and, at the same time, it is easy to handle when deducing previous work as special cases of our model since it is easily reducible to a constant. An example is solved to illustrate the method.     

The resource constrained single-item inventory problem with demand-dependent unit cost

In this paper, we present an economic order quantity (EOQ) with both demand-dependent unit cost and restrictions. An analytical solution of the EQO is derived using a recent and simple method, which isthe geometric programming approach. The EOQ inventory model with demand-dependent unit cost without any restriction and the classical EOQ inventory model are obtained.     

Optimal payment time under permissible delay in payment for products with deterioration

A permissible credit period is usually allowed to a retailer to pay back the dues without paying any interest to the supplier. The retailer can pay the supplier either at the end of the credit period or later incurring interest charges on the unpaid balance for the overdue period. The retailer is expected to settle the account at a time before the end of the inventory cycle time because the payable interest rate is generally higher than the earned interest rate. A model for optimal cycle and payment times is developed here for a retailer in a deteriorating-item inventory situation where a supplier allows a specified credit period to the retailer for payment without penalty. Under these conditions, this supplier-and-retailer system is modelled as a cost minimization problem to determine the optimal payment time under various system parameters. An iterative search procedure is applied to solve the problem, and the overall findings indicate that the retailer always has an option to pay after the permissible credit period depending on unit purchase and selling price, the deterioration rate of the products and the interest rate.     

An optimal replenishment model for inventory items with normally distributed deterioration

This paper deals with the inventory replenishment problem for deteriorating items with normally distributed shelf life, continuous time-varying demand, and shortages under the inflationary and time discounting environment. The reasons of choosing normal are twofold: it is one of the most important probability phenomena in the real world due to the classical central limit theorem, and it is also one of the most commonly used lifetime distributions in reliability contexts. The problem is formulated as a dynamic programming model and solved by numerical search techniques. The solutions of the model determine the optimal replenishment schedule over a finite planning horizon so that the present worth of the future costs associated with the system is minimized. In the extensive experiments, we validate the model, demonstrate the optimal replenishment schedule and lot-size, and carry out a comparative study to ascertain its contribution. In addition, sensitivity analysis was provided to help identify the most crucial factors that affect system performance. The experimental result shows that the deteriorating problem solved by an appropriate model (i.e. the proposed normal model) can save the total cost up to 2% approximately. It also identifies that the magnitudes of purchase cost per unit and demand rate are the most significant parameters that affect the replenishment decisions and cost.     

A queuing/management consideration on Japanese production systems

A single-stage lot/cell production under a Poisson arrival and exponential service in a batch is considered. The three economic queuing models of push and pull types are presented, an economic comparison of push versus pull types is considered, and a strategic management/design consideration to the lot production is given. First, the total expected operating cost is given for the three queuing models including the Omote-Kanban type similar to VMI. Second, the push versus pull system is discussed from a view of setup time, inventory or operating cost, and it is ascertained that the three types are alternative. Finally, a strategic management basis for economic traffic, leadtime setting is given, and discussed by the introduction of production matrix on 2-stage design.     

The effects of the warranty cost on the imperfect EMQ model with general discrete shift distribution

In this paper, we investigate the effect of the warranty cost on optimization of the economic manufacturing quality (EMQ). This is done for a deteriorating process where the production process shifts from the in-control state to the out-of-control state following a general discrete probability distribution. Once the production process goes out of control, the production process produces some defective items. The defective item cost includes reworking and warranty costs. Thus, in order to economically operate a production-inventory system with products sold under warranty, the tradeoffs among the production setup, inventory, and defective item cost, including the reworked cost before sale and the warranty cost after sale, needed to be analysed. This objective in this paper is to determine the production lot size while minimizing the total cost per unit of time per unit of time. Various special cases are presented. Two of them are extensions of results obtained previously in the literature. Finally, a numerical example is given which uses a discrete Weibull probability distribution. Sensitivity analysis of the model with respect to cost and time parameters is also performed.     

On the Issuing Policies for Perishable Items such as Red Blood Cells and Platelets in Blood Service

Red blood cells (RBCs) and platelets are examples of perishable items with a fixed shelf life. Recent studies show that transfusing fresh RBCs may lead to an improvement of patient outcomes. In addition, to better manage their inventory, hospitals prefer to receive fresh RBCs and platelets. Therefore, as well as minimizing outdates and shortages, reducing the average age of issue is a key performance criterion for blood banks. The issuing policy in a perishable inventory system has a substantial impact on the age of issue and outdate and shortage rates. Although several studies have compared the last in first out (LIFO) and the first in first out (FIFO) policies for perishable products, only a few studies have considered the situation of blood banks where replenishment is not controllable. In this study, we examine various issuing policies for a perishable inventory system with uncontrollable replenishment, and outline a modified FIFO policy. Our proposed modified FIFO policy partitions the inventory into two parts such that the first part holds the items with age less than a threshold. It then applies the FIFO policy in each part and the LIFO policy between the parts. We present two approximation techniques to estimate the average age of issue, the average time between successive outdates and the average time between successive shortages of the modified FIFO policy. Our analysis shows in several cases that where the objective function is a single economic function, or it is formulated as a multiobjective model, the modified FIFO policy outperforms the FIFO and LIFO policies.     

Production planning and inventory control in a company manufacturing PC parts: A case study

In this paper, we present a case study on the production planning and inventory system in a company manufacturing personal computer (PC) parts. In the case study, the targets are specified for developing a system for production planning and inventory control. The current state of the company is analysed for clarifying the points necessary to achieve the targets. Also, a system based on the analysis is proposed and its effects are estimated.     

Analysis of an EOQ inventory model with partial backordering and non-linear unit holding cost

In this paper, an economic order quantity inventory model is analyzed, considering that the unit cumulative holding cost has two significant components: a fixed cost which represents the cost of accommodating the item in the warehouse and a variable cost given by a potential function of the length of time over which the item is held in stock. Shortages are allowed and, during the stockout period, only a fraction of demand is partially backordered. The backordering cost includes a fixed cost and a cost linearly dependent on the length of time for which backorder exists. A solution procedure is developed for determining the optimal inventory policy. Moreover, to illustrate the effects of some parameters on the optimal policy and the minimum total inventory cost, a numerical study is developed.     

Heuristics for Base‐Stock Levels in Multi‐Echelon Distribution Networks

We study inventory optimization for locally controlled, continuous‐review distribution systems with stochastic customer demands. Each node follows a base‐stock policy and a first‐come, first‐served allocation policy. We develop two heuristics, the recursive optimization (RO) heuristic and the decomposition‐aggregation (DA) heuristic, to approximate the optimal base‐stock levels of all the locations in the system. The RO heuristic applies a bottom‐up approach that sequentially solves single‐variable, convex problems for each location. The DA heuristic decomposes the distribution system into multiple serial systems, solves for the base‐stock levels of these systems using the newsvendor heuristic of Shang and Song (2003), and then aggregates the serial systems back into the distribution system using a procedure we call “backorder matching.” A key advantage of the DA heuristic is that it does not require any evaluation of the cost function (a computationally costly operation that requires numerical convolution). We show that, for both RO and DA, changing some of the parameters, such as leadtime, unit backordering cost, and demand rate, of a location has an impact only on its own local base‐stock level and its upstream locations’ local base‐stock levels. An extensive numerical study shows that both heuristics perform well, with the RO heuristic providing more accurate results and the DA heuristic consuming less computation time. We show that both RO and DA are asymptotically optimal along multiple dimensions for two‐echelon distribution systems. Finally, we show that, with minor changes, both RO and DA are applicable to the balanced allocation policy.     

Multi‐Echelon Inventory Management under Short‐Term Take‐or‐Pay Contracts

We extend the Clark–Scarf serial multi‐echelon inventory model to include procuring production inputs under short‐term take‐or‐pay contracts at one or more stages. In each period, each such stage has the option to order/process at two different cost rates; the cheaper rate applies to units up to the contract quantity selected in the previous period. We prove that in each period and at each such stage, there are three base‐stock levels that characterize an optimal policy, two for the inventory policy and one for the contract quantity selection policy. The optimal cost function is additively separable in its state variables, leading to conquering the curse of dimensionality and the opportunity to manage the supply chain using independently acting managers. We develop conditions under which myopic policies are optimal and illustrate the results using numerical examples. We establish and use a generic one‐period result, which generalizes an important such result in the literature. Extensions to cover variants of take‐or‐pay contracts are included. Limitations are discussed.     

On vendor part delivery dates in a stochastic assembly system

This paper describes the development of a model for the determination of optimal mean part delivery dates in a stochastic assembly system for the objective of minimizing the expected cost of subassembly and part inventory. Parts are assembled at each station to a subassembly. The part delivery and processing times at assembly stations follow known probability distributions. An approximate solution technique based on the optimization of individual stations in isolation is developed. The approximation applies a correction factor, as a function of the variability in part delivery and processing time, cost parameters and number of stations, to the decisions from the single station solutions to compensate for interdependence between stations. Results indicate that this is an effective approach and yields good near-optimal solutions with very little computational effort. Insights regarding the effect of the type of distribution used, random processing times, variance of the distribution used and cost parameter values on part delivery dates are also reported.     

Determination of recovery effort for a probabilistic recovery system under various inventory control policies

In this study we investigate the desired level of recovery under various inventory control policies when the success of recovery is probabilistic. All the used and returned items go into a recovery process that is modelled as a single stage operation. The recovery effort is represented by the expected time spent for it. The effect of increasing recovery effort on the success probability together with unit cost of the operation is included by assuming general forms of dependencies. Alternative to recovered items, demand is satisfied by brand-new items. Four inventory control policies that differ in timing of and information used in purchasing decision are proposed. The objective is to find the recovery level together with inventory control parameter that minimize the long-run average total cost. A numerical study covering a wide range of system parameters is carried out. Finally computational results are presented with their managerial implications.     

Looking Upstream: Optimal Policies for a Class of Capacitated Multi‐Stage Inventory Systems

We consider a multi‐stage inventory system with stochastic demand and processing capacity constraints at each stage, for both finite‐horizon and infinite‐horizon, discounted‐cost settings. For a class of such systems characterized by having the smallest capacity at the most downstream stage and system utilization above a certain threshold, we identify the structure of the optimal policy, which represents a novel variation of the order‐up‐to policy. We find the explicit functional form of the optimal order‐up‐to levels, and show that they depend (only) on upstream echelon inventories. We establish that, above the threshold utilization, this optimal policy achieves the decomposition of the multidimensional objective cost function for the system into a sum of single‐dimensional convex functions. This decomposition eliminates the curse of dimensionality and allows us to numerically solve the problem. We provide a fast algorithm to determine a (tight) upper bound on this threshold utilization for capacity‐constrained inventory problems with an arbitrary number of stages. We make use of this algorithm to quantify upper bounds on the threshold utilization for three‐, four‐, and five‐stage capacitated systems over a range of model parameters, and discuss insights that emerge.     

An arborescent inventory model in a supply chain system

This study develops an arborescent (tree-like) inventory model with a constant demand rate. By considering the integration of the producer, distributors and retailers, a mathematical model and an economic ordering policy are developed. It can be shown that the integrated approach results in an impressive cost-reduction compared with an independent decision by the partial party. A numerical example of an arborescent inventory system is attached to demonstrate the economic ordering policy with the help of mathematical software - Maple V.     

Integrality in Stochastic Inventory Models

We study several finite‐horizon, discrete‐time, dynamic, stochastic inventory control models with integer demands: the newsvendor model, its multi‐period extension, and a single‐product, multi‐echelon assembly model. Equivalent linear programs are formulated for the corresponding stochastic dynamic programs, and integrality results are derived based on the total unimodularity of the constraint matrices. Specifically, for all these models, starting with integer inventory levels, we show that there exist optimal policies that are integral. For the most general single‐product, multi‐echelon assembly system model, integrality results are also derived for a practical alternative to stochastic dynamic programming, namely, rolling‐horizon optimization by a similar argument. We also present a different approach to prove integrality results for stochastic inventory models. This new approach is based on a generalization we propose for the one‐dimensional notion of piecewise linearity with integer breakpoints to higher dimensions. The usefulness of this new approach is illustrated by establishing the integrality of both the dynamic programming and rolling‐horizon optimization models of a two‐product capacitated stochastic inventory control system.