Comparison of supply chain planning concepts for general multi-item, multi-echelon systems

In this paper we present two alternative concepts to control general multi-item, multi-echelon systems under stochastic stationary demand for end items. Such systems consist of items that are assembled from other items and in turn are assembled into other items. Each assembly process involves a planned lead time. For such systems optimal control policies are unknown to-date. Therefore we resort to control concepts that at least enable an exact computation of the control parameters. The two alternative concepts represent two fundamentally different modeling concepts: an LP-based concept representing application of deterministic mathematical programming models in a rolling schedule context (the common practice in so-called Advanced Planning Systems), and modified base stock policies representing application of classical multi-echelon inventory models. The parameters of the LP-based concept can be detennined by discrete event simulation. The parameters of the modified base stock policies can be determined analytically. We compare the two concepts based on the required supply chain capital investment required to guarantee target end item service levels. Surprisingly, the modified base stock policies outperform the LP-based concept. We provide managerial insights as well as a deeper understanding into a number of fundamental issues related to supply chain planning and supply chain design

Multi-echelon Inventory Control with Integrated Shipment Decisions

Rising fuel prices and increasing environmental awareness emphasizes the importance of the transportation aspect in logistics. This calls for new improved inventory control methods that consider the effects of shipment strategies in a more realistic manner. This thesis, consisting of an introduction and three scientific papers, studies how shipment decisions can be included in the inventory control of distribution systems. The systems studied in the papers consist of a central warehouse that supplies goods to a number of retailers that face stochastic customer demand. The first two papers consider a system where shipments from the central warehouse are consolidated to groups of retailers periodically. This means that replenishment orders of one or several items from different retailers are consolidated and dispatched at certain time intervals. By doing so, transportation cost savings can be realized and emissions can be reduced. This is achieved by filling the vehicles or load carriers to a higher extent and by using cheaper and more environmentally friendly, transportation modes. The first paper explicitly focuses on how to include more realistic transportation costs and emissions. This is done by obtaining the distribution of the size of an arbitrary shipment leaving the central warehouse (directly affected by the shipment frequency). It is thereby easy to evaluate any system where the transportation costs and emissions are dependent on the size of the shipment. The paper also provides a detailed analysis of a system where there is an opportunity to reserve shipment capacity on an intermodal truck-train-truck solution to at least one of the retailer groups. For this system it is shown how to jointly optimize the shipment intervals, the reserved capacities on the intermodal transportation modes and the reorder points in the system. The presented optimization procedure is applicable in three scenarios; (i) the emissions are not considered, (ii) there is a fixed cost per unit of emission, and (iii) there is a constraint on the maximum emissions per time unit. The second paper extends the analysis of a similar time-based shipment consolidation system to handle compound Poisson demand (instead of pure Poisson demand). This system has a simpler transportation cost structure, but the more general demand structure makes the model applicable for a broader array of products. The paper also extends the model to handle fill rate constraints, which further improves the practical applicability. The cost analysis is performed with a new methodology, based on the nominal inventory position. This variable is a helpful tool for analyzing the dynamics of distribution systems. Another system where this tool can be used is studied in the third paper. In this paper all stock points use installation stock (R,Q) ordering policies (batch ordering). This implies that situations can occur when only part of a requested retailer order is available at the central warehouse. The existing literature predominantly assumes that the available units are shipped immediately and the remaining units are shipped as soon as they arrive to the central warehouse, referred to as partial delivery. An alternative is to wait until the entire order is available before dispatching, referred to as complete delivery. The paper introduces a cost for splitting the order and evaluates three delivery policies; the PD policy (only partial deliveries are used), the CD policy (only complete deliveries are used), and the state-dependent MSD policy (an optimization between a partial and a complete delivery is performed for each delivery). The MSD policy is proven to perform better than both the PD and the CD policy. In a numerical study it is shown that significant savings can be made by using the MSD policy

Exact Methods for Multi-echelon Inventory Control : Incorporating Shipment Decisions and Detailed Demand Information

Recent advances in information technologies and an increased environmental awareness have altered the prerequisites for successful logistics. For companies operating on a global market, inventory control of distribution systems is often an essential part of their logistics planning. In this context, the research objective of this thesis is: To develop exact methods for stochastic inventory control of multi-echelon distribution systems incorporating shipment decisions and/or detailed demand information.The thesis consists of five scientific papers (Paper I, II, III, IV and V) preceded by a summarizing introduction. All papers study systems with a central warehouse supplying a number of non-identical local warehouses (retailers) facing stochastic demand. For given replenishment policies, the papers provide exact expressions for evaluating the expected long-run system behavior (e.g., distributions of backorders, inventory levels, shipment sizes and expected costs) and present optimization procedures for the control variables. Paper I and II consider systems where shipments from the central warehouse are consolidated to groups of retailers and dispatched periodically. By doing so, economies of scale for the transports can be reached, reducing both transportation costs and emissions. Paper I assumes Poisson customer demand and considers volume-dependent transportation costs and emissions. The model involves the possibility to reserve intermodal (train) capacity in combination with truck transports available on demand. For this system, the expected inventory costs, the expected transportation costs and the expected transport emissions are determined. Joint optimization procedures for the shipment intervals, the capacity reservation quantities, the reorder points and order-up-to levels in the system are provided, with or without emission considerations. Paper II analyses the expected costs of the same system for compound Poisson demand (where customer demand sizes may vary), but with only one transportation mode and fixed transportation costs per shipment. It also shows how to handle fill rate constraints. Paper III studies a system where all stock points use installation stock (R,Q) ordering policies (batch ordering). This implies that situations can occur when only part of a requested retailer order is available at the central warehouse. In these situations, the models in existing literature predominantly assume that available units are shipped immediately (partial delivery). An alternative is to wait until the entire order is available before dispatching (complete delivery). The paper introduces a cost for splitting the order and evaluates a system where optimal choices between partial and complete deliveries are made for all orders. In a numerical study it is shown that significant savings can be made by using this policy compared to systems which exclusively use either partial or complete deliveries. Paper IV shows how companies can benefit from detailed information about their customer demand. In a continuous review base stock system, the customer demand is modeled with independent compound renewal processes at the retailers. This means that the customer inter-arrival times may follow any continuous distribution and the demand sizes may follow any discrete distribution. A numerical study shows that this model can achieve substantial savings compared to models using the common assumption of exponential customer inter-arrival times. Paper V is a short technical note that extends the scope of analysis for several existing stochastic multi-echelon inventory models. These models analyze the expected costs without first determining the inventory level distribution. By showing how these distributions can be obtained from the expected cost functions, this note facilitates the analysis of several service measures, including the ready rate and the fill rate

Inventory Analytics

"Inventory Analytics provides a comprehensive and accessible introduction to the theory and practice of inventory control – a significant research area central to supply chain planning. The book outlines the foundations of inventory systems and surveys prescriptive analytics models for deterministic inventory control. It further discusses predictive analytics techniques for demand forecasting in inventory control and also examines prescriptive analytics models for stochastic inventory control. Inventory Analytics is the first book of its kind to adopt a practicable, Python-driven approach to illustrating theories and concepts via computational examples, with each model covered in the book accompanied by its Python code. Originating as a collection of self-contained lectures, Inventory Analytics will be an indispensable resource for practitioners, researchers, teachers, and students alike.

Optimal expediting decisions in a continuous-stage serial supply chain

In this paper, we analyze expediting decisions in a continuous-time, continuous-stage serial supply chain facing a Poisson demand process. For each unit in the chain, one must decide at which speed it should be moved downstream, given the state of the system, so as to minimize total supply chain costs. We decompose the problem into a set of one-dimensional subproblems that can be easily solved and characterize the optimal expediting policy: under quite general assumptions, the optimal speed of a given unit accelerates upstream, and then slows down downstream. We finally provide a case study where we estimate the benefits of expediting compared to a fixed transportation speed and show them to be significant.lead-time management; optimal control; unit-tracking decomposition;

Evaluation of cost balancing policies in multi-echelon stochastic inventory control problems

Thesis (S.M.)--Massachusetts Institute of Technology, Computation for Design and Optimization Program, 2010.This electronic version was submitted by the student author. The certified thesis is available in the Institute Archives and Special Collections.Cataloged from student submitted PDF version of thesis.Includes bibliographical references (p. 67-68).We study a periodic-reviewed, infinite horizon serial network inventory control problem. The demands in different periods are independent of each other and follow an identical Poisson distribution. Unsatisfied demands are backlogged until they are satisfied by supply units. In each period, there is a per-unit holding cost is incurred for each unit of supply that stays in the system and a per-unit backorder cost is incurred for each unsatisfied unit of demand. The objective of the inventory control policy is to minimize the long-run expected average cost over an infinite horizon. The goal of the thesis is to evaluate the empirical performance of the dual balancing policy and several other variants of cost balancing policies through numerical simulations. The dual-balancing policy is based on two novel ideas: the marginal cost accounting scheme, which assigns to each decision all the costs that are made inevitable after that decision is made; and the cost balancing idea to balance opposing costs.(cont.) The dual-balancing policy can be modified in several ways to get other cost balancing policies. It has been proven that the dual-balancing policy has a worst-case guarantee of 2 but this does not indicate the empirical performance. An approximately optimal policy is considered as the benchmark to test the quality of the cost balancing policies. In the computational experiments, the dual-balancing policy shows an average error of 7.74% compared to the approximately optimal policy, much better than the theoretical worst-case guarantee. The three variants of cost balancing policies have made significant improvement on the performance of the dual-balancing policy. The accuracy of the dual-balancing policy is also affected by the system parameters. In addition, with high demand rate and long lead times, we have observed several scenarios when the cost balancing policies dominate the approximately optimal policy.by Qian Yu.S.M

Multiple sourcing in single- and multi-echelon inventory systems

This thesis deals with stochastic inventory models that focus on the following two aspects in particular: (i) the coordination of multiple supply sources and (ii) the optimization of the inventory allocation and sizing in multi-echelon systems. Initially, single-echelon inventory models with multiple sourcing and multi-echelon inventory models with single sourcing are analyzed separately. In the former case, the goal is the identification of effective inventory control policies. In the latter case, the focus lies on the development of a new multi-echelon approach, which combines the two major frameworks currently available in the literature. Subsequently, both aspects are integrated into a multi-echelon inventory model with multiple sourcing