Simultaneous production and logistics operations planning in semicontinuous food industries

The production and logistics operations planning in real-life single- or multi-site semicontinuous food industries is addressed in this work. A discrete/continuous-time mixed integer programming model, based on the definition of families of products, is developed for the problem in question. A remarkable feature of the proposed approach is that in the production planning problem timing and sequencing decisions are taken for product families rather than for products. However, material balances are realized for every specific product, thus permitting the detailed optimization of production, inventory, and transportation costs. Changeovers are also explicitly taken into account and optimized. Moreover, alternative transportation modes are considered for the delivery of final products from production sites to distribution centers. The efficiency and the applicability of the proposed approach is demonstrated by solving to optimality two industrial-size case studies, for an emerging real-life Greek dairy industry.     

Linking aggregate production planning with marketing pricing decisions

In this paper, we link production planning decisions to marketing decisions that involve the price of product groups. The focus of this paper is the development of a closed-loop procedure for aggregate production planning and pricing. We seek to satisfy uncertain demand while minimizing total costs that include material, labour, and inventory holding costs. The procedure is useful for variable demand to update short-term aggregate plans.     

Simultaneous Determination of Joint Product Cost Allocations and Cost-Plus Prices*

Use of the net realizable value approach for joint manufacturing cost allocations requires knowledge of selling prices of joint products. However, joint product selling prices themselves are functions of the allocated costs under a cost-plus pricing policy. In this case, it is necessary to determine joint cost allocations and joint product prices simultaneously. This paper applies a nonlinear programming (NLP) approach to simultaneously determine the optimal joint production decision, joint product cost-plus prices, and joint cost allocations using the net realizable value method. The NLP solution provides not only the optimal joint production and pricing decisions, but also the necessary conditions for such optimal decisions.     

The Retail Planning Problem Under Demand Uncertainty

We consider the retail planning problem in which the retailer chooses suppliers and determines the production, distribution, and inventory planning for products with uncertain demand to minimize total expected costs. This problem is often faced by large retail chains that carry private‐label products. We formulate this problem as a convex‐mixed integer program and show that it is strongly NP‐hard. We determine a lower bound by applying a Lagrangian relaxation and show that this bound outperforms the standard convex programming relaxation while being computationally efficient. We also establish a worst‐case error bound for the Lagrangian relaxation. We then develop heuristics to generate feasible solutions. Our computational results indicate that our convex programming heuristic yields feasible solutions that are close to optimal with an average suboptimality gap at 3.4%. We also develop managerial insights for practitioners who choose suppliers and make production, distribution, and inventory decisions in the supply chain.     

The Use of Flexible Manufacturing Capacity in Pharmaceutical Product Introductions*

This work considers the value of the flexibility offered by production facilities that can easily be configured to produce new products. We focus on technical uncertainty as the driver of this value, while prior works focused only on demand uncertainty. Specifically, we evaluate the use of process flexibility in the context of risky new product development in the pharmaceutical industry. Flexibility has value in this setting due to the time required to build dedicated capacity, the finite duration of patent protection, and the probability that the new product will not reach the market due to technical or regulatory reasons. Having flexible capacity generates real options, which enables firms to delay the decision about constructing product‐specific capacity until the technical uncertainty is resolved. In addition, initiating production in a flexible facility can enable the firm to optimize production processes in dedicated facilities. The stochastic dynamic optimization problem is formulated to analyze the optimal capacity and allocation decisions for a flexible facility, using data from existing literature. A solution to this problem is obtained using linear programming. The result of this analysis shows both the value of flexible capacity and the optimal capacity allocation. Due to the substantial costs involved with flexibility in this context, the optimal level of flexible capacity is relatively small, suggesting products be produced for only short periods before initiating construction of dedicated facilities.     

An investigation of company product decision making

This article is concerned with an investigation of the approaches taken by companies in making product decisions. The first part is concerned with a review of the range of product decisions as presented within the literature. This range is established within the context of corporate planning, with a major split between long term strategic planning product decisions, and short term operational planning product decisions. The second part of the article is concerned with the results of a survey that was designed to investigate the criteria that companies use within their product decision making. These criteria included those applicable to strategic planning, but also incorporated a range of criteria applicable to short term operational planning, as proposed in a recent article by Greenley [8]. The overall conclusion to the survey results was that a common and universal approach to product decision making cannot be identified within this sample of companies. A low level of agreement as to the relative degree of importance of the criteria was evident, and, little attention to differentiating product decisions with time was also evident. The results also challenge the importance given by the literature to the concepts of product life cycle, portfolio analysis and synergy. Finally, the author suggests two implications as a consequence of these results.     

Forest policy— formulation and implementation

This paper is concerned with the development of plans and policy with the U.K. State Forestry industry. The author outlines the structure within which plans and policies are developed. He emphasises the need for governments and foresters to be more aware of each others needs and potentials in planning. He highlights the problems of valuation in forestry (social as opposed to the private costs and benefits). Finally he suggests the components of an effective planning system in the forestry environment.     

An application of mathematical programming to soybean processing

In this paper, a mathematical programming methodology is applied to a production planning problem involving a soybean processing plant which can purchase its raw materials from multiple origins and must ship its finished products to multiple destinations. A time horizon production planning model is developed, with the objective of maximizing the net income produced by this plant. This model is tested for a five origin, three destination, processing network, over a thirteen month time horizon. Test results, in terms of a production plan and associated purchasing-allocation decisions, are presented and discussed.     

Integrated retail decisions with multiple selling periods and customer segments: Optimization and insights

Integrating retail decisions on such aspects as assortment, pricing, and inventory greatly improves profitability. We examine a multi-period selling horizon where a retailer jointly optimizes assortment planning, pricing, and inventory decisions for a product line of substitutable products, in a market with multiple customer segments. Focusing on fast-moving retail products, the problem is modeled as a mixed-integer nonlinear program where demand is driven by exogenous consumer reservation prices and endogenous assortment and pricing decisions. A mixed-integer linear reformulation is developed, which enables an exact solution to large problem instances (with up to a hundred products) in manageable times. Empirical evidence is provided in support of a classical deterministic maximum-surplus consumer choice model. Computational results and managerial insights are discussed. We find that the optimal assortment and pricing decisions do not exhibit a simple, intuitive structure that could be analytically characterized, which reflects the usefulness of optimization approaches to numerically identify attractive trade-offs for the decision-maker. We also observe that suboptimal inventory policies significantly decrease profitability, which highlights the importance of integrated decision-making. Finally, we find that the seasonality of consumer preferences and supply costs present an opportunity for boosting the profit via higher inventory levels and wider assortments.     

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.     

多品种集约生产计划问题的模糊方法

提出具有模糊需求量和模糊能力约束以及资本水平约束的多品种类集约生产计划问题 的模糊优化模型及模糊解方法. 通过对模糊需求量和模糊等式的描述,提出了模糊需求环境下 生产- 库存平衡方程的两种等价的描述方法, 并给出了模糊等式的实用解释. 建立了具有模 糊需求量和模糊能力约束集约生产计划问题的优化模型FMAPP ,并给出了求解模型的参数规 划方法.     

The Production of Several Items in a Single Facility with Linearly Changing Demand Rates

In this paper we extend the ELSP model to allow for linearly changing demand rates over a fixed planning horizon. This extension of the ELSP research provides a model that can be used in coordinating the production and marketing planning activities in a firm. The model allows the user to evaluate the impact of changes in product demand on production costs and customer service. We solve the model using a standard nonlinear programming package (MINOS) and show through examples based on actual production data how the model can be used to support coordinated production and marketing planning.     

Tactical production and distribution planning with dependency issues on the production process

Tactical production-distribution planning models have attracted a great deal of attention in the past decades. In these models, production and distribution decisions are considered simultaneously such that the combined plans are more advantageous than the plans resolved in a hierarchical planning process. We consider a two-stage production process, where in the first stage raw materials are transformed into continuous resources that feed the discrete production of end products in the second stage. Moreover, the setup times and costs of resources depend on the sequence in which they are processed in the first stage. The minimum scheduling unit is the product family which consists of products sharing common resources and manufacturing processes. Based on different mathematical modelling approaches to the production in the first stage, we develop a sequence-oriented formulation and a product-oriented formulation, and propose decomposition-based heuristics to solve this problem efficiently. By considering these dependencies arising in practical production processes, our model can be applied to various industrial cases, such as the beverage industry or the steel industry. Computation tests on instances from an industrial application are provided at the end of the paper.     

A two-stage stochastic programming approach for identifying optimal postponement strategies in supply chains with uncertain demand

In the course of globalization, applying mass-customization strategies has led to a high diversity of variants in many economic sectors. Thus, customer demands are often less predictable, and handling increasing inventory stocks as well as avoiding shortfalls have become particularly important. All these complexity drivers result in higher supply chain risks. Postponement strategies have been proposed as a suitable approach to address these problems. Although the concept of postponement and its impact on the supply chain are theoretically well discussed, optimally configuring the entire production and distribution activities is still challenging. We present a two-stage stochastic mixed-integer linear programming model, which comprises an integrated production and distribution planning approach, and considers postponement concepts. In comparison to earlier approaches that examine postponement strategies, our model supports the decision maker under demand uncertainty and considers lead times, penalty costs for shortfalls, as well as inventory-keeping decisions over a tactical planning horizon. This allows an integrated investigation of both form and logistics postponement concepts. Moreover, we consider the decision maker’s risk attitude identifying non-dominated profitable and risk-averse strategies. We illustrate the benefits of the model by using a case study from the apparel industry, and present the results of a sensitivity analysis with respect to varying demand uncertainty and demand correlations as well as different preferences regarding risk aversion. Furthermore, we carry out performance and quality benchmarks and compare the results of a standard mixed-integer linear programming solver, a parallel nested Benders approach and a sample average approximation technique.     

面向产品生命周期的部分柔性技术选择

本文研究随机需求下产品生命周期不同阶段的部分柔性技术选择与生产能力规划问题。部分柔性技术是相对于完全柔性技术而言的,一种生产技术的柔性程度定义为能生产一产品类中产品个数多少的能力。不同柔性强度的生产技术,其投资成本和运行成本不同。本文首先建立了以计划期上总成本最小为目标的技术选择和生产能力规划模型,然后根据产品在其生命周期不同阶段的特点与市场需求的特点,应用所建立的模型进行仿真并总结产品导入期和成熟期技术选择的特点。     

Optimal and Heuristic Decision Strategies for Integrated Production and Marketing Planning

In this study we examine the effects of integrating production and marketing decisions for a short- to medium-range planning horizon in a profit maximizing firm. We formulate two models for determining price, marketing expenditure, demand or production volume, and lot size for a single product with stable demand when economies of scale are present. The full integration (FI) model simultaneously determines all the decisions involved, while the partial integration (PI) model separates the lot sizing decision from the others, as happens frequently in practice. Geometric programming (GP) techniques and marginal analysis are used to compare FI and PI, and obtain important managerial implications regarding the two models.     

社交网络情境下基于同侪影响的产品线规划研究

依托社交网络优化产品线是实现“匹配消费者需求带动产品设计-制造-营销全流程协调发展”的重要途径,尽管已经引起实业界的重点关注,相应的学术研究却十分匮乏。鉴于此,本文基于同侪影响理论与前景理论,结合社交网络情境下消费者的产品需求、偏好及决策,构建涵盖产品线营销层面和设计层面的双层规划模型;然后结合智能手机产品线实例,运用嵌套灰狼算法对该双层规划模型进行求解验证。本研究旨在提出社交网络与产品线规划之间耦合作用的联合优化框架,为面向社交网络的产品线规划提供理论依据。     

Impact of Price Postponement on Capacity and Flexibility Investment Decisions

Investments in dedicated and flexible capacity have traditionally been based on demand forecasts obtained under the assumption of a predetermined product price. However, the impact on revenue of poor capacity and flexibility decisions can be mitigated by appropriately changing prices. While investment decisions need to be made years before demand is realized, pricing decisions can easily be postponed until product launch, when more accurate demand information is available. We study the effect of this price decision delay on the optimal investments on dedicated and flexible capacity. Computational experiments show that considering price postponement at the planning stage leads to a large reduction in capacity investments, especially in the more expensive flexible capacity, and a significant increase in profits. Its impact depends on demand correlation, elasticity and diversion, ratio of fixed to variable capacity costs, and uncertainty remaining at the times the pricing and production decisions are made.     

Concurrent consideration of product design,process planning and production planning activities

In manufacturing engineering, product design, process planning and production planning activities are often considered independently. However, in order to effectively respond to changes in business situations, such as changes in demand forecast, product mix and technology, it is desirable to consider them concurrently. For this purpose, a large-scale linear programming model has been developed. The model considers minimization of the sum of processing cost, late shipment cost and inventory holding cost as the objective, and concurrently selects product designs, and generates process plans and production plans. The number of columns in the formulation can be large and, hence, an efficient column generation scheme is developed to solve the model. The model and solution procedure are illustrated with examples.     

规避农副产品原材料产出不确定风险的商业保险策略

为了保证产品质量、降低生产成本，许多农副产品制造商选择自己种植原材料以满足农副产品的加工生产。然而，农作物的产出易受不利事件（如各种自然灾害）的影响而具有不确定性。这种不确定性可能导致最终产品产出不足，严重时甚至引发财务危机。为了应对潜在风险，农副产品制造商可向金融机构购买商业保险。本文建立了单周期农副产品制造商的计划产量决策模型，通过研究制造商购买商业保险的边界条件及最优商业保险策略，分析商业保险策略在制造商规避原材料产出不确定风险时所具有的价值。研究结果表明：（1）只有保费的安全因子低于外部融资的单位惩罚成本时，制造商才会购买商业保险；（2）最优商业保险策略与计划产量无关；（3）最终产品单位净收益越低，商业保险的价值反而越高。