Quantity Discount‐Based Inventory Coordination: Effectiveness and Critical Environmental Factors

It is understood that quantity discounts provide a practical foundation for coordinating inventory decisions in supply chains. The primary objective of this research is to test, under a variety of environmental conditions, the effectiveness of quantity discounts as an inventory coordination mechanism between a buyer and a supplier. A comprehensive simulation experiment with anova has been designed to investigate the impacts of (1) choice of quantity discount‐based inventory coordination policies, (2) magnitude of demand variation, (3) buyer's and supplier's relative inventory cost structure, and (4) buyer's economic time‐between‐orders on the effectiveness of supply chain inventory coordination. The analytical results confirm that the quantity discount policies have managerial properties as a mediator for inventory coordination. The results also show that the performance of quantity discount‐based inventory coordination policies is influenced significantly by environmental factors, such as the magnitude of demand variation, the buyer's and the supplier's inventory cost structure, and the buyer's economic time‐between‐orders.     

NERJIT: Using Net Requirement Data in Kanban‐Controlled Jumbled‐Flow Shops

The bold lines that have separated the application of specific production planning and control techniques to specific production systems are being blurred by continuous advances in production technologies and innovative operational procedures. Oral communication among dispatchers and production units has given way to electronic communication between production planners and these units by continuous progress in information technologies. Current production literature alludes to the idea that, collectively, these advances have paved the way for application of Just‐In‐Time (JIT) production concepts, which were originally developed for mass production systems, in intermittent production systems. But this literature does not actually consider the possibility. This article presents a modification to JIT procedures to make them more suitable for jumbled‐flow shops. This article suggests providing real‐time information about net‐requirements for each product to each work center operator for setting production priorities at each work center. Simulation experiments conducted for this study show that using Net‐Requirements in JIT (NERJIT) reduces customer wait time by 45–60% while reducing inventory slightly. The analysis of work centers’ input and output stock‐point inventories shows that using the information about net‐requirements results in production of items that are in current demand. NERJIT results in smaller input stock‐point inventory and availability of products with higher priority in the output stock‐points of work centers.     

Cash‐Flow Based Dynamic Inventory Management

Small‐to‐medium‐sized enterprises (SMEs), including many startup firms, need to manage interrelated flows of cash and inventories of goods. In this study, we model a firm that can finance its inventory (ordered or manufactured) with loans in order to meet random demand which in general may not be time stationary. The firm earns interest on its cash on hand and pays interest on its debt. The objective is to maximize the expected value of the firm's capital at the end of a finite planning horizon. The firm's state at the beginning of each period is characterized by the inventory level and the capital level measured in units of the product, whose sum represents the “net worth” of the firm. Our study shows that the optimal ordering policy is characterized by a pair of threshold parameters as follows. (i) If the net worth is less than the lower threshold, then the firm employs a base stock order up to the lower threshold. (ii) If the net worth is between the two thresholds, then the firm orders exactly as many units as it can afford, without borrowing. (iii) If the net worth is above the upper threshold, then the firm employs a base stock order up to the upper threshold. Further, upper and lower bounds for the threshold values are developed using two simple‐to‐compute myopic ordering policies which yield lower bounds for the value function. We also derive an upper bound for the value function by considering a sell‐back policy. Subsequently, it is shown that policies of similar structure are optimal when the loan and deposit interest rates are piecewise linear functions, when there is a maximal loan limit and when unsatisfied demand is backordered. Finally, further managerial insights are provided with extensive numerical studies.     

How Inventory Cost Influences Introduction Timing of Product Line Extensions

In the industry with radical technology push or rapidly changing customer preference, it is firms' common wisdom to introduce high‐end product first, and follow by low‐end product‐line extensions. A key decision in this “down‐market stretch” strategy is the introduction time. High inventory cost is pervasive in such industries, but its impact has long been ignored during the presale planning stage. This study takes a first step toward filling this gap. We propose an integrated inventory (supply) and diffusion (demand) framework and analyze how inventory cost influences the introduction timing of product‐line extensions, considering substitution effect among successive generations. We show that under low inventory cost or frequent replenishment ordering policy, the optimal introduction time indeed follows the well‐known “now or never” rule. However, sequential introduction becomes optimal as the inventory holding gets more substantial or the product life cycle gets shorter. The optimal introduction timing can increase or decrease with the inventory cost depending on the marketplace setting, requiring a careful analysis.     

MANAGING CYCLIC INVENTORIES

Cyclic inventory is the buffer following a machine that cycles over a set of products, each of which is subsequently consumed in a continuous manner. Scheduling such a machine is interesting when the changeover times from one product to another are non‐trivial—which is generally the case. This problem has a substantial literature, but the common practices of “lot‐splitting” and “maximization of utilization” suggest that many practitioners still do not fully understand the principles of cyclic inventory. This paper is a tutorial that demonstrates those principles. We show that cyclic inventory is directly proportional to cycle length, which in turn is directly proportional to total changeover time, and inversely proportional to machine utilization. We demonstrate the virtue of “maximum changeover policies” in minimizing cyclic inventory—and the difficulty in making the transition to an increased level of demand. In so doing, we explicate the different roles of cyclic inventory, transitional inventory, and safety stock. We demonstrate the interdependence of the products in the cycle—the lot‐size for one product cannot be set independently of the remaining products. We also give necessary conditions for consideration of improper schedules (i.e., where a product can appear more than once in the cycle), and demonstrate that both lot‐splitting and maximization of utilization are devastatingly counter‐productive when changeover time is non‐trivial.     

Managing Retail Shelf and Backroom Inventories When Demand Depends on the Shelf‐Stock Level

Inventory displayed on the retail sales floor not only performs the classical supply function but also plays a role in affecting consumers’ buying behavior and hence the total demand. Empirical evidence from the retail industry shows that for some types of products, higher levels of on‐shelf inventory have a demand‐increasing effect (“billboard effect”) while for some other types of products, higher levels of on‐shelf inventory have a demand‐decreasing effect (“scarcity effect”). This suggests that retailers may use the amount of shelf stock on display as a tool to influence demand and operate a store backroom to hold the inventory of items not displayed on the shelves, introducing the need for efficient management of the backroom and on‐shelf inventories. The purpose of this study is to address such an issue by considering a periodic‐review inventory system in which demand in each period is stochastic and depends on the amount of inventory displayed on the shelf. We first analyze the problem in a finite‐horizon setting and show under a general demand model that the system inventory is optimally replenished by a base‐stock policy and the shelf stock is controlled by two critical points representing the target levels to raise up/drop down the on‐shelf inventory level. In the infinite‐horizon setting, we find that the optimal policies simplify to stationary base‐stock type policies. Under the billboard effect, we further show that the optimal policy is monotone in the system states. Numerical experiments illustrate the value of smart backroom management strategy and show that significant profit gains can be obtained by jointly managing the backroom and on‐shelf inventories.     

Managing Demand Risk in Tactical Supply Chain Planning for a Global Consumer Electronics Company

We consider the problem of managing demand risk in tactical supply chain planning for a particular global consumer electronics company. The company follows a deterministic replenishment‐and‐planning process despite considerable demand uncertainty. As a possible way to formally address uncertainty, we provide two risk measures, “demand‐at‐risk” (DaR) and “inventory‐at‐risk” (IaR) and two linear programming models to help manage demand uncertainty. The first model is deterministic and can be used to allocate the replenishment schedule from the plants among the customers as per the existing process. The other model is stochastic and can be used to determine the “ideal” replenishment request from the plants under demand uncertainty. The gap between the output of the two models as regards requested replenishment and the values of the risk measures can be used by the company to reallocate capacity among different products and to thus manage demand/inventory risk.     

Customer‐Base Concentration and Inventory Efficiencies: Evidence from the Manufacturing Sector

What is the link between customer‐base concentration and inventory efficiencies in the manufacturing sector? Using hand‐collected data from 10‐K Filings, we find that manufacturers with more concentrated customer bases hold fewer inventories for less time and are less likely to end up with excess inventories, as indicated by the lower likelihood and magnitude of inventory write‐downs and reversals. Using disaggregated inventory disclosures, we find that inventory efficiencies primarily flow through the finished goods inventory account, while raw material efficiencies are offset by higher work‐in‐process holdings and longer work‐in‐process cycles. In additional analysis, we document a valuation premium for more concentrated manufacturers after controlling for other firm characteristics, including default risk and cost of capital estimates. We conclude that investors trade off the costs and benefits of relationships with a limited number of major customers and, on balance, consider customer‐base concentration as a net positive for firm valuation. Overall, our study adds to interdisciplinary research in accounting and operations management by shedding new light on the relevance of major customer disclosures for fundamental analysis and valuation in the manufacturing sector.     

Demand–Supply Mismatches and Stock Market Performance: A Retailing Perspective

We provide empirical evidence that the volatility of inventory productivity relative to the volatility of demand is a predictor of future stock returns in a sample of publicly listed U.S. retailers over the period 1985–2013. This key performance indicator, entitled demand–supply mismatch (DSM), captures the fact that low variation in inventory productivity relative to variation in demand is indicative of the superior synchronization of demand‐ and supply‐side operations. Applying the Fama and French (1993) three‐factor model augmented with a momentum factor (Carhart 1997), we find that zero‐cost portfolios formed by buying the two lowest and selling the two highest quintiles of DSM stocks yield abnormal stock returns of up to 1.13%. These strong market anomalies related to DSM are observed over the entire sample period and persist after controlling for alternative inventory productivity measures and firm characteristics that are known to predict future stock returns. Further, we reveal that DSM is indicative of lower future earnings and lower sales growth and provide evidence that the observed market inefficiency results from investors’ failure to incorporate all of the information that inventory contains into the pricing of stocks.     

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.     

On the Unimodality of the Profit Function of the Pricing Newsvendor

In this note, we study the price‐setting newsvendor problem. We use three conditions, the log‐convexity of the coefficient of variation, the log‐concavity of the deterministic profit function, and the log‐convexity of the random noise's expectation conditional on having leftover inventory to establish the log‐concavity of the retailer's expected profit function. This new result is complementary to existing results and removes some assumptions in the pricing and inventory coordination literature. It also addresses the conjecture made by Petruzzi and Dada (1999), and can be applied in the pricing game.     

Designing Service Level Agreements for Inventory Management

Service level agreements (SLAs) are widely employed forms of performance‐based contracts in operations management. They compare performance during a period against a contracted service level and penalize outcomes exceeding some allowed deviation. SLAs have a number of design characteristics that need careful tuning to ensure that incentives are properly aligned. However, there is little theoretical research in this area. Using an example of an SLA for outsourcing inventory management, we make a number of recommendations. First it is preferable, if possible, that penalties be proportional to the underperformance rather than lump‐sum ones. This goes a long way towards mitigating strategic (“gaming”) behavior by the supplier. Second, it might be thought that giving “bonuses for good performance” rather than “penalties for bad performance” are essentially identical apart from the former being a more positive approach to management. This turns out to be incorrect in the case of large percentage service rate targets and that penalties will normally be preferred by the buying firm. Third, in order not to incorrectly penalize underperformance resulting purely from “noise” rather than supplier efforts, management might think it best to make allowed deviations from the target generous. Again intuition is not a helpful guide here: for proportional penalties, acceptable performance deviations should be close to the target. Although these results come from a particular inventory application, it is likely that the lessons are applicable to SLAs in general.     

考虑成本和收益净现值的确定性存储决策模型研究

净现值是企业决策中需要考虑的重要宏观经济因素.本文建立了考虑成本和收益净现值的连续时间有限时段确定性库存系统的最优存储和定价决策模型,证明了给定价格下最优策略中任意两个相邻订货周期之间的递推关系,分析了该关系的解析性质,并得出订货周期长度的上下限.在此基础上提出求解最优存储策略和最优价格的两步优化算法.最后通过数值算例对本文模型及结果做出说明.     

Exploring Framing Effects in Inventory Control Decisions: Violations of Procedure Invariance

Recent research on decision framing has shown that (i) there are multiple types of framing effects and (ii) the context of the decision can influence framing effects. This research examines decision framing effects in inventory control contexts by questioning the assumption of procedure invariance, that preference should not be impacted by how options are presented to a supply chain manager making an inventory control decision. Study 1 uses three single‐shot decision experiments to establish that all three types of framing effects identified by Levin et al. ( 1998 ) apply in basic inventory control contexts. Results were consistent with theory in all three cases. Given this evidence that framing effects have potential to impact inventory control decisions, two laboratory experiments in Study 2 utilize multi‐period decision tasks to demonstrate that framing effects can impact performance in a dynamic inventory decision setting similar to practice. One of the experiments in Study 2 was conducted with student subjects, while the other with inventory managers from a large retail firm. Results from both experiments provide evidence that even when initial framing effects on order quantities fade, there can be longer term effects on inventory levels and performance. Furthermore, these effects are robust to education and professional experience. The findings suggest that although a manager might select appropriate inventory control metrics, prudence must be exercised in the presentation of these metrics, and that mere presentation can be used to alleviate known human biases in inventory control decisions.     

Optimal Inventory Control with Retail Pre‐Packs

A pre‐pack is a collection of items used in retail distribution. By grouping multiple units of one or more stock keeping units (SKU), distribution and handling costs can be reduced; however, ordering flexibility at the retail outlet is limited. This paper studies an inventory system at a retail level where both pre‐packs and individual items (at additional handling cost) can be ordered. For a single‐SKU, single‐period problem, we show that the optimal policy is to order into a “band” with as few individual units as possible. For the multi‐period problem with modular demand, the band policy is still optimal, and the steady‐state distribution of the target inventory position possesses a semi‐uniform structure, which greatly facilitates the computation of optimal policies and approximations under general demand. For the multi‐SKU case, the optimal policy has a generalized band structure. Our numerical results show that pre‐pack use is beneficial when facing stable and complementary demands, and substantial handling savings at the distribution center. The cost premium of using simple policies, such as strict base‐stock and batch‐ordering (pre‐packs only), can be substantial for medium parameter ranges.     

The Effect of Distribution Processes on Replenishment Lead Time and Inventory

We investigate the interrelationship of distribution center picking policies and supply chain inventory performance. In particular, we show how the picking sequence in the upstream supply chain link affects the inventory levels of items being replenished to a downstream link for a common “ship‐when‐full” trailer dispatching policy. Perturbing the picking sequence affects items’ inventory levels asymmetrically which causes the aggregate system inventory to vary. We separate the items in replenishment into those units in transit and those awaiting shipment from the upstream distribution step: we call the latter the residual replenishment. We show that the process governing aggregate residual replenishment is Markov and has a stationary distribution that is discrete uniform. Computing the item‐level residual distribution is intractable and so we develop analytical models from which we derive hypotheses for the effectiveness of stable vs. random picking sequences, how item residual replenishment varies with stable picking sequences, and how the aggregate inventory level changes with picking sequence. These suggest a heuristic sequencing algorithm for minimizing inventory, which performs well in simulation tests over a large testbed of parameter sets.     

Supply Chain Management of Fresh Products with Producer Transportation*

This article considers a class of fresh‐product supply chains in which products need to be transported by the upstream producer from a production base to a distant retail market. Due to high perishablility a portion of the products being shipped may decay during transportation, and therefore, become unsaleable. We consider a supply chain consisting of a single producer and a single distributor, and investigate two commonly adopted business models: (i) In the “pull” model, the distributor places an order, then the producer determines the shipping quantity, taking into account potential product decay during transportation, and transports the products to the destination market of the distributor; (ii) In the “push” model, the producer ships a batch of products to a distant wholesale market, and then the distributor purchases and resells to end customers. By considering a price‐sensitive end‐customer demand, we investigate the optimal decisions for supply chain members, including order quantity, shipping quantity, and retail price. Our research shows that both the producer and distributor (and thus the supply chain) will perform better if the pull model is adopted. To improve the supply chain performance, we propose a fixed inventory‐plus factor (FIPF) strategy, in which the producer announces a pre‐determined inventory‐plus factor and the distributor compensates the producer for any surplus inventory that would otherwise be wasted. We show that this strategy is a Pareto improvement over the pull and push models for both parties. Finally, numerical experiments are conducted, which reveal some interesting managerial insights on the comparison between different business models.     

Updating Inventories of Substitutable Resources in Response to Forecast Updates

We show simple yet optimal results to update the inventory/capacity levels, expected profit, fill rates, and service levels of substitutable resources in response to an updating of the mean demand forecasts for the resources. We find that a change in the mean demand of one resource does not affect the optimal inventory level of any other resource. The results are obtained for demands with location‐scale distribution, and for a revenue structure satisfying a triangle property such that the manager will always use the inventory of a resource to meet her own demand first before using it for substitution. The results for updating the performance measures also extend to managers who maintain non‐optimal inventory/capacity levels. Implications for procurement, sales and operational planning, and multi‐store operations are discussed.