A new heuristic to solve the one-warehouse N-retailer problem

We deal with a multi-echelon inventory system in which one warehouse supplies an item to multiple retailers. Customer demand arrives at each retailer at a constant rate. The retailers replenish their inventories from the warehouse that in turn orders from an outside supplier. It is assumed that shortages are not allowed and lead times are negligible. The goal is to determine replenishment policies that minimize the overall cost in the system. We develop a heuristic to compute efficient policies, which also can easily be used in a spreadsheet application. The main idea consists of finding a balance between the replenishment and the inventory holding costs at each installation. This new heuristic we compare with two other approaches proposed in the literature; the computational studies show that in most of the instances generated the new method provides lower costs.     

A decision rule for coordination of inventory and transportation in a two-stage supply chain with alternative supply sources

This paper deals with a two-stage supply chain that consists of two distribution centers and two retailers. Each member of the supply chain uses a (Q,R) inventory policy, and incurs standard inventory holding and backlog costs, as well as ordering and transportation costs. The distribution centers replenish their inventory from an outside supplier, and the retailers replenish inventory from one of the two distribution centers. When a retailer is ready to replenish its inventory that retailer must decide whether it should replenish from the first or second distribution center. We develop a decision rule that minimizes the total expected cost associated with all outstanding orders at the time of order placement; the retailers then repeatedly use this decision rule as a heuristic. A simulation study which compares the proposed policy to three traditional ordering policies illustrates how the proposed policy performs under different conditions. The numerical analysis shows that, over a large set of scenarios, the proposed policy outperforms the other three policies on average.     

Coordination of split deliveries in one-warehouse multi-retailer distribution systems

In this paper, we consider a distribution system where a warehouse is responsible for replenishing the inventories at multiple retailers by a fleet of vehicles of limited capacity. If a distribution policy of the system involves split deliveries, that is, the inventory of at least one retailer is replenished by using multiple vehicle routes, the coordination of the deliveries can further reduce the inventory cost of the retailer. We consider the coordination where two split deliveries are realized by direct shipping and multiple-stop shipping, respectively. To the best of our knowledge, this kind of coordination was never studied in the literature but can find its application in inventory routing problems. This paper proposes and analyses a class of coordination policies for the split deliveries which can reduce the inventory costs of the retailers without increasing transportation costs. A non-linear programming model is established for formulating the class of polices. Because the optimal coordination policy corresponding to an optimal solution of the model may be hard to find and/or implement, two simple but effective coordination policies are proposed. The inventory cost savings realized by the two policies are evaluated analytically and algorithmically. Our theoretical analysis and computational experiments show that both policies are effective. Under certain conditions, they can save 50% of the inventory costs at the retailers without increasing transportation costs.     

An integrated approach for logistic and vendor managed inventory in supply chain

In this paper, a quaternary policy system towards integrated logistics and inventory aspect of the supply chain has been proposed. A system of multi retailers and distributors, with each distributor following a unique policy, will be analysed. The first policy is continuous time replenishment policy where the retailers’ inventory is replenished in every time interval. In the next three policies, inventory of the retailers will be replenished by some definite policy factors. The vendor managed inventory (VMI) system is used for updating the inventory of the retailers. An order-up-to policy (q, Q) is used for updating the inventory of distributors. Total erstwhile demands to the retailer will be used to determine the amount of inventory acclivity. Furthermore, the distributors will be sending the delivery vehicles to few fellow retailers who are shortlisted according to the policy, followed by the retailers and associated distributors. On the basis of random demand that the retailers are facing from end customers and the total demand that has incurred in the supply chain, products are unloaded to the selected retailers from the delivery vehicle. The path of the delivery vehicle is retrieved by dynamic ant colony optimization. In addition, a framework has been developed to measure the end-customer satisfaction level and total supply chain cost incorporating the inventory holding cost, ordering cost and the transportation cost. The framework has been numerically moulded with different settings to compare the performance of the quadruplet policies.     

A multi-phase heuristic for the production routing problem

This study considers the production routing problem where a plant produces and distributes a single item to multiple retailers over a multi-period time horizon. The problem is to decide on when and how much to produce and stock at the plant, when and how much to serve and stock at each retailer, and vehicle routes for shipments such that the sum of fixed production setup cost, variable production cost, distribution cost, and inventory carrying cost at the plant and retailers is minimized. A multi-phase heuristic is proposed for the problem. The proposed heuristic is a mathematical programming-based heuristic that relies on formulating and solving restricted versions of the problem as mixed integer programs. The computational experiments on benchmark instances show favorable results with regard to the quality of the solutions found at the expense of higher computing times on large instances. In particular, the heuristic managed to find new best solutions for the 65% of benchmark instances.     

A tabu search procedure for coordinating production,inventory and distribution routing problems

This paper addresses the problem of optimally coordinating a production‐distribution system over a multi‐period finite horizon, where a facility production produces several items that are distributed to a set of customers by a fleet of homogeneous vehicles. The demand for each item at each customer is known over the horizon. The production planning determines how much to produce of each item in every period, while the distribution planning defines when customers should be visited, the amount of each item that should be delivered to customers and the vehicle routes. The objective is to minimize the sum of production and inventory costs at the facility, inventory costs at the customers and distribution costs. We also consider a related problem of inventory routing, where a supplier receives or produces known quantities of items in each period and has to solve the distribution problem. We propose a tabu search procedure for solving such problems, and this approach is compared with vendor managed policies proposed in the literature, in which the facility knows the inventory levels of the customers and determines the replenishment policies.     

A supplier selection and order allocation problem with stochastic demands

We consider a system comprising a retailer and a set of candidate suppliers that operates within a finite planning horizon of multiple periods. The retailer replenishes its inventory from the suppliers and satisfies stochastic customer demands. At the beginning of each period, the retailer makes decisions on the replenishment quantity, supplier selection and order allocation among the selected suppliers. An optimisation problem is formulated to minimise the total expected system cost, which includes an outer level stochastic dynamic program for the optimal replenishment quantity and an inner level integer program for supplier selection and order allocation with a given replenishment quantity. For the inner level subproblem, we develop a polynomial algorithm to obtain optimal decisions. For the outer level subproblem, we propose an efficient heuristic for the system with integer-valued inventory, based on the structural properties of the system with real-valued inventory. We investigate the efficiency of the proposed solution approach, as well as the impact of parameters on the optimal replenishment decision with numerical experiments.     

Design of Stochastic Distribution Networks Using Lagrangian Relaxation

This paper addresses the design of single commodity stochastic distribution networks. The distribution network under consideration consists of a single supplier serving a set of retailers through a set of distribution centers (DCs). The number and location of DCs are decision variables and they are chosen from the set of retailer locations. To manage inventory at DCs, the economic order quantity (EOQ) policy is used by each DC, and a safety stock level is kept to ensure a given retailer service level. Each retailer faces a random demand of a single commodity and the supply lead time from the supplier to each DC is random. The goal is to minimize the total location, shipment, and inventory costs, while ensuring a given retailer service level. The introduction of inventory costs and safety stock costs leads to a nonlinear NP-hard optimization problem. A Lagrangian relaxation approach is proposed. Computational results are presented and analyzed showing the effectiveness of the proposed approach.     

基于购买行为的随机生命周期易逝品库存策略

研究需求和商品生命周期均为随机的零售商库存管理问题,提出按照购买行为特征对需求进行分类,在不同类型的客户之间进行库存分配并允许缺货的库存策略.通过构建动态规划模型,求解出零售商最优库存策略,包括补货策略和库存分配策略.与先到先服务策略相比,该策略能显著提升零售商的利润,减少商品损坏的损失.     

An integrated replenishment model with quantity discounts, reentry and downward substitution for control wafers

This paper considers control wafers replenishment problem in wafer fabrication factories. A dynamic lot-sizing replenishment problem with reentry and downward substitution is examined in a pulling control production environment. The objective is to set the inventory level so as to minimize the total cost of control wafers, where the costs include order cost, purchase cost, setup cost, production cost and holding cost, while maintaining the same level of production throughput. In addition, purchase quantity discounts and precise inventory level are considered in the replenishment model. The control wafers replenishment problem is first constructed as a network, and is then transformed into a mixed integer programming model. Lastly, an efficient heuristic algorithm is proposed for solving large-scale problems. A numerical example is given to illustrate the practicality for empirical investigation. The results demonstrate that the proposed mixed integer programming model and the heuristic algorithm are effective tools for determining the inventory level of control wafers for multi-grades in multi-periods.     

随机需求随机补货间隔零售商补货控制策略研究

研究分销系统中零售商的补货控制策略．分销系统中各零售商可独立决定自己的补到水平．零售商需求率是随机变量．服从某一泊松分布;分销中心循环为各零售商送货．送货间隔是随机变量．认为所有未满足的需求销售机会都丢失,零售商既要支付库存持有费用．又要支付缺货损失费用．给出了收益数学期望值函数,求出了送货间隔是均匀分布随机变量时使收益数学期望值最大化的零售商补到水平控制策略．     

The production size and inventory policy for a manufacturer in a two-echelon inventory model

This paper proposes a two-echelon inventory model for a periodical commodity, in which the market and manufacturing channels are combined. This model can be used to solve the production policy, the order policies of the raw materials for the manufacturer, and order size for the retailer. By assuming that the retailers’ demand obeys normal distribution and that the retailer makes orders according to the Newsboy Rule, we derive the necessary and sufficient conditions for the optimal solution of production size, wholesale price, and replenishment cycle of raw materials for the manufacturer. Also, the necessary condition is explored in order to gain managerial insights and economic implications based on numerical examples and sensitivity analysis.     

Combining DC-programming and steepest-descent to solve the single-vehicle inventory routing problem

The single-vehicle cyclic inventory routing problem (SV-CIRP) is concerned with a repeated distribution of a product from a single depot to a selected subset of retailers having stable demands. If a retailer is selected for replenishment, the supplier collects a retailer-related fixed reward. The objective is to determine the subset of retailers to cyclically replenish, the quantities to be delivered to each, and to design the vehicle delivery routes so that the expected total distribution and inventory cost is minimized while the total collected rewards from the selected retailers is maximized. The resulting distribution plan must prevent stockouts from occurring at each retailer. In this paper, the underlying optimization problem for the SV-CIRP is formulated as a mixed-integer program with linear constraints and a nonlinear objective function. An optimization approach combining DC-programming and Branch-and-Bound within a steepest descent hybrid algorithm, denoted by DCA-SDHA, is developed for its solution. The approach is tested on some randomly generated problems and the obtained results are compared with results from the standard steepest descent hybrid algorithm (SDHA). These encouraging results show that the proposed approach is indeed computationally more effective and is worth being further investigated for the solution of medium to large instances.     

Integrated Inventory Control and Facility Location Decisions in a Multi-Echelon Supply Chain Network with Hubs

This paper develops mathematical models to coordinate facility location and inventory control for a four-echelon supply chain network consisting of multiple suppliers, warehouses, hubs and retailers. The hubs help in reducing transportation costs by consolidating products from multiple warehouses and directing the larger shipments to the retailer. The integrated models studied in this paper simultaneously determines three types of decisions: (i) facility location—the number and location of warehouses and hubs, (ii) allocation—assignment of suppliers to located warehouses and retailers to located warehouses via the location hubs, and (iii) inventory control decisions at each located warehouse. The goal is to minimize the facility location, transportation and the inventory costs. A mixed integer nonlinear programming formulation is first presented. The nonlinear integer programming formulation is then transformed into a conic mixed integer program and a novel and compact conic mixed integer programming formulation. Computational runs are conducted using commercial solvers to compare the performance of the different formulations. The compact conic mixed integer programming formulation was found to significantly outperform the other formulations by achieving significant computational savings. The results demonstrate that large scale instances of certain multi-echelon supply chain network design problems can be solved using commercial solvers through intelligent reformulation of the model.     

An integrated production and inventory model for a system comprising an assembly supply chain and a distribution network

This study investigates the production and inventory problem for a system comprising an assembly supply chain and a distribution network. A uniform lot size is produced uninterruptedly with a single setup at each production stage. Equal-sized batch shipment policy is applied to the whole system and the number of batches can be varied. All retailers have agreed on a joint replenishment policy with a common replenishment cycle. The objective is to determine the optimal common replenishment cycle, the number of batches of each production stage and retailer, all of which minimises the integrated total cost. Moreover, a new concept is introduced; namely, critical replenishment cycle. The replenishment cycle division (RCD) and recursive tightening (RT) methods are then developed to obtain the optimal solutions to the subject problem. Two theorems are verified to ensure the solutions obtained by the RCD and RT methods reaching the global optimum. An example is presented to illustrate the procedures involved in the RCD and RT methods.     

A local search method for periodic inventory routing problem

Inventory routing problem considers inventory allocation and routing problems simultaneously, in which the replenishment policies and routing arrangement are determined by the supplier under the vendor managed inventory mode. What we consider here is a periodic inventory routing problem that once the delivery time, quantity and routing are determined, they will remain the same in the following periods. The problem is modeled concisely, and then it is decomposed into two subproblems, inventory problem and vehicle routing problem. The inventory problem is solved by proposing a local search method, which is achieved by four operators on delivery quantity and retailer’s demand. Insertion operator aims to insert a new replenishment point of a retailer while removal operator is to remove a replenishment point. Besides, addition operator is adopted as an assistant tool, and crossover operator is proposed for some special cases. We also propose a tabu search method to solve the routing problem. Finally, the computational results show that the method is efficient and stable.     

Controlling lead times and minor ordering costs in the joint replenishment problem with stochastic demands under the class of cyclic policies

In this paper, we consider the periodic review joint replenishment problem under the class of cyclic policies. For each item, the demand in the protection interval is assumed stochastic. Moreover, a fraction of shortage is lost, while the other quota is backordered. We suppose that lead times and minor ordering costs are controllable. The problem concerns determining the cyclic replenishment policy, the lead times, and the minor ordering costs in order to minimize the long‐run expected total cost per time unit. We established several properties of the cost function, which permit us to derive a heuristic algorithm. A lower bound on the minimum cost is obtained, which helps us to evaluate the effectiveness of the proposed heuristic. The heuristic is also compared with a hybrid genetic algorithm that is specifically developed for benchmarking purposes. Numerical experiments have been carried out to investigate the performance of the heuristic.     

Optimal control of service for facilities holding inventory

This paper addresses the problem of optimally controlling service rates for an inventory system of service facilities. We consider a finite capacity system with Poisson arrivals and exponentially distributed leadtimes and service times. For given values of maximum inventory and reorder levels, we determine the service rates to be employed at each instant of time so that the long-run expected cost rate is minimized. The problem is modelled as a semi-Markov decision problem. We establish the existence of a stationary optimal policy and we solve it by employing linear programming. Several instances of a numerical example, which provide insight into the behaviour of the system, are presented.Scope and purposeIn this article we discuss the problem of inventory control of service parts at a service facility where there is only a limited waiting space for customers. If a customer enters the service facility and sees all the waiting spaces occupied he/she will leave the facility, which results in both intangible losses (loss of goodwill) and tangible losses (loss in profit). Hence, the service provider aims at obtaining an optimal rate at which service is to be provided by balancing costs due to waiting time and limited waiting spaces against costs due to ordering and overheads due to storing items. We develop an algorithm that controls the service rate as a function of the number of customers waiting for service.     

允许缺货待补的季节性商品二阶联合库存最优订购策略

针对季节性商品提出了二阶单周期缺货待补联合库存模型,其中假设零售商的库存策略采用报童模型且零售商的需求量服从正态分布。对制造商总利润函数的最优解,提出了充分与必要条件,以期可以简便迅速地获得制造商的最优生产批量以及最优订购周期。最后,通过数值算例及在管理上的含义对必要条件进行了充分的讨论。     

Joint shipment consolidation and inventory decisions in a two-stage distribution system

This study is motivated by a problem that an industrial distributorship faced while distributing automotive spare parts to service and repair centers. Considering the problem encountered, we present an analytical model for joint inventory and shipment consolidation decisions in a two-stage distribution system with a single distribution center, multiple non-identical retailers, and an outside supplier. The retailers face stochastic end-customer demand and use continuous review to replenish inventories. On the other hand, the distribution center uses a periodic review policy and employs a time-based shipment consolidation policy to dispatch retailers’ accumulated orders at the end of each consolidation cycle. We present an exact optimization technique to compute the optimal replenishment quantity at the distribution center, order-up-to level at retailers, and a shipment consolidation cycle length to measure the effects of inventory at retailers on the overall performance. Finally, we perform numerical experiments to measure the impact of various parameters on the overall distribution system.