Multi-Item Grouping Algorithm Yielding Near-Optimal Logistics Cost

This article describes an algorithm used to formulate an inbound consolidation strategy when multi-items are replenished in groups and when total logistics cost is to be minimized. The importance of this algorithm is threefold (1) no optimal procedure exists for grouping multi-items when minimizing total logistics cost, (2) a complete enumeration of all possible groups (from which the optimal grouping set can be identified) is impractical due to the combinatorial nature of the grouping problem, and (3) no other heuristics have been developed that adequately reflect shipping cost in the analysis like this one does. We report the experience of using this algorithm to group and reorder 75 selected ensembles containing a total of 517 inventory items of a retail merchandising firm.     

The Individually Responsible and Rational Decision Approach to Economic Lot Sizes for One Vendor and Many Purchasers

Banerjee's [2] joint economic lot size (JELS) model, along with related works by Monahan [12] and Lal and Staelin [10], represents one approach to minimizing the total inventory carrying and ordering costs of a vendor and his purchaser(s). Noting that JELS philosophy requires a coordinated system and that its practical implementation is problematic, we present an alternative approach to the same problem: the individually responsible and rational decision (IRRD) approach. The IRRD approach is consistent with a free enterprise system and easy to implement. In order to show that the IRRD approach is also more economical than the JELS approach, we first build a more refined JELS model for the case of one vendor and many identical purchasers. Drawing on earlier criticisms of specific JELS models, our refinement relaxes the lot-for-lot assumption commonly used by JELS scholars. To be comparable with earlier works, we retain the assumption of deterministic conditions and demonstrate the economic advantages of IRRD over JELS through a numerical example. An algebraic proof of IRRD's superiority over JELS is offered in the more general and realistic case of a vendor dealing with K nonidentical purchasers with reasonably predictable annual demand but uncertain order quantities and timings.     

SOME COMMENTS ON “A SYSTEMS PERSPECTIVE ON MATERIALS REQUIREMENTS PLANNING”*

We believe there are some serious deficiencies in the Morecroft article on MRP problems which appeared in a recent issue of this journal. The article, at the most, shows that MRP, inappropriately imposed on an existing production system, can result in undesirable system performance. This does not represent a new or startling conclusion. Four problem areas in the article are discussed, and suggested alternative approaches are offered.     

A ONE-PERIOD STOCHASTIC INVENTORY PROBLEM WITH A LUMP-SUM PENALTY COST

This paper presents an inventory problem related to the one-period stochastic inventory (or “newsboy”) problem. In this problem, the firm has to decide how much product to order to meet a random one-period demand. The version of the problem presented is novel in two respects. First, demand is explicitly permitted to be negative, and second, the penalty (or shortage) cost is assumed to be independent of the magnitude of the shortage. This situation is shown to change the form of the cost function and to complicate the determination of optimal policies. The form of the optimal policy is developed, and two example problems are presented in some detail.     

Efficient Heuristics for MRP Lot Sizing with Variable Production/Purchasing Costs*

Two heuristics based on branch and bound (B&B) are developed to solve closed-loop material requirements planning (MRP) lot-sizing problems that have general product structures and variable costs. A “look ahead method'’(LAM) heuristic allows for variable production/purchasing costs and uses a single-level B&B procedure to rapidly improve lower bound values; thus, LAM efficiently uses computer-storage capacity and allows solution of larger problems. The “total average modification'’(TAM) heuristic uses B&B, applied level by level, and modified setup and carrying costs to solve the variable production/purchasing costs MRP lot-sizing problem. LAM and TAM are tested on problems and compared to heuristics in the literature. TAM may be used to solve large MRP lot-sizing problems encountered in practice.     

Lowering Inventory Systems Costs by Using Regression-Derived Estimators of Demand Variability*

Scientific techniques for inventory management typically are applied to systems containing many items. Such techniques require an estimation of the demand variance (and mean) of each item from historical data. This research demonstrates a significant potential for improvement in system cost performance from using least-squares regression fits of a variance-to-mean functional relation instead of the standard statistical variance estimate. Even when there is a moderate degree of heterogeneity among items and when the form of the variance-to-mean relation is misspecified, substantial cost savings may be realized. The cost of statistical uncertainty may be reduced by half. The research also provides evidence that system cost is fairly insensitive to the number of items used to fit the regression. This paper provides the underlying reason why a regression-derived variance estimator yields lower cost: it is less variable than the usual individual item variance estimator.     

On the Joint Lot-Sizing Problem with Zero Setup Costs

In a recent paper, Pinto and Mabert [5] presented a lot-sizing rule and an improvement procedure for the joint lot-sizing problem with zero setup costs. We show that this procedure often yields infeasible schedules. We also present and discuss two interesting properties of the joint lot-sizing problem with zero setup costs. A numerical example to illustrate the second property is provided.     

Statistical measurement of the inventory shortage cost

In searching for the optimal inventory control policy, the objective is to minimize the expected total costs related, of which the shortage cost is an important element. Due to the difficulty in calculating the indirect cost of the loss of goodwill resulted from the shortage, practitioners and researchers often simply assume a fixed penalty cost on the inventory shortage or switch to the alternative method by assigning a specific customer service level. The development of an appropriate tool for measuring the shortage cost can help a business control the total costs and improve the productivity more effectively. This paper proposes probabilistic measurements of the shortage cost, based on mathematical relationship between the cost and the shortage amount. The derived closed-form estimates of the expected shortage cost value can then be applied to support the determination of the optimal inventory control policy.     

COST INCREASES DUE TO DEMAND UNCERTAINTY IN MRP LOT SIZING

This paper analyzes the cost increases due to demand uncertainty in single-level MRP lot sizing on a rolling horizon. It is shown that forecast errors have a tremendous effect on the cost effectiveness of lot-sizing techniques even when these forecast errors are small. Moreover, the cost differences between different techniques become rather insignificant in the presence of forecast errors. Since most industrial firms face demand uncertainty to some extent, our findings may have important managerial implications. Various simulation experiments give insight into both the nature and the magnitude of the cost increases for different heuristics. Analytical results are developed for the constant-demand case with random noise and forecasting by exponential smoothing. It is also shown how optimal buffers can be obtained by use of a simple model. Although the analysis in this paper is restricted to simplified cases, the results merit further consideration and study. This paper is one of the first to inject forecast errors into MRP lot-sizing research. As such it attempts to deal with one of the major objections against the practical relevance of previous research in this area.