Lot sizing with piecewise concave production costs

Cataloged from PDF version of article.We study the lot-sizing problem with piecewise concave production costs and concave holding costs. This problem is a generalization of the lot-sizing problem with quantity discounts, minimum order quantities, capacities, overloading, subcontracting or a combination of these. We develop a dynamic programming algorithm to solve this problem and answer an open question in the literature: we show that the problem is polynomially solvable when the breakpoints of the production cost function are time invariant and the number of breakpoints is fixed. For the special cases with capacities and subcontracting, the time complexity of our algorithm is as good as the complexity of algorithms available in the literature. We report the results of a computational experiment where the dynamic programming is able to solve instances that are hard for a mixed-integer programming solver. We enhance the mixed-integer programming formulation with valid inequalities based on mixing sets and use a cut-and-branch algorithm to compute better bounds. We propose a state space reduction–based heuristic algorithm for large instances and show that the solutions are of good quality by comparing them with the bounds obtained from the cut-and-branch

Fully Polynomial Approximation Schemes for Single-Item Capacitated Economic Lot-Sizing Problems

NP-hard cases of the single-item capacitated lot-sizing problem have been the topic of extensive research and continue to receive considerable attention. However, surprisingly few theoretical results have been published on approximation methods for these problems. To the best of our knowledge, until now no polynomial approximation method is known which produces solutions with a relative deviation from optimality that is bounded by a constant. In this paper we show that such methods do exist, by presenting an even stronger result: the existence of fully polynomial approximation schemes. The approximation scheme is first developed for a quite general model, which has concave backlogging and production cost functions and arbitrary (monotone) holding cost functions. Subsequently we discuss important special cases of the model and extensions of the approximation scheme to even more general models

An Algorithm for Single-item Capacitated Economic Lot Sizing with Piecewise Linear Production Costs and General Holding Costs

We consider the Capacitated Economic Lot Size problem with piecewise linear production costs and general holding costs, which is an NP-hard problem but solvable in pseudo-polynomial time. A straightforward dynamic programming approach to this problem results in an [TeX: $O(n^2 \\bar{c} \\bar{d} )$] algorithm, where [TeX: $n$] is the number of periods, and [TeX: $\\bar d$ and $\\bar c$] are the average demand and the average production capacity over the $n$ periods, respectively. However, we present a dynamic programming procedure with complexity [TeX: $O(n^2 \\bar{q} \\bar{d} )$], where [TeX: $\\bar q$] is the average number of pieces of the production cost functions. In particular, this means that problems in which the production functions consist of a fixed set-up cost plus a linear variable cost are solved in [TeX: $O(n^2 \\bar{d})$] time. Hence, the running time of our algorithm is only linearly dependent on the magnitude of the data. This result also holds if extensions such as backlogging and start-up costs are considered. Moreover, computational experiments indicate that the algorithm is capable of solving quite large problem instances within a reasonable amount of time. For example, the average time needed to solve test instances with 96 periods, 8 pieces in every production function and average demand of 100 units, is approximately 40 seconds on a SUN SPARC 5 workstation

Valid inequalities for the single-item capacitated lot sizing problem with step-wise costs

This paper presents a new class of valid inequalities for the single-item capacitated lotsizing problem with step-wise production costs (LS-SW). We first provide a survey of different optimization methods proposed to solve LS-SW. Then, flow cover and flow cover inequalities derived from the single node flow set are described in order to generate the new class of valid inequalities. The single node flow set can be seen as a generalization of some valid relaxations of LS-SW. A new class of valid inequalities we call mixed flow cover, is derived from the integer flow cover inequalities by a lifting procedure. The lifting coefficients are sequence independent when the batch sizes (V) and the production capacities (P) are constant and if V divides P. When the restriction of the divisibility is removed, the lifting coefficients are shown to be sequence independent. We identify some cases where the mixed flow cover inequalities are facet defining. A cutting plane algorithmis proposed for these three classes of valid inequalities. The exact separation algorithmproposed for the constant capacitated case runs in polynomial time. Finally, some computational results are given to compare the performance of the different optimization methods including the new class of valid inequalities.single-item capacitated lot sizing problem, flow cover inequalities, cutting plane algorithm

Four equivalent lot-sizing models

We study the following lot-sizing models that recently appeared in the literature: a lot-sizing model with aremanufacturing option, a lot-sizing model with production time windows, and a lot-sizing model with cumulativecapacities. We show the equivalence of these models with a classical model: the lot-sizing model with inventory bounds.lot-sizing;equivalent models

The stochastic lot-sizing problem with quantity discounts

This paper addresses the stochastic lot-sizing problem with quantity discounts. In particular, we examine the uncapacitated finite-period economic lot-sizing problem in which the parameters in each period are random and discrete. When an order is placed, a fixed cost is incurred and an all-unit quantity discount is awarded based on the quantity ordered. The lead time is zero and the order is delivered immediately. First we study the case with overstocks by which the excess inventory incurs a holding cost. The objective in this case is to minimize the expected total cost including ordering and holding costs. The stochastic dynamics is modeled with a scenario tree. We characterize properties of the optimal policy and propose a polynomial time algorithm with complexity O ( n 3 ) for single discount level, where n is the number of nodes in the scenario tree. We extend the results to cases allowing stockout and multi-discount levels. Numerical experiments are conducted to evaluate the performance of the algorithm and to gain the man- agement insights

Multi-item capacitated lot-sizing problems with setup times and pricing decisions

We study a multi-item capacitated lot-sizing problem with setup times and pricing (CLSTP) over a finite and discrete planning horizon. In this class of problems, the demand for each independent item in each time period is affected by pricing decisions. The corresponding demands are then satisfied through production in a single capacitated facility or from inventory, and the goal is to set prices and determine a production plan that maximizes total profit. In contrast with many traditional lot-sizing problems with fixed demands, we cannot, without loss of generality, restrict ourselves to instances without initial inventories, which greatly complicates the analysis of the CLSTP. We develop two alternative Dantzig–Wolfe decomposition formulations of the problem, and propose to solve their relaxations using column generation and the overall problem using branch-and-price. The associated pricing problem is studied under both dynamic and static pricing strategies. Through a computational study, we analyze both the efficacy of our algorithms and the benefits of allowing item prices to vary over time. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/65027/1/20394_ftp.pd

Modeling Industrial Lot Sizing Problems: A Review

In this paper we give an overview of recent developments in the field of modeling single-level dynamic lot sizing problems. The focus of this paper is on the modeling various industrial extensions and not on the solution approaches. The timeliness of such a review stems from the growing industry need to solve more realistic and comprehensive production planning problems. First, several different basic lot sizing problems are defined. Many extensions of these problems have been proposed and the research basically expands in two opposite directions. The first line of research focuses on modeling the operational aspects in more detail. The discussion is organized around five aspects: the set ups, the characteristics of the production process, the inventory, demand side and rolling horizon. The second direction is towards more tactical and strategic models in which the lot sizing problem is a core substructure, such as integrated production-distribution planning or supplier selection. Recent advances in both directions are discussed. Finally, we give some concluding remarks and point out interesting areas for future research

Lot sizing with piecewise concave production costs

We study the lot-sizing problem with piecewise concave production costs and concave holding costs. This problem is a generalization of the lot-sizing problem with quantity discounts, minimum order quantities, capacities, overloading, subcontracting or a combination of these. We develop a dynamic programming algorithm to solve this problem and answer an open question in the literature: we show that the problem is polynomially solvable when the breakpoints of the production cost function are time invariant and the number of breakpoints is fixed. For the special cases with capacities and subcontracting, the time complexity of our algorithm is as good as the complexity of algorithms available in the literature. We report the results of a computational experiment where the dynamic programming is able to solve instances that are hard for a mixed-integer programming solver. We enhance the mixed-integer programming formulation with valid inequalities based on mixing sets and use a cut-and-branch algorithm to compute better bounds. We propose a state space reduction-based heuristic algorithm for large instances and show that the solutions are of good quality by comparing them with the bounds obtained from the cut-and-branch. © 2014 INFORMS