电子商务环境下的存储策略优化研究:固定存储还是分类随机存储

库位推荐与拣货过程效率的提升是降低仓库运营成本的两个重要方面。而仓库的存储策略会对仓库运营总成本产生重要影响。本文首先在分类随机存储策略与固定存储策略下构建了库位推荐与拣货路径联合优化的混合整数规划模型;其次,基于快销品行业、医药行业和图书行业下的订单结构特点,采用修正的差分进化算法对两种存储策略进行了对比分析。结论表明：存储策略的优劣不仅与订单结构有关,同时也与单位存储成本与单位拣货成本的比重有关。当比重不高于0.25时,三种行业均是固定存储策略的总成本更低;（2）当比重介于0.25和0.26之间时,快销品行业和医药行业均是固定存储策略的总成本更低,而图书行业下是分类随机存储的成本更低;（3）当比重介于0.26和0.27之间时,快销品行业下是固定存储策略的总成本更低,而图书和医药行业下是分类随机存储的总成本更低。（4）当比重不低于0.27时,三种行业下均是分类随机存储策略的总成本更低。本文可以为不同行业下的仓库存储策略的选择提供一定的参考价值。     

自动化立体仓库中出入库任务顺序与出库位置选择集成优化研究

具有多个出口的自动化立体仓库系统是一种将存储和分拣相结合的新型仓储技术,其最典型的特征是在货架底层有很多个出库位置以供取货人员分拣。研究此系统中出入库任务排序与出口选择的集成优化问题,以最小化堆垛机完成所有任务的移动距离为目标,将此问题转化为一个混合整数规划模型。根据问题的特点设计了两阶段启发式算法求解此问题,数值结果表明设计的算法能在较短时间内给出近似最优解,同时与企业常用的先到先服务方法相比,该算法可以缩短超过20%的移动距离。     

AN OPERATIONAL PLANNING CONCEPT FOR DEEP LANE STORAGE SYSTEMS

The main advantage of deep lane storage systems compared with conventional high bay warehouses is seen in a better space utilization, because products are stored in channels one pallet behind the other. However, for deep lane storage systems the last-in-first-out principle holds and direct access to pallets is lost apart from the last pallet entering a channel. To operate deep lane storage systems effectively, namely, providing high throughput rates even at times of high storage rack utilization requires a sophisticated operational planning system. We will describe a totally new concept consisting of five modules for storage and retrieval assignments, as well as for a reorganization of storage location occupations.     

Revenue Management in Order‐Driven Production Systems

This article investigates the effectiveness of a tactical demand‐capacity management policy to guide operational decisions in order‐driven production systems. The policy is implemented via a heuristic that attempts to maximize revenue by selectively accepting or rejecting customer orders for multiple product classes when demand exceeds capacity constantly over the short term. The performance of the heuristic is evaluated in terms of its ability to generate a higher profit compared to a first‐come‐first‐served (FCFS) policy. The policies are compared over a wide range of conditions characterized by variations in both internal (firm) and external (market) factors. The heuristic, when used with a Whole Lot order‐processing approach, produces higher profit compared to FCFS when profit margins of products are substantially different from each other and demand exceeds capacity by a large amount. In other cases it is better to use the heuristic in conjunction with the Split Lot order‐processing approach.     

Order Progress Information: Improved Dynamic Emergency Ordering Policies

Technologies such as radio‐frequency identification and global positioning systems can provide improved real‐time tracking information for products and replenishment orders along the supply chain. We call this type of visibility order progress information. In this paper, we investigate how order progress information can be used to improve inventory replenishment decisions. To this end, we examine a retailer facing a stochastic lead time for order fulfillment. We characterize a replenishment policy that is based on the classical (Q, R) policy and that allows for releasing emergency orders in response to the order progress information. We show that the optimal structure of this policy is given by a sequence of threshold values dependent on order progress information. In a numerical study we evaluate the cost savings due to this improved replenishment policy.     

Staffing Call Centers with Uncertain Arrival Rates and Co‐sourcing

In a call center, staffing decisions must be made before the call arrival rate is known with certainty. Once the arrival rate becomes known, the call center may be over‐staffed, in which case staff are being paid to be idle, or under‐staffed, in which case many callers hang‐up in the face of long wait times. Firms that have chosen to keep their call center operations in‐house can mitigate this problem by co‐sourcing; that is, by sometimes outsourcing calls. Then, the required staffing N depends on how the firm chooses which calls to outsource in real time, after the arrival rate realizes and the call center operates as a M/M/N + M queue with an outsourcing option. Our objective is to find a joint policy for staffing and call outsourcing that minimizes the long‐run average cost of this two‐stage stochastic program when there is a linear staffing cost per unit time and linear costs associated with abandonments and outsourcing. We propose a policy that uses a square‐root safety staffing rule, and outsources calls in accordance with a threshold rule that characterizes when the system is “too crowded.” Analytically, we establish that our proposed policy is asymptotically optimal, as the mean arrival rate becomes large, when the level of uncertainty in the arrival rate is of the same order as the inherent system fluctuations in the number of waiting customers for a known arrival rate. Through an extensive numerical study, we establish that our policy is extremely robust. In particular, our policy performs remarkably well over a wide range of parameters, and far beyond where it is proved to be asymptotically optimal.     

Dedicated Transportation Subnetworks: Design,Analysis, and Insights

A dedicated subnetwork (DSN) refers to a subset of lanes, with associated loads, in a shipper's transportation network, for which resources—trucks, drivers, and other equipment—are exclusively assigned to accomplish shipping requirements. The resources assigned to a DSN are not shared with the rest of the shipper's network. Thus, a DSN is an autonomously operated subnetwork and, hence, can be subcontracted. We address a novel problem of extracting a DSN for outsourcing to one or more subcontractors, with the objective of maximizing the shipper's savings. In their pure form, the defining conditions of a DSN are often too restrictive to enable the extraction of a sizable subnetwork. We consider two notions—deadheading and lane‐sharing—that aid in improving the size of the DSN. We show that all the optimization problems involved are both strongly NP‐hard and APX‐hard, and demonstrate several polynomially solvable special cases arising from topological properties of the network and parametric relationships. Next, we develop a network‐flow‐based heuristic that provides near‐optimal solutions to practical instances in reasonable time. Finally, using a test bed based on data obtained from a national 3PL company, we demonstrate the substantial monetary impact of subcontracting a DSN and offer useful managerial insights.     

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.     

Value of Sharing Production Yield Information in a Serial Supply Chain

New developments in corporate information technology such as enterprise resource planning systems have significantly increased the flow of information among members of supply chains. However, the benefits of sharing information can vary depending on the supply chain structure and its operational characteristics. Most of the existing research has studied the impact of sharing downstream information (e.g., a manufacturer sharing information with its suppliers). We evaluate the benefits of sharing upstream yield information (e.g., a supplier sharing information with the manufacturer) in a two‐stage serial supply chain in which the supplier has multiple internal processes and is faced with uncertain output due to yield losses. We are interested in determining when the sharing of the supplier's information is most beneficial to the manufacturer. After proposing an order‐up‐to type heuristic policy, we perform a detailed computational study and observe that this information is most beneficial when the supplier's yield variance is high and when end‐customer demand variance is low. We also find that the manufacturer's backorder‐to‐holding cost ratio has little, if any, impact on the usefulness of information.     

Intelligent Procedures for Intra‐Day Updating of Call Center Agent Schedules

For nearly all call centers, agent schedules are typically created several days or weeks before the time that agents report to work. After schedules are created, call center resource managers receive additional information that can affect forecasted workload and resource availability. In particular, there is significant evidence, both among practitioners and in the research literature, suggesting that actual call arrival volumes early in a scheduling period (typically an individual day or week) can provide valuable information about the call arrival pattern later in the same scheduling period. In this paper, we develop a flexible and powerful heuristic framework for managers to make intra‐day resource adjustment decisions that take into account updated call forecasts, updated agent requirements, existing agent schedules, agents' schedule flexibility, and associated incremental labor costs. We demonstrate the value of this methodology in managing the trade‐off between labor costs and service levels to best meet variable rates of demand for service, using data from an actual call center.     

Sustainable storage assignment and dwell-point policies for automated storage and retrieval systems

Picking time reduction has been the traditional perspective for warehouse optimisation. When sustainability is considered, optimisation of warehouse operations should be read in terms of energy efficiency other than response time. Each location in the rack of an automated storage and retrieval system is associated with the value of energy consumed by the crane to reach it. Since picking performance strictly depends on storage location assignments, the time-based full turnover strategy is compared to the energy-based one. Three models of energy consumption are considered for traditional and new-generation cranes. Assignments are then compared in terms of dedicated zone shapes, time and energy performances within a given time horizon. Different shapes of the rack and product ABC curves are analysed. Dwell-point policies are also analysed from the new sustainable perspective, adding energy-saving performance to the traditional picking time reduction.     

The Role of Contract Expirations in Service Parts Management

The majority of after‐sales service providers manage their service parts inventory by focusing on the availability of service parts. This approach, combined with automatic replenishment systems, leads to reactive inventory control policies where base stock levels are adjusted only after a service contract expires. Consequently, service providers often face excess stock of critical service parts that are difficult to dispose due to their specificity. In this study, we address this problem by developing inventory control policies taking into account contract expirations. Our key idea is to reduce the base stock level of the one‐for‐one policy before obsolescence (a full or partial drop in demand rate) occurs and let demand take away excess stock. We refer to this policy as the single‐adjustment policy. We benchmark the single‐adjustment policy with the multiple‐adjustment policy (allowing multiple base stock adjustments) formulated as a dynamic program and verify that for a wide range of instances the single‐adjustment policy is an effective heuristic for the multiple‐adjustment policy. We also compare the single‐adjustment policy with the world‐dependent base stock policy offered by Song and Zipkin (1993) and identify the parameter combinations where both policies yield similar costs. We consider two special cases of the single‐adjustment policy where the base stock level is kept fixed or the base stock adjustment is postponed to the contract expiration time. We find that the initial demand rate, contract expiration time, and size of the drop in demand rate are the three key parameters driving the choice between the single‐adjustment policy and its special cases.     

Class‐Based Storage with a Finite Number of Items: Using More Classes is not Always Better

Class‐based storage is widely studied in the literature and applied in practice. It divides all stored items into a number of classes according to their turnover. A class of items with higher turnover is allocated to a region closer to the warehouse depot. In the literature, it has been shown that the use of more storage classes leads to a shorter travel time for storing and retrieving items. A basic assumption in this literature is that the required storage space for all items equals their average inventory level, which is valid only if an infinite number of items can be stored in each storage region. This study revisits class‐based storage by considering each storage space to contain only a finite number of items. We develop a travel time model and an algorithm that can be used for determining the optimal number and boundaries of storage classes in warehouses. Different from the conventional research, our findings illustrate that commonly a small number of classes is optimal. In addition, we find the travel time is fairly insensitive to the number of storage classes in a wide range around the optimum. This suggests that a manager can select a near‐optimal number of storage classes in an easy way and need not be worried about the impact of storage‐class reconfigurations. We validate our findings for various cases, including different ABC‐demand curves, space‐sharing factors, number of items, storage rack shapes, discrete storage locations, and stochastic item demand.     

End‐of‐Life Inventory Problem with Phaseout Returns

We consider the service parts end‐of‐life inventory problem of a capital goods manufacturer in the final phase of its life cycle. The final phase starts as soon as the production of parts terminates and continues until the last service contract expires. Final order quantities are considered a popular tactic to sustain service fulfillment obligations and to mitigate the effect of obsolescence. In addition to the final order quantity, other sources to obtain serviceable parts are repairing returned defective items and retrieving parts from phaseout returns. Phaseout returns happen when a customer replaces an old system platform with a next‐generation one and returns the old product to the original equipment manufacturer (OEM). These returns can well serve the demand for service parts of other customers still using the old generation of the product. In this study, we study the decision‐making complications as well as cost‐saving opportunities stemming from phaseout occurrence. We use a finite‐horizon Markov decision process to characterize the structure of the optimal inventory control policy. We show that the optimal policy consists of a time‐varying threshold level for item repair. Furthermore, we study the value of phaseout information by extending the results to cases with an uncertain phaseout quantity or an uncertain schedule. Numerical analysis sheds light on the advantages of the optimal policy compared to some heuristic policies.     

EOQ-based inventory management in single-machine multi-item systems

The present paper proposes an approach for including the finite capacity constraint in the EOQ model (and, in more general terms, in inventory systems) to study the context of single-machine multi-item systems. In particular, the proposed approach regulates the processing of different items by a shared resource according to a control model based on an ordering policy that combines the Economic Order Quantity with a policy based on minimum and maximum inventory levels (min–max policy). To achieve such a challenging result, the present work exploits the analogy between “switched arrival systems” (a particular class of hybrid systems) and min-max inventory systems. The development and parameterization of the abovementioned control model, therefore, refers to switched arrival systems control theory and mixed-integer linear programming. The present work also contributes to the integration of static tools (i.e., the EOQ model) and control tools, approaching these areas. The paper concludes with a real case application that illustrates the proposed approach and allows for a future research path to be drawn.     

Scheduling Truck Arrivals at an Air Cargo Terminal

We consider the scheduling of truck arrivals at an air cargo terminal. By coordinating arrivals of cargo delivery trucks with outbound flight departure schedules, some of the shipments can be transferred directly to the departing flights, while others will be stored at the terminal's storage facility and incur extra handling and storage costs. The objective is to obtain a feasible schedule so as to minimize the total cost of operations. We formulate the problem as a time‐indexed integer program and show that, even with limited number of unloading docks at the terminal, the problem is non‐trivial (NP‐hard in the strong sense). Our solution method includes an exact solution procedure to determine an optimal unloading sequence for the shipments carried by each truck, together with a Lagrangian relaxation‐based heuristic for assigning trucks to truck docks and determining truck arrival times. We conducted computational experiments to test the performance of our solution method. Computational results show that our method can generate near‐optimal solutions efficiently. Our simulation results indicate that the scheduling approach proposed in this paper has the potential to generate significant cost savings over a first‐come, first‐served approach currently used at the air cargo terminal that we observed.     

无人仓系统储位分配问题的优化模型与算法

考虑到无人仓系统补货阶段货架上只有部分空余储位的特点，研究了补货商品储位分配问题的优化模型与算法。以同一货架上存放的商品之间关联度之和最大化为目标建立了混合整数规划模型；结合贪婪算法和邻域搜索算法设计了求解模型的两阶段方法。第一阶段利用贪婪算法求初始可行解；第二阶段利用邻域搜索算法对初始可行解进行优化。利用一个具体算例验证了邻域搜索算法的优化效果，结果显示，通过邻域搜索算法对初始可行解的优化，可以使目标函数值至少提升27%。进一步利用多个小规模算例分析了两阶段算法的近似比和求解速度，验证了算法的快速有效性。本文的研究结果不仅解决了货架初始状态非空情况下的储位分配问题，同样适合解决货架初始状态为空的情况，因此更加符合实际场景，可以作为无人仓管理信息系统的核心模型和算法。     

A Bayesian Inventory Model Using Real‐Time Condition Monitoring Information

Lack of coordination between machinery fault diagnosis and inventory management for spare parts can lead to increased inventory costs and disruptions in production activity. We develop a framework for incorporating real‐time condition monitoring information into inventory decisions for spare parts. We consider a manufacturer who periodically replenishes inventory for a machine part that is subject to deterioration. The deterioration is captured via condition monitoring and modeled using a Wiener process. The resulting degradation model is used to derive the life distribution of a functioning part and to estimate the demand distribution for spare parts. This estimation is periodically updated, in a Bayesian manner, as additional information on part deterioration is obtained. We develop an inventory model that incorporates this updated demand distribution and demonstrate that a dynamic base‐stock policy, in which the optimal base‐stock level is a function of some subset of the observed condition monitoring information, is optimal. We propose a myopic critical fractile policy that captures the essence of the optimal policy, but is easier to compute. Computational experiments indicate that this heuristic performs quite well relative to the optimal policy. Adaptive inventory policies such as these can help manufacturers to increase machine availability and reduce inventory costs.     

Flexible Backup Supply and the Management of Lead‐Time Uncertainty

We consider replenishment decisions for a constant rate demand environment from a supplier with uncertain lead times. We study the potential use of a flexible backup supplier as an emergency response to accurate lead‐time information arriving at (or close after) the beginning of the demand interval and well after an original order with the stochastic lead‐time supplier has been placed. The emergency response decisions involve whether to order and how much from the flexible backup supplier, with the objective of minimizing the cost of meeting demand. We derive the optimal emergency‐response policy and clearly outline its implications on the optimized safety lead time of the original order placement and on the cost of meeting demand. We examine the impact on the use of the flexible backup supplier of factors like the arrival time of accurate lead‐time information and the response lead time of the backup supplier. We further study the potential benefits of the use of the flexible backup supplier in a dual role: as one of the two suppliers in a redundant supply system assigned to originally meet the demand and as an emergency response to later‐arriving lead‐time information. Our numerical studies illustrate the benefits from the use of the flexible backup supplier as an emergency response, but for reasonable purchase premiums and short lead times of flexible backup supply options, their use in a dual (regular and emergency response) role often leads to improved performance over safety lead‐time single and uncertain lead‐time supplier‐replenishment strategies. The benefits of the backup supply options are accentuated the higher the lead‐time uncertainty of the stochastic lead‐time supplier is.     

Real‐Time Delay Estimation Based on Delay History in Many‐Server Service Systems with Time‐Varying Arrivals

Motivated by interest in making delay announcements in service systems, we study real‐time delay estimators in many‐server service systems, both with and without customer abandonment. Our main contribution here is to consider the realistic feature of time‐varying arrival rates. We focus especially on delay estimators exploiting recent customer delay history. We show that time‐varying arrival rates can introduce significant estimation bias in delay‐history‐based delay estimators when the system experiences alternating periods of overload and underload. We then introduce refined delay‐history estimators that effectively cope with time‐varying arrival rates together with non‐exponential service‐time and abandonment‐time distributions, which are often observed in practice. We use computer simulation to verify that our proposed estimators outperform several natural alternatives.