Markdown Budgets for Retail Buyers: Help or Hindrance?

For many retailers, markdown decisions are taken by retail buyers whose compensation is based on sales revenue so their objective is to maximize it through the season. This implies that the buyers' objectives are not perfectly aligned with the overall profitability the firm. Many retailers set markdown budgets prior to the season to control margin erosion and increase profitability. Markdown budget constrains the buyers on the amount of discounts that they can apply on a given inventory of merchandise and sets a limit on the dollar value of markdowns for the season. While markdown budgets may be useful in preventing excessive discounts, they can have a detrimental effect on the buyers' ability to respond to poor market and remove distressed inventory. We investigate the effectiveness of this practice in aligning the incentives of buyers with that of the firm, and provide guidance on how these budgets should be established ahead of time. We consider a firm with a fixed inventory of a seasonable item, and a single chance to mark the price down. The retailer knows only the demand distribution at the beginning of the season, but the market information is revealed during the season to the buyer. We first characterize the buyer's markdown policy and understand the circumstances under which this can be different from the retailer's markdown policy. We use our model to determine the optimal markdown budget and quantify its effectiveness considering different factors such as the level of demand uncertainty, initial markup, and market's responsiveness to markdowns.     

Managing Inventory with Cash Register Information: Sales Recorded but Not Demands

Inventory inaccuracy is common in many businesses. While retailers employ cash registers to enter incoming orders and outgoing sales, inaccuracy arises because they do not record invisible demand such as spoilage, damage, pilferage, or returns. This setting results in incomplete inventory and demand information. An important inventory control problem therefore is to maximize the total expected discounted profit under this setting. Allowing for dependence between demand and invisible demand, we obtain the associated dynamic programming equation with an infinite‐dimensional state space, and reduce it to a simpler form by employing the concept of unnormalized probability. We develop an analytical upper bound on the optimal profit as well as an iterative algorithm for an approximate solution of the problem. We compare profits of the iterative solution and the myopic solution, and then to the upper bound. We see that the iterative solution performs better than the myopic solution, and significantly so in many cases. Furthermore, it gives a profit not far from the upper bound, and is therefore close to optimal. Using our results, we also discuss meeting inventory service levels.     

The Effect of Lead Time Uncertainty on Safety Stocks

The pressure to reduce inventory investments in supply chains has increased as competition expands and product variety grows. Managers are looking for areas they can improve to reduce inventories without hurting the level of service provided. Two areas that managers focus on are the reduction of the replenishment lead time from suppliers and the variability of this lead time. The normal approximation of lead time demand distribution indicates that both actions reduce inventories for cycle service levels above 50%. The normal approximation also indicates that reducing lead time variability tends to have a greater impact than reducing lead times, especially when lead time variability is large. We build on the work of Eppen and Martin (1988) to show that the conclusions from the normal approximation are flawed, especially in the range of service levels where most companies operate. We show the existence of a service‐level threshold greater than 50% below which reorder points increase with a decrease in lead time variability. Thus, for a firm operating just below this threshold, reducing lead times decreases reorder points, whereas reducing lead time variability increases reorder points. For firms operating at these service levels, decreasing lead time is the right lever if they want to cut inventories, not reducing lead time variability.     

Late season low inventory assortment effects in the newsvendor problem

The assumption of the newsvendor being able to satisfy demand as long as on-hand inventory is positive does not hold for a non-homogenous product. Consumers who do not find a unit of the product which satisfies their secondary features preferences may not purchase the product even though the newsvendor has positive on-hand inventory. This is likely to occur late in the season as inventory level declines. We solve a newsvendor problem in which the probability of purchase by consumers is increasing in on-hand inventory for any inventory level below that which is needed to have a complete assortment. We identify the sufficient optimality condition for the order quantity. We show that, unlike the case of inventory-dependent demand models in the literature, the optimal order quantity may decrease due to the assortment effect. We investigate two types of pre-end of season discounts, immediate all-units and delayed, as ways to mitigate the late season assortment effect and show that in some cases, they can increase the newsvendor׳s profit and free up the shelf space for other products.     

Managing finished-goods inventory under capacitated delayed differentiation

Delayed differentiation or postponement is widely advocated to mitigate conflicts between product diversity and inventory cost savings. Manufacturers practicing postponement often suffer from severely constrained finishing capacities and noticeable finishing lead times. Therefore, inventories are still needed for finished products. Using the concept of inventory shortfall, this paper studies base-stock inventory models with and without demand forecasting and provides a computationally efficient method to set optimal inventory targets for finished products under capacitated postponement. Computations show inventory-saving benefit quickly vanishes after the capacity reaches a certain level. The value of forecasted advance-demand information (ADI) to postponement is justified, but can easily be overstated. Finishing capacities usually force manufacturers to build ahead according to demand forecast. When capacity limitation becomes severe, intuitions often guide producers to build to forecast even more than finishing lead times ahead. Results of this research indicate that these intuitions may be invalid and build to forecast more than finishing lead times ahead may not be a good practice. Further studies reveal that under capacitated postponement the forecasted advance-demand information is useful only when the variance of demand forecast errors is less than that of demands, and show that the optimal forecast lead time can be obtained in the same way as if the capacity is unlimited.     

Lot sizing and scheduling: a survey of practices in Brazilian companies

The lot sizing and scheduling (LSS) problem has motivated much research in production planning and control. However, while there are many papers on modelling this problem, there is scant research on how it is addressed in the industry. We present a survey of Brazilian industry practices in LSS, intending to understand the problem faced by operations managers, drawing parallels with academic findings to identify gaps between theory and practice and opportunities for future research. We confirm that the main objective of practitioners in companies operating under MTS strategy is to maximise service level, followed by inventory reduction. Availability of raw material, demand uncertainty and safety stock levels, lack of decision support software and the impact of sequence-dependent set-up times are other major concerns highlighted by the practitioners. Lastly, we confirmed that despite the relevant body of research on this problem, there is still a large gap between theory and practice.     

Assessing Service Level Targets in Production and Inventory Planning*

In production and stock planning, the relationship between customer service, defined as the ability to meet demand for finished goods from in-stock inventory, and expected profits or expected costs can be represented by a simple reliability curve. The shape of this curve depends upon the parameters of the demand process, specifically the expected level of demand, standard deviation and correlation structure, as well as upon the capacities and initial state of the production and inventory system. A model is presented which explicitly determines this trade-off curve for a firm. The model is intended both as an operational model to aid managers in setting revenue and service targets which are compatible with the capacities and resources of the firm, and as a tool for exploring relationships between the parameters of the demand process and the constraints of the physical production and inventory system. The results illustrate that the level of risk depends strongly on the variability of the demand process, the cost structure, the capacities and initial state of the system and, to a lesser extent, the correlation in demand between succeeding periods. Results suggest that establishing service level targets consistent with the firm's strategic orientation must be done in consideration of both the characteristics of the demand process and the capacities of the production and inventory system. The model provides a tool for estimating the premium above unit cost which must be paid to provide a designated service level.     

制造企业服务业务扩展及其认知因素研究

制造企业的竞争越来越激烈,几乎所有的企业都要面对快速反应多变市场和应对价格压力的要求,面对越来越小的产品利润空间和越来越复杂的客户需求,本文从对工业服务管理文献分析和制造企业的调查研究入手,揭示了制造企业从纯粹的产品生产者向客户支持方案提供者发展的转移趋势.通过对瑞士和德国30多家机器和设备制造企业进行的调查研究,说明了服务业务对制造企业在开发财务、营销和战略机会上的重要作用,并对转移过程中服务业务的扩展过程进行了总结.结合具体企业实践,本文对制约制造企业扩展服务业务中在管理动机上的认知因素进行了分析和研究.结合中国加入WTO后,中国制造企业将全面融入国际竞争的背景,本文期望对中国制造企业的发展和竞争地位的提高提供理论和实践上的指导.     

A New Two‐Bin Policy for Inventory Systems with Differentiated Demand Classes

We consider an inventory system under continuous review with two demand classes that are different in terms of service level required (or penalty cost incurred for backordering of demand). Prior literature has proposed the critical level rationing (CLR) policy under which the demand from the lower priority class is backordered once inventory falls below the critical level. While this reduces the penalty cost for the higher demand class, the fill rate achieved for the lower priority demand class gets compromised. In this study, we propose a new class of two‐bin (2B) policy for the problem. The proposed 2B policy assigns separate bins of inventory for the two demand classes. The demand for each class is fulfilled from its assigned bin. However, when the bin intended for the higher demand class is empty, the demand from the higher class can still be fulfilled with the inventory from the other bin. The advantage of the 2B policy is that better fill rates are achieved, especially for the lower demand class. Computational results show that the proposed policy is able to provide a much higher service level for the lower priority class demand without increasing the total cost too much and without affecting the service level for the higher priority class. When a service level constrained optimization problem is considered, the 2B policy dominates the CLR policy when the service level difference for the two classes is not too high or the service levels required for both the classes are relatively lower.     

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.     

A demand classification scheme for spare part inventory model subject to stochastic demand and lead time

In this study, we aim to develop a demand classification methodology for classifying and controlling inventory spare parts subject to stochastic demand and lead time. Using real data, the developed models were tested and their performances were evaluated and compared. The results show that the Laplace model provided superior performance in terms of service level, fill rate (FR) and inventory cost. Compared with the current system based on normal distribution, the proposed Laplace model yielded significant savings and good results in terms of the service level and the FR. The Laplace and Gamma optimisation models resulted in savings of 82 and 81%, respectively.     

Pricing Decisions During Inter‐Generational Product Transition

How should companies price products during an inter‐generational transition? High uncertainty in a new product introduction often leads to extreme cases of demand and supply mismatches. Pricing is an effective tool to either prevent or alleviate these problems. We study the optimal pricing decisions in the context of a product transition in which a new‐generation product replaces an old one. We formulate the dynamic pricing problem and derive the optimal prices for both the old and new products. Our analysis sheds light on the pattern of the optimal prices for the two products during the transition and on how product replacement, along with several other dynamics including substitution, external competition, scarcity, and inventory, affect the optimal prices. We also determine the optimal initial inventory for each product and discuss a heuristic method.     

ABC Classification: Service Levels and Inventory Costs

ABC inventory classifications are widely used in practice, with demand value and demand volume as the most common ranking criteria. The standard approach in ABC applications is to set the same service level for all stock keeping units (SKUs) in a class. In this paper, we show (for three large real life datasets) that the application of both demand value and demand volume as ABC ranking criteria, with fixed service levels per class, leads to solutions that are far from cost optimal. An alternative criterion proposed by Zhang et al. performs much better, but is still considerably outperformed by a new criterion proposed in this paper. The new criterion is also more general in that it can take criticality of SKUs into account. Managerial insights are obtained into what class should have the highest/lowest service level, a topic that has been disputed in the literature.     

Inventory Management for Customers with Alternative Lead Times

It is common for suppliers operating in batch‐production mode to deal with patient and impatient customers. This paper considers inventory models in which a supplier provides alternative lead times to its customers: a short or a long lead time. Orders from patient customers can be taken by the supplier and included in the next production cycle, while orders from impatient customers have to be satisfied from the on‐hand inventory. We denote the action to commit one unit of on‐hand inventory to patient or impatient customers as the inventory‐commitment decision, and the initial inventory stocking as the inventory‐replenishment decision. We first characterize the optimal inventory‐commitment policy as a threshold type, and then prove that the optimal inventory‐replenishment policy is a base‐stock type. Then, we extend our analysis to models to consider cases of a multi‐cycle setting, a supply‐capacity constraint, and the on‐line charged inventory‐holding cost. We also evaluate and compare the performances of the optimal inventory‐commitment policy and the inventory‐rationing policy. Finally, to further investigate the benefits and pitfalls of introducing an alternative lead‐time choice, we use the customer‐choice model to study the demand gains and losses, known as demand‐induction and demand‐cannibalization effects, respectively.     

The newsvendor problem with barter exchange

Barter exchange, as an alternative to move distressed inventory, has become increasingly popular in business. Many companies barter their unsold product for the product they need via barter exchange platforms at full prices. In this paper we consider the newsvendor problem with the barter exchange option. A retailer (the newsvendor) facing stochastic demand not only sells its product, but also buys other product that it needs from the market. It either trades its unsold product for the product it needs on a barter platform or disposes of its unsold product at discounted prices at the end of the selling season like in the classical newsvendor model. We derive the retailer’s optimal order quantity, then analytically and numerically examine the impacts of barter on the retailer’s inventory decisions and profit. We find that barter exchange can help the retailer to manage demand uncertainty and improve profit. The optimal order quantity decreases with barter commission and barter uncertainty, while increases with demand uncertainty and the value of the product that the retailer needs. Barter is more advantageous with lower barter commission, larger demand uncertainty, lower barter uncertainty, and higher value of the product it needs.     

基于备件需求优先级的随机库存控制模型研究

根据所安装设备发生故障时对生产过程的影响,备件的需求可划分为关键需求和非关键需求。基于此,研究了需求服从泊松分布、提前期等于常数、基于(S-1,S)订货策略的随机库存模型,提出当库存降低到预定水平,则预留存货以满足关键需求的控制策略,并给出了不同优先级备件服务水平的计算方法。最后结合某核电站库存管理中的一个实例,验证了本文所设计模型的优点和准确性。     

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.     

Inventory control with seasonality of lead times

The practical challenges posed by the seasonality of lead times have largely been ignored within the inventory control literature. The length of the seasons, as well as the length of the lead times during a season, may demonstrate cyclical patterns over time. This study examines whether inventory control policies that anticipate seasonal lead-time patterns can reduce costs. We design a framework for characterizing different seasonal lead-time inventory problems. Subsequently, we examine the effect of deterministic and stochastic seasonal lead times within periodic review inventory control systems. We conduct a base case analysis of a deterministic system, enabling two established and alternating lead-time lengths that remain valid through known intervals. We identify essential building blocks for developing solutions to seasonal lead-time problems. Lastly, we perform numerical experiments to evaluate the cost benefits of implementing an inventory control policy that incorporates seasonal lead-time lengths. The findings of the study indicate the potential for cost improvements. By incorporating seasonality in length of seasons and length of lead times within the season into the control models, inventory controllers can make more informed decisions when ordering their raw materials. They need smaller buffers against lead-time variations due to the cyclical nature of seasonality. Reductions in costs in our experiments range on average between 18.9 and 26.4% (depending on safety time and the probability of the occurrence of stock out). Therefore, inventory control methods that incorporate seasonality instead of applying large safety stock or safety time buffers can lead to substantial cost reductions.     

供应链网络系统的牛鞭效应时滞因素分析与库存控制策略研究

牛鞭效应的存在严重影响了供应链系统的运作效率,增加了供应链管理的复杂性。本文基于供应链网络库存状态的内部系统动力学机制,构建了供应链网络库存系统的状态转移模型,并引入时滞影响因素,通过供应链网络库存系统的波动状态描述牛鞭效应。在此模型基础上,针对供应链网络系统的牛鞭效应问题,提出了一类新的基于库存波动状态的动态供应链库存控制策略,并运用系统稳定性理论,将该策略的参数优化求解问题转化成线性矩阵不等式的求解问题。最后通过系统仿真深入分析了供应链网络库存系统对库存控制策略参数以及系统时滞因素的敏感性,并验证了该动态库存控制策略可以有效地抑制牛鞭效应。     

提前期、构建成本和短缺量拖后率均可控的EOQ模型

传统库存模型通常将提前期和构建成本视为不可控制。事实上可以通过追加投资缩短提前期和降低构建成本。缺货期间,为减少订单丢失量和补偿顾客的损失,供应商会给予一定的价格折扣。现实库存系统中,容易得到需求的期望值和标准差,但较难得到其分布规律。基于此,考虑短缺量拖后率与价格折扣和缺货期间库存水平相关,提出了一种需求为任意分布且提前期和构建成本均可控的EOQ模型,证明了模型存在唯一最优解,给出了一种寻优算法。数值仿真分析表明,一般情况下,压缩提前期和降低构建成本能降低订购批量和安全库存,降低库存总成本;短缺量拖后系数和缺货概率对库存总成本影响较大,企业应尽量降低缺货概率,尤其在短缺量拖后系数较小时。