Performance Evaluation of Stochastic Multi-Echelon Inventory Systems: A Survey

Globalization, product proliferation, and fast product innovation have significantly increased the complexities of supply chains in many industries. One of the most important advancements of supply chain management in recent years is the development of models and methodologies for controlling inventory in general supply networks under uncertainty and their widefspread applications to industry. These developments are based on three generic methods: the queueing-inventory method, the lead-time demand method and the flow-unit method. In this paper, we compare and contrast these methods by discussing their strengths and weaknesses, their differences and connections, and showing how to apply them systematically to characterize and evaluate various supply networks with different supply processes, inventory policies, and demand processes. Our objective is to forge links among research strands on different methods and various network topologies so as to develop unified methodologies.Masdar Institute of Science and TechnologyNational Science Foundation (U.S.) (NSF Contract CMMI-0758069)National Science Foundation (U.S.) (Career Award CMMI-0747779)Bayer Business ServicesSAP A

Stein–Chen approximation and error bounds for order fill rates in assemble‐to‐order systems

Assemble‐to‐order (ATO) is an important operational strategy for manufacturing firms to achieve quick response to customer orders while keeping low finished good inventories. This strategy has been successfully used not only by manufacturers (e.g., Dell, IBM) but also by retailers (e.g., Amazon.com). The evaluation of order‐based performance is known to be an important but difficult task, and the existing literature has been mainly focused on stochastic comparison to obtain performance bounds. In this article, we develop an extremely simple Stein–Chen approximation as well as its error‐bound for order‐based fill rate for a multiproduct multicomponent ATO system with random leadtimes to replenish components. This approximation gives an expression for order‐based fill rate in terms of component‐based fill rates. The approximation has the property that the higher the component replenishment leadtime variability, the smaller the error bound. The result allows an operations manager to analyze the improvement in order‐based fill rates when the base‐stock level for any component changes. Numerical studies demonstrate that the approximation performs well, especially when the demand processes of different components are highly correlated; when the components have high base‐stock levels; or when the component replenishment leadtimes have high variability. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2012Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/94479/1/21514_ftp.pd

Optimal Structural Results for Assemble-to-Order Generalized M-Systmes

Cataloged from PDF version of article.We consider an assemble-to-order generalized M-system with multiple components and multiple products, batch ordering of components, random lead times, and lost sales. We model the system as an in nite-horizon Markov decision process and seek an optimal control policy, which speci es when a batch of components should be produced and whether an arriving demand for each product should be satis ed. To facilitate our analysis, we introduce new functional characterizations for convexity and submodularity with respect to certain non-unitary directions. These help us characterize optimal inventory replenishment and allocation policies under a mild condition on component batch sizes via a new type of policy: lattice-dependent base-stock and lattice-dependent rationing

Certainty Equivalent Planning for Multi-Product Batch Differentiation: Analysis and Bounds

We consider a multi-period planning problem faced by a firm that must coordinate the production and allocations of batches to end products for multiple markets. Motivated by a problem faced by a biopharmaceutical firm, we model this as a discrete-time inventory planning problem where in each period the firm must decide how many batches to produce and how to differentiate batches to meet demands for different end products. This is a challenging problem to solve optimally, so we derive a theoretical bound on the performance of a Certainty Equivalent (CE) control for this model, in which all random variables are replaced by their expected values and the corresponding deterministic optimization problem is solved. This is a variant of an approach that is widely used in practice. We show that while a CE control can perform very poorly in certain instances, a simple re-optimization of the CE control in each period can substantially improve both the theoretical and computational performance of the heuristic, and we bound the performance of this re-optimization. To address the limitations of CE control and provide guidance for heuristic design, we also derive performance bounds for two additional heuristic controls -- (1) Re-optimized Stochastic Programming (RSP), which utilizes full demand distribution but limits the adaptive nature of decision dynamics, and (2) Multi-Point Approximation (MPA), which uses limited demand information to model uncertainty but fully capture the adaptive nature of decision dynamics. We show that although RSP in general outperforms the re-optimized CE control, the improvement is limited. On the other hand, with a carefully chosen demand approximation in each period, MPA can significantly outperform RSP. This suggests that, in our setting, explicitly capturing decision dynamics adds more value than simply capturing full demand information.http://deepblue.lib.umich.edu/bitstream/2027.42/116386/1/1296_Ahn.pd

Spare parts inventory control for an aircraft component repair shop

We study spare parts inventory control for a repair shop for aircraft components. Defect components that are removed from the aircraft are sent to such a shop for repair. Only after inspection of the component, it becomes clear which specific spare parts are needed to repair it, and in what quantity they are needed. Market requirements on shop performance are reflected in fill rate requirements on the turn around times of the repairs for each component type. The inventory for spare parts is controlled by independent min-max policies. Because parts may be used in the repair of different component types, the resulting optimization problem has a combinatorial nature. Practical instances may consist of 500 component types and 4000 parts, and thus pose a significant computational challenge. We propose a solution algorithm based on column generation. We study the pricing problem, and develop a method that is very efficient in (repeatedly) solving this pricing problem. With this method, it becomes feasible to solve practical instances of the problem in minutes

An enhanced approximation mathematical model inventorying items in a multi-echelon system under a continuous review policy with probabilistic demand and lead-time

An inventory system attempts to balance between overstock and understock to reduce the total cost and achieve customer demand in a timely manner. The inventory system is like a hidden entity in a supply chain, where a large complete network synchronizes a series of interrelated processes for a manufacturer, in order to transform raw materials into final products and distribute them to customers. The optimality of inventory and allocation policies in a supply chain for a cement industry is still unknown for many types of multi-echelon inventory systems. In multi-echelon networks, complexity exists when the inventory issues appear in multiple tiers and whose performances are significantly affected by the demand and lead-time. Hence, the objective of this research is to develop an enhanced approximation mathematical model in a multi-echelon inventory system under a continuous review policy subject to probabilistic demand and lead-time. The probability distribution function of demand during lead-time is established by developing a new Simulation Model of Demand During Lead-Time (SMDDL) using simulation procedures. The model is able to forecast future demand and demand during lead-time. The obtained demand during lead-time is used to develop a Serial Multi-echelon Inventory (SMEI) model by deriving the inventory cost function to compute performance measures of the cement inventory system. Based on the performance measures, a modified distribution multi-echelon inventory (DMEI) model with the First Come First Serve (FCFS) rule (DMEI-FCFS) is derived to determine the best expected waiting time and expected number of retailers in the system based on a mean arrival rate and a mean service rate. This research established five new distribution functions for the demand during lead-time. The distribution functions improve the performance measures, which contribute in reducing the expected waiting time in the system. Overall, the approximation model provides accurate time span to overcome shortage of cement inventory, which in turn fulfil customer satisfaction

Periodic review base-stock replenishment policy with endogenous lead times.

In this paper, we consider a two stage supply chain where the retailer's inventory is controlled by the periodic review, base-stock level (R,S) replenishment policy and the replenishment lead times are endogenously generated by the manufacturer's production system with finite capacity. We extend the work of Benjaafar and Kim (2004) who study the effect of demand variability in a continuously reviewed base-stock policy with single unit demands. In our analysis, we allow for demand in batches of variable size, which is a common setting in supply chains. A procedure is developed using matrix analytic methods to provide an exact calculation of the lead time distribution, which enables the computation of the distribution of lead time demand and consequently the safety stock in an exact way instead of using approximations. Treating the lead time as an endogenous stochastic variable has a substantial impact on safety stock. We numerically show that the exogenous lead time assumption may dramatically degrade customer service.Production/inventory systems; Base-stock replenishment policy; endogenous lead times; Safety stock; Phase-type distribution; Matrix-analytical methods;