Estimating operational costs in an electric utility

Generation expansion planning in the electric utility industry requires consideration of uncertainties in both the demand and supply of electric power. The expected demand is usually expressed via a load-duration curve, while, on the supply side, each generating unit has a given nameplate capacity and a predicted reliability. This paper focuses on considerations of the supply-side uncertainties and their effects on estimating operating costs in electric utility planning. However, the methods and analysis developed in this paper may be applicable to a wider class of production planning problems which deal with any nonstorable product with time varying demand. Two methods for estimating the energy generation from each generating unit are compared. The first is the method of probabilistic simulation, while the second involves a heuristic technique usually denoted the derating method. A bias inherent in the derating method is examined by comparing it with a probabilistic simulation method. The bias is examined for various load curve shapes. In certain cases, a closed form expression for the bias is obtained. However, a closed form expression of the bias for an arbitrary load curve is difficult to achieve. In these situations some examples are studied in which the trend of the relative bias among plants in the loading order is examined. Finally, the bias is examined using actual 1977 load and supply data for some New England utilities.     

A diagnostic analysis of the impact of forecast errors on production planning via MRP system nervousness

Abstract. The purpose of this paper is to examine the impact of forecast errors on the performance of a multi-product, multilevel production planning system via MRP system nervousness. The accuracy of forecasting methods was at one time a major concern of production scheduling and inventory control. However, with the advent of material requirements planning (MRP) systems, the significance of selecting an accurate forecasting method has diminished. Inaccurate forecast results are taken as a fact of life in production planning. Instead of attempting to develop an accurate forecasting method, efforts have been devoted towards providing an appropriate buffering method ai the master production schedule level or on the shop floor level to counteract fluctuations in demand. MRP is capable of rescheduling planned orders as well as open orders to restore the priority integrity after the disruptive changes of forecast errors occur. Nevertheless, excessive rescheduling may lead to a problem, generally referred to as system nervousness. This study investigates this problem by means of a computer simulation model. The results show that the presence of forecasi     

The Value of Weather Information for E‐Commerce Operations

To be efficient, logistics operations in e‐commerce require warehousing and transportation resources to be aligned with sales. Customer orders must be fulfilled with short lead times to ensure high customer satisfaction, and the costly under‐utilization of workers must be avoided. To approach this ideal, forecasting order quantities with high accuracy is essential. Many drivers of online sales, including seasonality, special promotions and public holidays, are well known, and they have been frequently incorporated into forecasting approaches. However, the impact of weather on e‐commerce operations has not been rigorously analyzed. In this study, we integrate weather data into the sales forecasting of the largest European online fashion retailer. We find that sunshine, temperature, and rain have a significant impact on daily sales, particularly in the summer, on weekends, and on days with extreme weather. Using weather forecasts, we have significantly improved sales forecast accuracy. We find that including weather data in the sales forecast model can lead to fewer sales forecast errors, reducing them by, on average, 8.6% to 12.2% and up to 50.6% on summer weekends. In turn, the improvement in sales forecast accuracy has a measurable impact on logistics and warehousing operations. We quantify the value of incorporating weather forecasts in the planning process for the order fulfillment center workforce and show how their incorporation can be leveraged to reduce costs and increase performance. With a perfect information planning scenario, excess costs can be reduced by 11.6% compared with the cost reduction attainable with a baseline model that ignores weather information in workforce planning.     

Coordinated Contract Decisions in a Make‐to‐Order Manufacturing Supply Chain: A Stochastic Programming Approach

One of the important objectives of supply chain S&OP (Sales and Operations Planning) is the profitable alignment of customer demand with supply chain capabilities through the coordinated planning of sales, production, distribution, and procurement. In the make‐to‐order manufacturing context considered in this paper, sales plans cover both contract and spot sales, and procurement plans require the selection of supplier contracts. S&OP decisions also involve the allocation of capacity to support sales plans. This article studies the coordinated contract selection and capacity allocation problem, in a three‐tier manufacturing supply chain, with the objective to maximize the manufacturer's profitability. Using a modeling approach based on stochastic programming with recourse, we show how these S&OP decisions can be made taking into account economic, market, supply, and system uncertainties. The research is based on a real business case in the Oriented Strand Board (OSB) industry. The computational results show that the proposed approach provides realistic and robust solutions. For the case considered, the planning method elaborated yields significant performance improvements over the solutions obtained from the mixed integer programming model previously suggested for S&OP.     

Flexible Capacity Investments and Product Mix: Optimal Decisions and Value of Postponement Options

In this article, we study a firm's interdependent decisions in investing in flexible capacity, capacity allocation to individual products, and eventual production quantities and pricing in meeting uncertain demand. We propose a three‐stage sequential decision model to analyze the firm's decisions, with the firm being a value maximizer owned by risk‐averse investors. At the beginning of the time horizon, the firm sets the flexible capacity level using an aggregate demand forecast on the envelope of products its flexible resources can accommodate. The aggregate demand forecast evolves as a Geometric Brownian Motion process. The potential market share of each product is determined by the Multinomial Logit model. At a later time and before the end of the time horizon, the firm makes a capacity commitment decision on the allocation of the flexible capacity to each product. Finally, at the end of the time horizon, the firm observes the demand and makes the production quantity and pricing decisions for end products. We obtain the optimal solutions at each decision stage and investigate their optimal properties. Our numerical study investigates the value of the postponed capacity commitment option in supplying uncertain operation environments.     

Impact of information exchange on supplier forecasting performance

Forecasts of demand are crucial to drive supply chains and enterprise resource planning systems. Usually, well-known univariate methods that work automatically such as exponential smoothing are employed to accomplish such forecasts. The traditional Supply Chain relies on a decentralized system where each member feeds its own Forecasting Support System (FSS) with incoming orders from direct customers. Nevertheless, other collaboration schemes are also possible, for instance, the Information Exchange framework allows demand information to be shared between the supplier and the retailer. Current theoretical models have shown the limited circumstances where retailer information is valuable to the supplier. However, there has been very little empirical work carried out. Considering a serially linked two-level supply chain, this work assesses the role of sharing market sales information obtained by the retailer on the supplier forecasting accuracy. Weekly data from a manufacturer and a major UK grocery retailer have been analyzed to show the circumstances where information sharing leads to improved forecasting accuracy. Without resorting to unrealistic assumptions, we find significant evidence of benefits through information sharing with substantial improvements in forecast accuracy.     

Forecasting Product Returns for Remanufacturing Operations

Driven by legislative pressures, an increasing number of manufacturing companies have been implementing comprehensive recycling and remanufacturing programs. The accurate forecasting of product returns is important for procurement decisions, production planning, and inventory and disposal management in such remanufacturing operations. In this study, we consider a manufacturer that also acts as a remanufacturer, and develop a generalized forecasting approach to determine the distribution of the returns of used products, as well as integrate it with an inventory model to enable production planning and control. We compare our forecasting approach to previous models and show that our approach is more consistent with continuous time, provides accurate estimates when the return lags are exponential in nature, and results in fewer units being held in inventory on average. The analysis revealed that these gains in accuracy resulted in the most cost savings when demand volumes for remanufactured products were high compared to the volume of returned products. Such situations require the frequent acquisition of cores to meet demand. The results show that significant cost savings can be achieved by using the proposed approach for sourcing product returns.     

配额——交易机制下动态批量生产和减排投资策略研究

随着我国碳排放交易市场的建立和发展,在碳排放约束下逐步降低单位产出的碳排放水平成为企业生产经营管理中的中长期约束性目标。本文在一个多周期决策模型中研究了配额-交易机制下企业的最优动态批量生产、碳排放权交易和减排投资联合决策问题。生产商在整个决策周期期初决定是否进行减排投资以及投资规模,根据每个周期的生产计划决定减排设备的运行计划。根据节能减排技术的特点,本文假设生产商运行减排设备时不仅降低了产品的单位生产碳排放量,而且降低了产品的单位生产成本。本文基于广义Benders分解法对模型进行了最优性分析,得到了最优生产决策和最优减排投资决策的一些基本性质,并通过数值实验分析了碳排放配额和碳排放权价格对生产商总成本、总排放以及减排投资决策的影响。本文的数值实验分析结果发现:(1)当碳交易市场上的碳排放权充足时,减少碳排放配额或改变碳排放配额的分配方式并不能影响生产商的碳排放水平;(2)碳排放权价格是影响生产商的碳排放水平和减排投资规模的关键因素;(3)随着碳排放权价格的上升,即使拥有足够的碳排放配额,生产商仍会不断提高减排投资规模以获得减排收益。研究结果对碳排放交易体系下生产企业进行减排技术投资具有较强的管理启示。     

An aggregate production planning framework for the evaluation of volume flexibility

Flexibility in manufacturing has been identified as one of the key factors to success in the marketplace. Many types of flexibility have been identified in the literature among which volume flexibility is one of the most important. Volume flexibility of a manufacturing system is defined as its ability to be operated profitably at different overall output levels. Volume flexibility permits a manufacturing system to adjust production upwards or downwards within wide limits. In this paper, we develop an aggregate production planning model for volumeflexible production systems. The model can be used with a Monte Carlo simulation to evaluate the optimal level of investment in volume flexibility for a firm operating under a given set of market conditions. In addition, the model can be used to develop some conclusions about the relationship between the value of volume flexibility and the cost of holding inventory, the cost of shortage, forecast accuracy, and the length of the planning horizon.     

Marketing planning and corporate planning

The market planning subset of the corporate planning process has unique difficulties associated with technical, organizational and behavioural problems. A major technical problem is that of getting the company sales forecast right. The paper suggests a check-list for budget reviewers aimed at producing more realism in forecasting (Section II).Organizational problems are discussed in terms of allowing time for full concurrence between budget framers and reviewers (Section III). The little-discussed behavioural problems associated with the interface between line management and marketing staff specialists are outlined in Section IV with some suggestions for overcoming them.     

A note on supply risk and inventory outsourcing

To fully accommodate the correlations between semiconductor product demands and external information such as the end market trends or regional economy growth, a linear dynamic system is introduced in this paper to improve the forecasting performance in supply chain operations. In conjunction with the generic Gaussian noise assumptions, the proposed state-space model leads to an expectation-maximisation (EM) algorithm to estimate model parameters and predict production demands. When the dimension of external indicators is high, principal component analysis (PCA) is applied to reduce the model order and corresponding computational complexity without loss of substantial statistical information. Experimental study on some real electronic products demonstrates that this forecasting methodology produces more accurate predictions than other conventional approaches, which thereby helps improve the production planning and the quality of semiconductor supply chain management.     

Optimal Dynamic Order Scheduling under Capacity Constraints Given Demand‐Forecast Evolution

We consider a manufacturer without any frozen periods in production schedules so that it can dynamically update the schedules as the demand forecast evolves over time until the realization of actual demand. The manufacturer has a fixed production capacity in each production period, which impacts the time to start production as well as the production schedules. We develop a dynamic optimization model to analyze the optimal production schedules under capacity constraint and demand‐forecast updating. To model the evolution of demand forecasts, we use both additive and multiplicative versions of the martingale model of forecast evolution. We first derive expressions for the optimal base stock levels for a single‐product model. We find that manufacturers located near their market bases can realize most of their potential profits (i.e., profit made when the capacity is unlimited) by building a very limited amount of capacity. For moderate demand uncertainty, we also show that it is almost impossible for manufacturers to compensate for the increase in supply–demand mismatches resulting from long delivery lead times by increasing capacity, making lead‐time reduction a better alternative than capacity expansion. We then extend the model to a multi‐product case and derive expressions for the optimal production quantities for each product given a shared capacity constraint. Using a two‐product model, we show that the manufacturer should utilize its capacity more in earlier periods when the demand for both products is more positively correlated.     

Rough-cut capacity planning for remanufacturing firms

Capacity planning is a critical element of any successful production planning and control system. A method of rough-cut capacity planning is developed, based on the bill-of-resources approach, that can be used to plan for capacity required for firms in a remanufacturing including overhaul repair operations environment. The modified bill-of-resources approach developed takes into account two major stochastic elements inherent in this environment; probabilistic material replacement factors and probabilistic routing files. A detailed example from an actual repair overhaul operation is presented to illustrate the technique.     

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.     

Technological forecasting for power generation—A study using the Delphi technique

Technological forecasting is a powerful technique for obtaining insights into possible futuristic innovations. The forecast can provide a basis for long-range planning and policy formulation in organizations. Technological forecasting, though a useful and powerful tool, has yet to be applied widely in developing countries. This paper outlines a forecasting exercise carried out by the authors using the Delphi technique in India. The focus of the exercise was on electric energy generation and transportation. The findings have been compared with other available studies in India in similar areas. The paper also illustrates how additional information inputs can mould such forecasts. For this purpose, the authors have compared the results of the current study with the results of a similar study carried out in the same organization 8 years earlier. The change in perception regarding the timing of certain items is very evident and the underlying reasons have been given.     

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.     

A strategic and global manufacturing capacity management optimisation model: A Scenario-based multi-stage stochastic programming approach

Large-scale multinational manufacturing firms often require a significant investment in production capacity and extensive management efforts in strategic planning in an uncertain business environment. In this research we first discuss what decision terms and boundary conditions a holistic capacity management model for the manufacturing industry must contain. To better understand how these decision terms and constraints have been employed by the recent model developers in the area of capacity and resource management modelling for manufacturing, 69 optimisation-based (deterministic and stochastic) models have been carefully selected from 2000 to 2018 for a brief comparative analysis. The results of this comparison shows although applying uncertainty into capacity modelling (in stochastic form) has received a greater deal of attention most recently (since 2010), the existing stochastic models are yet very simplistic, and not all the strategic terms have been employed in the current model developments in the field. This lack of a holistic approach although is evident in deterministic models too, the existing stochastic counterparts proved to include much less decision terms and inclusive constraints, which limits them to a limited applications and may cause sub-optimal solutions. Employing this set of holistic decision terms and boundary conditions, this work develops a scenario-based multi-stage stochastic capacity management model, which is capable of modelling different strategic terms such as capacity level management (slight, medium and large capacity volume adjustment to increase/decrease capacity), location/relocation decisions, merge/decomposition options, and product management (R&D, new product launch, product-to-plant and product-to-market allocation, and product phase-out management). Possibility matrix, production rates, different financial terms and international taxes, inflation rates, machinery depreciation, investment lead-time and product cycle-time are also embedded in the model in order to make it more practical, realistic and sensitive to strategic decisions and scenarios. A step-by-step open-box validation has been followed while designing the model and a holistic black-box validation plan has been designed and employed to widely validate the model. The model then has been verified by deploying a real-scaled case of Toyota Motors UK (TMUK) decision of mothballing one of their production lines in the UK after the global recession in 2010.     

基于季节调整和Holt-Winters的月度负荷预测方法

针对负荷序列中异常数据会导致模型误设或参数估计发生偏差的问题,提出利用季节调整方法,先对原始负荷序列进行季节调整,获得消除离群值、节假日影响的季节调整后序列和季节成分序列;然后用改进的Holt-Winters方法对季节调整后成分进行预测,用虚拟回归方法预测季节成分序列;最后对各成分预测结果重构得到最终预测结果的月度负荷预测方法。通过实例检验,提出的方法能明显提高预测精度,预测效果要优于季节性Holt-Winters、SARIMA、神经网络、支持向量机等模型。     

Evaluating Probabilistic Forecasts with Bayesian Signal Detection Models

We propose the use of signal detection theory (SDT) to evaluate the performance of both probabilistic forecasting systems and individual forecasters. The main advantage of SDT is that it provides a principled way to distinguish the response from system diagnosticity, which is defined as the ability to distinguish events that occur from those that do not. There are two challenges in applying SDT to probabilistic forecasts. First, the SDT model must handle judged probabilities rather than the conventional binary decisions. Second, the model must be able to operate in the presence of sparse data generated within the context of human forecasting systems. Our approach is to specify a model of how individual forecasts are generated from underlying representations and use Bayesian inference to estimate the underlying latent parameters. Given our estimate of the underlying representations, features of the classic SDT model, such as the receiver operating characteristic (ROC) curve and the area under the ROC curve (AUC), follow immediately. We show how our approach allows ROC curves and AUCs to be applied to individuals within a group of forecasters, estimated as a function of time, and extended to measure differences in forecastability across different domains. Among the advantages of this method is that it depends only on the ordinal properties of the probabilistic forecasts. We conclude with a brief discussion of how this approach might facilitate decision making.