On Optimal Expediting Policy for Supply Systems with Uncertain Lead‐Times

We examine the role of expediting in dealing with lead‐time uncertainties associated with global supply chains of “functional products” (high volume, low demand uncertainty goods). In our developed stylized model, a retailer sources from a supplier with uncertain lead‐time to meet his stable and known demand, and the supply lead‐time is composed of two random duration stages. At the completion time of the first stage, the retailer has the option to expedite a portion of the replenishment order via an alternative faster supply mode. We characterize the optimal expediting policy in terms of if and how much of the order to expedite and explore comparative statics on the optimal policy to better understand the effects of changes in the cost parameters and lead‐time properties. We also study how the expediting option affects the retailer's decisions on the replenishment order (time and size of order placement). We observe that with the expediting option the retailer places larger orders closer to the start of the selling season, thus having this option serve as a substitute for the safety lead‐time and allowing him to take increased advantages of economies of scale. Finally we extend the basic model by looking at correlated lead‐time stages and more than two random lead‐time stages.     

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.     

Integrated Order Scheduling and Packing

We consider an integrated production–distribution scheduling model in a make‐to‐order supply chain consisting of one supplier and one customer. The supplier receives a set of orders from the customer at the beginning of a planning horizon. The supplier needs to process all the orders at a single production line, pack the completed orders to form delivery batches, and deliver the batches to the customer. Each order has a weight, and the total weight of the orders packed in a batch must not exceed the capacity of the delivery batch. Each delivery batch incurs a fixed distribution cost. The problem is to find jointly a schedule for order processing and a way of packing completed orders to form delivery batches such that the total distribution cost (or equivalently, the number of delivery batches) is minimized subject to the constraint that a given customer service level is guaranteed. We consider two customer service constraints—meeting the given deadlines of the orders; or requiring the average delivery lead time of the orders to be within a given threshold. Several problems of the model with each of those constraints are considered. We clarify the complexity of each problem and develop fast heuristics for the NP‐hard problems and analyze their worst‐case performance bounds. Our computational results indicate that all the heuristics are capable of generating near optimal solutions quickly for the respective problems.     

Contingency Strategies in Managing Supply Systems with Uncertain Lead‐Times

The globalization of markets and geographic dispersion of production facilities, combined with a heavy outsourcing of supply chain processes, have substantially increased the exposure of supply chains to supply lead‐times of long and uncertain nature. In this paper, we study the potential use of two contingency strategies on top of the conventionally used time buffer—statically planned safety lead‐time (SL)—approach to deal with the lead‐time uncertainty. These are (1) the ex‐ante planning for disruption safety stock (DSS) to be released when a “disruption” (in this case, late delivery of the order) occurs; and (2) the ex‐post dynamic emergency response (DER), which dynamically decides on the timing and size of an emergency order to be placed. Our work elaborates on the optimal parameter setting for these strategies, compares their added values when used to complement the traditional SL approach, and examines how the use of the contingency strategies affects the SL and corresponding cycle length of a periodic review system. Our research finds that: (1) the above contingency strategies reduce the reliance on the SL and are cost effective when the coefficient of variation (CV) of the uncertain lead‐time is high; (2) it is important to re‐optimize the SL to account for the contingency plans; and (3) re‐optimization of the cycle length to account for the presence of the contingency responses, as opposed to using an EOQ‐determined cycle length, does not significantly improve the cost performance. However, such re‐optimization does well in the SL approach when the CV of the uncertain lead‐time is high.     

The Impact of Capacity Costs on Product Differentiation in Delivery Time,Delivery Reliability,and Price

We develop an analytical framework for studying the role capacity costs play in shaping the optimal differentiation strategy in terms of prices, delivery times, and delivery reliabilities of a profit‐maximizing firm selling two variants (express and regular) of a product in a capacitated environment. We first investigate three special cases. The first is an existing model of price and delivery time differentiation with exogenous reliabilities, which we only review. The second focuses on time‐based (i.e., length and reliability) differentiation with exogenous prices. The third deals with deciding on all features for an express variant when a regular product already exists in the marketplace. We subsequently address the integrative framework of time‐and‐price‐based differentiation for both products in a numerical study. Our results shed light on the role that customer preferences towards delivery times, reliabilities and prices, and the capacity costs (absolute and relative) have on the firm's optimal product positioning policy.     

A Capacitated Multi‐echelon Inventory Placement Model under Lead Time Constraints

We develop an inventory placement model in the context of general multi‐echelon supply chains where the delivery lead time promised to the customer must be respected. The delivery lead time is calculated based on the available stocks of the different input and output products in the different facilities and takes into account the purchasing lead times, the manufacturing lead times, and the transportation lead times. We assume finite manufacturing capacities and consider the interactions of manufacturing orders between time periods. Each facility manages the stocks of its input and output products. The size of customer orders and their arrival dates and due dates are assumed to be known as in many B2B situations. We perform extensive computational experiments to derive managerial insights. We also derive analytical insights regarding the manufacturing capacities to be installed and the impacts of the frequency of orders on the system cost.     

Willingness to Pay for Shifting Inventory Risk: The Role of Contractual Form

In order to reduce their inventory risk, firms can attempt to contract with their suppliers for shorter supply lead‐times, with their buyers for longer demand lead‐times, or both. We designed a controlled laboratory experiment to study contracts that shift a focal firm's inventory risk to its supply chain partners and address two questions. First, is it more effective if the cost of shifting inventory risk is framed as a fixed fee or in per‐unit cost terms? We find that, generally, our participants are willing to pay more to avoid supply–demand mismatches than the expected costs from such mismatches. This tendency to overpay is mitigated under fixed fee schemes. Second, does it matter whether the option to reduce inventory risk is the outcome of either increased responsiveness from the upstream supplier or advanced demand information from the downstream buyer? Our results suggest that this difference, when only a matter of framing, has no significant effect on willingness‐to‐pay.     

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.     

Demand and Production Management with Uniform Guaranteed Lead Time

Recently, innovation‐oriented firms have been competing along dimensions other than price, lead time being one such dimension. Increasingly, customers are favoring lead time guarantees as a means to hedge supply chain risks. For a make‐to‐order environment, we explicitly model the impact of a lead time guarantee on customer demands and production planning. We study how a firm can integrate demand and production decisions to optimize expected profits by quoting a uniform guaranteed maximum lead time to all customers. Our analysis highlights the increasing importance of lead time for customers, as well as the tradeoffs in achieving a proper balance between revenue and cost drivers associated with lead‐time guarantees. We show that the optimal lead time has a closed‐form solution with a newsvendor‐like structure. We prove comparative statics results for the change in optimal lead time with changes in capacity and cost parameters and illustrate the insights using numerical experimentation.     

Optimal Sourcing and Lead‐Time Reduction under Evolutionary Demand Risk

We develop a real‐options model for optimizing production and sourcing choices under evolutionary supply‐chain risk. We model lead time as an endogenous decision and calculate the cost differential required to compensate for the risk exposure coming from lead time. The shape of the resulting cost‐differential frontier reveals the term structure of supply‐chain risk premiums and provides guidance as to the potential value of lead‐time reduction. Under constant demand volatility, the break‐even cost differential increases in volatility and lead time at a decreasing rate, making incremental lead‐time reduction less valuable than full lead‐time reduction. Stochastic demand volatility increases the relative value of incremental lead‐time reduction. When demand has a heavy right tail, the value of lead‐time reduction depends on how extreme values of demand are incorporated into the forecasting process. The cost‐differential frontier is invariant to discount rates, making the cost of capital irrelevant for choosing between lead times. We demonstrate the managerial implications of the model by applying it first to the classic Sport‐Obermeyer case and then to a supplier‐selection problem faced by a global manufacturer.     

Optimal Expediting Policies for a Serial Inventory System with Stochastic Lead Time

In recent supply chains, often operating multiple delivery modes such as standard freight shipping and air is an effective way of addressing both delivery lead time uncertainties and service rates. We propose a model on how to optimally operate multiple delivery modes. We consider a serial supply chain and an expediting option from intermediate installations to the downstream of the chain. The goods move stochastically among the installations and the system faces a stochastic demand. We identify systems that yield simple optimal policies, in which both regular ordering and expediting follow a variant of the base stock policy. Expediting allows the system to be leaner due to the reduced regular order amount. In addition, we provide managerial insights linking expediting, base stock levels, and expediting costs based on analytical and numerical results.     

Coordinating Supply Chains via Advance‐Order Discounts,Minimum Order Quantities,and Delegations

To avoid inventory risks, manufacturers often place rush orders with suppliers only after they receive firm orders from their customers (retailers). Rush orders are costly to both parties because the supplier incurs higher production costs. We consider a situation where the supplier's production cost is reduced if the manufacturer can place some of its order in advance. In addition to the rush order contract with a pre‐established price, we examine whether the supplier should offer advance‐order discounts to encourage the manufacturer to place a portion of its order in advance, even though the manufacturer incurs some inventory risk. While the advance‐order discount contract is Pareto‐improving, our analysis shows that the discount contract cannot coordinate the supply chain. However, if the supplier imposes a pre‐specified minimum order quantity requirement as a qualifier for the manufacturer to receive the advance‐order discount, then such a combined contract can coordinate the supply chain. Furthermore, the combined contract enables the supplier to attain the first‐best solution. We also explore a delegation contract that either party could propose. Under this contract, the manufacturer delegates the ordering and salvaging activities to the supplier in return for a discounted price on all units procured. We find the delegation contract coordinates the supply chain and is Pareto‐improving. We extend our analysis to a setting where the suppliers capacity is limited for advance production but unlimited for rush orders. Our structural results obtained for the one‐supplier‐one‐manufacturer case continue to hold when we have two manufacturers.     

Coordinating a Semi‐Centralized Global Production Network Through Different Levels of Headquarters Involvement

Motivated by our experience with a global company, we propose and study the concept of a semi‐centralized supply chain and analyze its coordination issues. We focus on a supply chain consisting of a home plant and a foreign branch, both of which are under the same parent company but have considerable autonomy. The role of the home plant is to provide a key component to the foreign branch with guaranteed service (required by the headquarters). Because of a high fixed order cost, the branch orders the component rather infrequently, causing high expediting costs at the home plant. Our purpose is to help the headquarters to improve the supply chain efficiency. We show that under certain conditions, the headquarters can coordinate the supply chain by setting an upper bound on the expediting frequency. If these conditions fail to hold, a simple fixed cost‐sharing contract coordinates the supply chain. When centralized control is too costly or infeasible, the headquarters may delegate the contract design rights to the subunits. If the home plant receives the rights, the supply chain performance can be significantly improved (sometimes to near optimality). These results provide guidance to the headquarters on whether, when, and to whom to delegate the coordination initiatives.     

Selection of supply portfolio under disruption risks

This paper deals with the optimal selection of supply portfolio in a make-to-order environment in the presence of supply chain disruption risks. Given a set of customer orders for products, the decision maker needs to decide from which supplier to purchase custom parts required for each customer order to minimize total cost and mitigate the impact of disruption risks. The selection of suppliers and allocation of orders is based on price and quality of purchased parts and reliability of delivery. The two types of disruption scenarios are considered: scenarios with independent local disruptions of each supplier and scenarios with local and global disruptions that may result in all suppliers disruption simultaneously. The problem is formulated as a single- or bi-objective mixed integer program and a value-at-risk and conditional value-at-risk approach is applied to control the risk of supply disruptions. The proposed portfolio approach is capable of optimizing the supply portfolio by calculating value-at-risk of cost per part and minimizing expected worst-case cost per part simultaneously. Numerical examples are presented and some computational results are reported.     

The Impact of E‐Replenishment Strategy on Make‐to‐Order Supply Chain Performance

This research investigates the impact of electronic replenishment strategy on the operational activities and performance of a two‐stage make‐to‐order supply chain. We develop simulation‐based rolling schedule procedures that link the replenishment processes of the channel members and apply them in an experimental analysis to study manual, semi‐automated, and fully automated e‐replenishment strategies in decentralized and coordinated decision‐making supply chain structures. The average operational cost reductions for moving from a manual‐based system to a fully automated system are 19.6, 29.5, and 12.5%, respectively, for traditional decentralized, decentralized with information sharing, and coordinated supply chain structures. The savings are neither equally distributed among participants, nor consistent across supply chain structures. As expected, for the fully coordinated system, total costs monotonically decrease with higher levels of automation. However, for the two decentralized structures, under which most firms operate today, counter‐intuitive findings reveal that the unilateral application of e‐procurement technology by the buyer may lower his purchasing costs, but increase the seller's and system's costs. The exact nature of the relationship is determined by the channel's operational flexibility. Broader results indicate that while the potential economic benefit of e‐replenishment in a decentralized system is substantial, greater operational improvements maybe possible through supply chain coordination.     

Pareto‐Improving Contracts for Express Package Delivery Services

We address the problem of an express package delivery company in structuring a long‐term customer contract whose terms may include prices that differ by day‐of‐week and by speed‐of‐service. The company traditionally offered speed‐of‐service pricing to its customers, but without day‐of‐week differentiation, resulting in customer demands with considerable day‐of‐week seasonality. The package delivery company hoped that using day‐of‐week and speed‐of‐service price differentiation for contract customers would induce these customers to adjust their demands to become counter‐cyclical to the non‐contract demand. Although this usually cannot be achieved by pricing alone, we devise an approach that utilizes day‐of‐week and speed‐of‐service pricing as an element of a Pareto‐improving contract. The contract provides the lowest‐cost arrangement for the package delivery company while ensuring that the customer is at least as well off as he would have been under the existing pricing structure. The contract pricing smoothes the package delivery company's demand and reduces peak requirements for transport capacity. The latter helps to decrease capital costs, which may allow a further price reduction for the customer. We formulate the pricing problem as a biconvex optimization model, and present a methodology for designing the contract and numerical examples that illustrate the achievable savings.     

A MODEL FOR BATCH ADVANCED AVAILABLE‐TO‐PROMISE

The available‐to‐promise (atp) function is becoming increasingly important in supply chain management since it directly links production resources with customer orders. In this paper, a mixed integer programming (mip) ATP model is presented. This model can provide an order‐promising and ‐fulfillment solution for a batch of orders that arrive within a predefined batching interval. A variety of constraints, such as raw material availability, production capacity, material compatibility, and customer preferences, are considered. Simulation experiments using the model investigate the sensitivity of supply chain performance to changes in certain parameters, such as batching interval size and customer order flexibility.     

Impact of Customer Traffic and Service Process Outsourcing Levels on e‐Retailer Operational Performance

Many service firms deliver services via a mix of internally developed and delivered (i.e., insourced) and externally developed and delivered (i.e., outsourced) service processes. Service process outsourcing is especially common in e‐retailing. Portions of e‐retail customer ordering processes and delivery processes can be digitized and contracted to third‐party vendors. Via outsourcing, service systems change from dyadic to triadic. Prior research examines consumer perceptions of dyadic (consumer to e‐retailer) outcomes, but little research considers service co‐delivery with outsourcing partners (i.e., triadic systems). Literature also does not focus on joint associations of service process outsourcing and customer traffic with e‐retailer operations. We analyze several years of data on North American e‐retailers. We first examine factors associated with e‐retailer outsourcing levels, for front‐end and back‐end service processes. We observe customer traffic is positively associated with future outsourcing. We then examine how outsourcing moderates associations between contemporaneous customer traffic and e‐retailer operational performance, as measured by numbers of processed orders, website response times, and customer satisfaction. Results suggest outsourcing levels are associated with operational outcomes, yet surprisingly, high outsourcing and high traffic jointly may not benefit e‐retailers.     

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.     

The Impact of Forecast Errors on Early Order Commitment in a Supply Chain*

Supply chain partnership involves mutual commitments among participating firms. One example is early order commitment, wherein a retailer commits to purchase a fixed‐order quantity and delivery time from a supplier before the real need takes place. This paper explores the value of practicing early order commitment in the supply chain. We investigate the complex interactions between early order commitment and forecast errors by simulating a supply chain with one capacitated supplier and multiple retailers under demand uncertainty. We found that practicing early order commitment can generate significant savings in the supply chain, but the benefits are only valid within a range of order commitment periods. Different components of forecast errors have different cost implications to the supplier and the retailers. The presence of trend in the demand increases the total supply chain cost, but makes early order commitment more appealing. The more retailers sharing the same supplier, the more valuable for the supply chain to practice early order commitment. Except in cases where little capacity cushion is available, our findings are relatively consistent in the environments where cost structure, number of retailers, capacity utilization, and capacity policy are varied.