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.     

A Stochastic Inventory Model With Fast‐Ship Commitments

We present a multiperiod model of a retail supply chain, consisting of a single supplier and a single retailer, in which regular replenishment occurs periodically but players have the option to support fast delivery when customers experience a stockout during a replenishment period. Because expedited shipments increase the supplier's transportation cost, and possibly production/inventory costs, the supplier typically charges a markup over and above the prevailing wholesale price for fast‐shipped items. When fast shipping is not supported, items are backordered if customers are willing to wait until the start of the next replenishment period. We characterize the retailers and the supplier's optimal stocking and production policies and then utilize our analytical framework to study how the two players respond to changes in supply chain parameters. We identify a sufficient condition such that the centralized supply chain is better off with the fast‐ship option. We find a range of markups for fast‐ship orders such that the fast‐ship option is preferred by both the supplier and the retailer in a decentralized chain. However, a markup that is a win–win for both players may not exist even when offering fast‐ship option is better for the centralized chain. Our analysis also shows that depending on how the markup is determined, greater customer participation in fast‐ship orders does not necessarily imply more profits for the two players. For some predetermined markups, the retailer's profit with the fast‐ship option is higher when more customers are willing to wait. However, the retailer may not be able to benefit from the fast‐ship option because the supplier may choose not to support the fast‐ship option when fast‐ship participation increases due to the fact that the fast‐ship participation rate adversely affects the initial order size.     

Optimal Planning Quantities for Product Transition

The replacement of an existing product with a new one presents many challenges. In particular, uncertainties in a new product introduction often lead to extreme cases of demand and supply mismatches. This paper addresses inventory planning decisions for product upgrades when there is no replenishment opportunity during the transition period. We allow product substitution: when a company runs out of the old product, a customer may be offered the new product as a substitute. We show that the optimal substitution decision is a time‐varying threshold policy and establish the optimal planning policy. Further, we determine the optimal delay in a new product introduction, given the initial inventory of the old product.     

The Impact of Revenue‐Maximizing Priority Pricing on Customer Delay Costs

Speed is an increasingly important determinant of which suppliers will be given customers' business and is defined as the time between when an order is placed by the customer and when the product is delivered, or as the amount of time customers must wait before they receive their desired service. In either case, the speed a customer experiences can be enhanced by giving priority to that particular customer. Such a prioritization scheme will necessarily reduce the speed experienced by lower‐priority customers, but this can lead to a better outcome when different customers place different values on speed. We model a single resource (e.g., a manufacturer) that processes jobs from customers who have heterogeneous waiting costs. We analyze the price that maximizes priority revenue for the resource owner (i.e., supplier, manufacturer) under different assumptions regarding customer behavior. We discover that a revenue‐maximizing supplier facing self‐interested customers (i.e., those that independently minimize their own expected costs) charges a price that also minimizes the expected total delay costs across all customers and that this outcome does not result when customers coordinate to submit priority orders at a level that seeks to minimize their aggregate costs of priority fees and delays. Thus, the customers are better off collectively (as is the supplier) when the supplier and customers act independently in their own best interests. Finally, as the number of priority classes increases, both the priority revenues and the overall customer delay costs improve, but at a decreasing rate.     

The Impact of Information Sharing and Advance Order Information on a Supply Chain with Balanced Ordering

This paper considers a supply chain with one supplier and multiple retailers that face exogenous heterogeneous end‐customer demands, where all parties utilize base‐stock policies. Each retailer is restricted to order once in every order cycle and their orders are replenished in a balanced manner within the cycle. Our study investigates the impact of information sharing and advance order information (AOI) on the supply chain. We find that the supplier benefits from the two mechanisms via two important factors, the information about observed end‐customer demands and the decision on re‐establishing the replenishment sequence. We derive the supplier's optimal sequence for stochastically comparable end‐customer demands with AOI and propose a sequencing rule for the setting with information sharing. Our numerical study examines the cost impacts of two proposed mechanisms on the entire supply chain.     

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.     

随机订单干扰下考虑合并决策的供应链网络调度研究

为满足客户个性化需求的快速响应，企业需具备柔性的外部供应链网络结构，以协同方式共同完成产品生产。本文考虑具有交互特征的多个不同类型协同供应链网络，构建生产成本、库存成本、等待成本以及订单延期交货成本最小化的目标函数，并设计合并决策判断变量构建同类订单在相同协同企业处的开始时间约束。此外，模型中考虑确定订单以及随机订单两种类型订单，并设计随机订单在区间时间段中离散时间点的到达概率。为获取协同供应链网络生产调度优化策略，基于随机订单到达与否的场景构建四个子决策模型，并进一步设计判断提前安排随机订单协同生产和不提前安排随机订单协同生产不同调度策略下成本差异的主决策模型。仿真结果表明合并决策在带来生产成本效益的同时也引起了部分订单的延期交货，且不同类型的协同供应链网络对随机订单的抗干扰能力存在一定程度的差异。     

Are Patients Patient? The Role of Time to Appointment in Patient Flow

The current state of outpatient healthcare delivery is characterized by capacity shortages and long waits for appointments, yet a substantial fraction of valuable doctors’ capacity is wasted due to no‐shows. In this study, we examine the effect of wait to appointment on patient flow, specifically on a patient's decision to schedule an appointment and to subsequently arrive to it. These two decisions may be dependent, as appointments are more likely to be scheduled by patients who are more patient and are thereby more likely to show up. To estimate the effect of wait on these two decisions, we introduce the willingness to wait (WTW), an unobservable variable that affects both bookings and arrivals for appointments. Using data from a large healthcare system, we estimate WTW with a state‐of‐the‐art non‐parametric method. The WTW, in turn, allows us to estimate the effect of wait on no‐shows. We observe that the effect of increased wait on the likelihood of no‐shows is disproportionately greater among patients with low WTW. Thus, although reducing the wait to an appointment will enable a provider to capture more patient bookings, the effects of wait time on capacity utilization can be non‐monotone. Our counterfactual analysis suggests that increasing wait times can sometimes be beneficial for reducing no‐shows.     

Using Frontier Portfolios to Improve Make‐to‐Order Operations

Make‐to‐order (MTO) manufacturers face a common problem of maintaining a desired service level for delivery at a reasonable cost while dealing with irregular customer orders. This research considers a MTO manufacturer who produces a product consisting of several custom parts to be ordered from multiple suppliers. We develop procedures to allocate orders to each supplier for each custom part and calculate the associated replenishment cost as well as the probability of meeting the delivery date, based on the suppliers' jobs on hand, availability, process speed, and defective rate. For a given delivery due date, a frontier of service level and a replenishment cost frontier are created to provide a range of options to meet customer requirements. This method can be further extended to the case when the delivery due date is not fixed and the manufacturer must “crash” its delivery time to compete for customers.     

竞争环境下的轴-辐式集装箱海运网络设计问题

针对航运企业的重组与全球扩张引起的竞争问题,提出了竞争环境下的轴-辐式集装箱海运网络设计模型。模型采用基于路径的变量作为决策变量,利用离散函数来表示航运企业与航运联盟的竞争可吸引的流量(或客户),目的在于通过设计混合轴-辐式集装箱海运网络,实现以更低的服务成本和更短的服务时间最大化可吸引的流量,建立了枢纽港口数量约束、航线连接约束、航线中转约束、流量竞争约束等,运用多点交叉遗传算法进行求解,最后结合亚欧航线的集装箱海运市场进行实例分析,对考虑客户需求多样性与航运联盟对策下的轴-辐式集装箱海运网络进行设计,并验证了算法的计算效果。     

Stabilized‐Cycle Strategy for Capacitated Lot Sizing with Multiple Products: Fill‐Rate Constraints in Rolling Schedules

In practice, deterministic, multi‐period lot‐sizing models are implemented in rolling schedules since this allows the revision of decisions beyond the frozen horizon. Thus, rolling schedules are able to take realizations and updated forecasts of uncertain data (e.g., customer demands) into account. Furthermore, it is common to hold safety stocks to ensure given service levels (e.g., fill rate). As we will show, this approach, implemented in rolling schedules, often results in increased setup and holding costs while (over‐)accomplishing given fill rates. A well‐known alternative to deterministic planning models are stochastic, static, multi‐period planning models used in the static uncertainty strategy, which results in stable plans. However, these models have a lack of flexibility to react to the realization of uncertain data. As a result, actual costs may differ widely from planned costs, and downside deviations of actual fill rates from those given are very high. We propose a new strategy, namely the stabilized cycle. This combines and expands upon ideas from the literature for minimizing setup and holding costs in rolling schedules, while controlling actual product‐specific fill rates for a finite reporting period. A computational study with a multi‐item capacitated medium‐term production planning model has been executed in rolling schedules. On the one hand, it demonstrates that the stabilized‐cycle strategy yields a good compromise between costs and downside deviations. Furthermore, the stabilized‐cycle strategy weakly dominates the order‐based strategy for both constant and seasonal demands.     

订单不确定条件下的供应链协同决策研究

在产品客户化程度较高的装配生产中,制造商在获得客户的订单需求信息,但订单尚未签订的情况下,往往就要求供应商开始生产订单所需的零部件,以便客户订单签订后可以立刻开始产品的装配生产,从而实现尽快向客户交付订单的目的。但是,在客户订单不确定条件下,供应商提前生产零部件存在着一定的风险。一旦客户订单最终未能签订,由于零部件客户化程度一般也比较高,在相当长一段时间内很难被其它订单消化,从而形成呆滞库存。本文基于这样的运作环境,通过数学建模分析,研究了制造商何时向供应商下达零部件订单最优,以及供应商的最优生产决策问题,并给出了具体的决策方法。最后通过算例验证了模型的结论,并分析了生产延滞成本分担系数对供应商和制造商双方期望利润的影响。     

Selecting sourcing partners for a make-to-order supply chain

Make-to-order manufacturers face an idiosyncratic and complex situation in the sourcing selection process. Although they can source from several key suppliers, each order requires custom key parts that cannot be stocked. Our research provides a decision model to facilitate the sourcing process for these manufacturers using information about their sourcing partners’ cost and processing time. The manufacturer can calculate the total cost and on-time probability for all possible combinations of certified suppliers and key part allotments to obtain a sourcing portfolio with several sourcing alternatives for a desired service level. The portfolio allows the manufacturer to make trade-offs between cost and reliability to finish the job on time. Additionally, the portfolio can be obtained for a given due date or for reduced due dates in a competitive bid situation. The portfolio approach allows the manufacturer to maintain control over the sourcing selection process by partnering with sourcing members to keep costs low without losing the needed flexibility to meet customer demands.     

无人零售业态下自动售卖机联合补货策略研究

研究无人零售业态下自动售卖机的多产品联合补货问题，建立由补货成本、库存持有成本、缺货成本构成的平均补货成本模型，分析容量约束与固定补货阈值下的最优补货策略。结果表明，企业会倾向于在剩余较少产品时进行补货，剩余的产品往往是投影面积最小使得相同面积可容纳最多数量的产品；比较最优补货时间与平均补货成本发现，延长补货时间可以降低平均补货成本，在补货阈值越大、固定补货成本越低或售卖机容量越小时，最优补货时间会降低，反之，平均补货成本会增加。此外，分析不同成本变动对平均成本的影响发现，单位成本变动均会引起平均补货成本的增加，且在单位库存持有成本变动时，最优补货策略会发生转移，向单位库存持有成本降低至一定程度的产品或向投影面积最低即相同面积可容纳数量最小的产品转移。     

Modelling the tradeoff between postponement capacity and forecast accuracy

The ability to offer rapid delivery of a wide variety of customised products requires companies to maintain high levels of product inventories to quickly respond to customer demands. One alternative for reducing final product inventories while providing the required customer service level is delayed product differentiation, known as postponement. This strategy, however, can result in significant costs of increasing capacity at the postponement stage. Another alternative is to improve forecast accuracy, resulting in costs associated with more sophisticated forecasting methodologies. In this study we model the costs associated with each alternative and the resulting reductions in inventory levels, while maintaining a constant service level. We illustrate the interaction between these variables using a numerical example motivated by our work with a local manufacturer of non-durable household goods. Our findings show that large cost differences can exist between the two strategies, and that these costs play a significant role in determining the best strategy. Also, the value of the product (through holding cost) sets a limit on the benefit that can be realised by either strategy. These results have important managerial implications that should be considered when making the postponement decision.     

B2C电子商务环境下订单拣选与配送联合调度优化

如何在顾客下单后协调好拣选和配送环节,在最短的时间、以较低的成本将商品从货架上拣出、打包后配送到顾客手中,已成为B2C电子商务物流管理中亟待解决的问题。本文尝试以最小化订单履行时间为目标,构建非线性拣选与配送联合调度模型,以解决订单拣选顺序、拣选作业方式、车辆行驶线路等联合决策。为求解此NP难问题,设计了三阶段启发式算法：首先采用“聚类-路径优化”思想,依据顾客位置进行配送方案确认;然后采用基于相似度聚类的订单分批规则对每条配送线路的订单进行分批合并;最后调整拣选任务与配送线路顺序。通过数据实验对模型进行验证,并与传统拣选与配送分开优化的结果进行对比。结果表明,三阶段算法能够有效缩短订单完成时间、降低配送车辆等待时间、改善配送资源利用率。     

A Model of Consumer Inertia with Applications to Dynamic Pricing

This paper introduces a decision model of consumer inertia. Consumers exhibit inertia when they have an inherent bias to delay purchases. Inertia may induce consumers to wait even when it is optimal to buy immediately. We embed our decision model within a dynamic pricing context. There is a firm that sells a fixed capacity over two time periods to an uncertain number of both rational and inertial consumers. We find that consumer inertia has both positive and negative effects on profits: it decreases demand (in period one) but intensifies competition among consumers for the product (in period two). We show that our model of inertia is consistent with well‐established behavioral regularities, such as loss aversion and probability weighting in the sense of prospect theory, and hyperbolic time preferences. We offer practical recommendations for firms to influence the level of consumer inertia. These include offering returns policies (to mitigate potential consumer losses), providing decision aids (to avoid perception errors), and offering flexible payment options (to lower transaction costs).     

How Long Should a Customer Wait for Service?

A major concern for service managers is the determination of how long a customer should wait to be served. Services, due to the customer's direct interaction with the process, must face a trade-off between minimizing the cost of having a customer wait and the cost of providing good service. A total cost model is presented for determining how long a customer should wait when these two conflicting cost components are considered. An integral part of this model includes a measure of customer satisfaction with waiting time which is used to develop a waiting cost function. The model is then applied to a major fast food chain, using data collected at several locations. Analysis of the data reveals that the “ideal” waiting time for this firm is significantly less than the current corporate waiting time policy. Thus, as indicated by the model, a corporate policy change is recommended to provide much faster service. The adoption of such a policy would result in increased labor costs, and would simultaneously increase the firm's overall profits. Although appearing contradictory, increases in current labor costs and long-term profits are both possible when management takes the long-range perspective suggested in this paper.     

A NUMERICAL ANALYSIS OF CAPACITATED POSTPONEMENT

Customer satisfaction can be achieved by providing rapid delivery of a wide variety of products. High levels of product variety require correspondingly high levels of inventory of each item to quickly respond to customer demand. Delayed product differentiation has been identified as a strategy to reduce final product inventories while providing the required customer service levels. However, it is done so at the cost of devoting large production capacities to the differentiation stage. We study the impact of this postponement capacity on the ability to achieve the benefits of delayed product differentiation. We examine a single‐period capacitated inventory model and consider a manufacturing system that produces a single item that is finished into multiple products. After assembly, some amount of the common generic item is completed as non‐postponed products, whereas some of the common item is kept as in‐process inventory, thereby postponing the commitment to a specific product. The non‐postponed finished‐goods inventory is used first to meet demand. Demand in excess of this inventory is met, if possible, through the completion of the common items. Our results indicate that a relatively small amount of postponement capacity is needed to achieve all of the benefits of completely delaying product differentiation for all customer demand. This important result will permit many firms to adopt this delaying strategy who previously thought it to be either technologically impossible or prohibitively expensive to do so.     

Longitudinal Analysis of Inhibitors of Manufacturer Delivery Performance

This article examines demand, manufacturing, and supply factors proposed to inhibit manufacturer delivery execution. Extant research proposes many factors expected to harm delivery performance. Prior cross‐sectional empirical research examines such factors at the plant level, generally finding factors arising from dynamic complexity to be significant, but factors arising from detail complexity to be insignificant. Little empirical research examines the factors using product‐level operating data, which arguably makes more sense for analyzing how supply chain complexity factors inhibit delivery. For purposes of research triangulation, we use longitudinal product‐level data from MRP systems to examine whether the factors inhibit internal manufacturing on time job rates and three customer‐oriented measures of delivery performance: product line item fill rates, average delivery lead times, and average tardiness. Our econometric models pool product line item data across division plants and within distinct product families, using a proprietary monthly dataset on over 100 product line items from the environmental controls manufacturing division of a Fortune 100 conglomerate. The data summarize customer ordering events of over 900 customers and supply chain activities of over 80 suppliers. The study contributes academically by finding significant detail complexity inhibitors of delivery that prior studies found insignificant. The findings demonstrate the need for empirical research using data disaggregated below the plant‐level unit of analysis, as they illustrate how some factors previously found insignificant indeed are significant when considered at the product‐level unit of analysis. Managers can use the findings to understand better which drivers and inhibitors of delivery performance are important.