Real-time Allocation Decisions in Multi-echelon Inventory Control

Inventory control is a crucial activity for many companies. Given the recent advances in information technology, there have never been greater opportunities for coordinated inventory control across supply chain facilities. But how do we design efficient control methods and policies that take advantage of the detailed information that is now becoming available? This doctoral thesis investigates these issues within the field of inventory control theory. The objective of the research is: To develop mathematical models and policies for efficient control and increased understanding of stochastic multi-echelon inventory systems, with a focus on allocation decisions and the use of real-time information. This thesis is based on five scientific papers which are preceded by a summarizing introduction. The papers address different types of inventory distribution systems, all consisting of a central stocking facility that supplies an arbitrary number of local stocking facilities (referred to as retailers). The retailers face stochastic end customer demand. The systems are characterized by the presence of real-time inventory information, including continuously updated information on the current inventory levels at different facilities and on the locations of outstanding orders. In Paper I and Paper II we derive and evaluate different decision rules for stock allocation (known as allocation policies) for a central warehouse which applies a time based shipment consolidation strategy. The allocation policy determines how the central warehouse should distribute its stock among different retailers in case of shortages. New allocation policies that utilize real-time information are compared to the commonly used First Come - First Served policy which requires less information. In Paper III we shift focus to the delivery policy at a central warehouse which supplies multiple retailers that order in batches. When the central warehouse cannot satisfy an entire retailer order immediately, the delivery policy determines if the order should be shipped in several parts or in its entirety when all items are available. We investigate the value of using a new delivery policy that uses real-time information on when replenishments will arrive at the central warehouse. The information is used to determine the best course of action for each order placed by the retailers. We also study how to allocate safety stocks to all facilities in the system given this new policy. In Paper IV and Paper V we consider a system where retailers may receive emergency shipments from a support warehouse in combination with regular replenishments from a central warehouse/outside supplier. We investigate how safety stocks should be allocated between the retailers and the support warehouse. Furthermore, we evaluate the benefits of tracking orders in real time and using this information in the decision whether or not to request an emergency shipment

Near-optimal heuristics to set base stock levels in a two-echelon distribution network

We consider a continuous-review two-echelon distribution network with one central warehouse and multiple local stock points, each facing independent Poisson demand for one item. Demands are fulfilled from stock if possible and backordered otherwise. We assume base stock control with one-for-one replenishments and the goal is to minimize the inventory holding and backordering costs. Although this problem is widely studied, only enumerative procedures are known for the exact optimization. A number of heuristics exist, but they ??nd solutions that are far from optimal in some cases (over 20% error on realistic problem instances). We propose a heuristic that is computationally e??cient and ??nds solutions that are close to optimal: 0.1% error on average and less than 3.0% error at maximum on realistic problem instances in our computational experiment

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

Effective Multi-echelon Inventory Systems for Supplier Selection and Order Allocation

Successful supply chain management requires an effective sourcing strategy to counteract uncertainties in both the suppliers and demands. Therefore, determining a better sourcing policy is critical in most of industries. Supplier selection is an essential task within the sourcing strategy. A well-selected set of suppliers makes a strategic difference to an organization\u27s ability to reduce costs and improve the quality of its end products. To discover the cost structure of selecting a supplier, it is more interesting to further determine appropriate levels of inventory in each echelon for different suppliers. This dissertation focuses on the study of the integrated supplier selection, order allocation and inventory control problems in a multi-echelon supply chain. First, we investigate a non-order-splitting inventory system in supply chain management. In particular, a buyer firm that consists of one warehouse and N identical retailers procures a type of product from a group of potential suppliers, which may have different prices, ordering costs, lead times and have restriction on minimum and maximum total order size, to satisfy stochastic demand. A continuous review system that implements the order quantity, reorder point (Q, R) inventory policy is considered in the proposed model. The model is solved by decomposing the mixed integer nonlinear programming model into two sub-models. Numerical experiments are conducted to evaluate the model and some managerial insights are obtained with sensitivity analysis. In the next place, we extend the study to consider the multi-echelon system with the order-splitting policy. In particular, the warehouse acquisition takes place when the inventory level depletes to a reorder point R, and the order Q is simultaneously split among m selected suppliers. This consideration is important since it could pool lead time risks by splitting replenishment orders among multiple suppliers simultaneously. We develop an exact analysis for the order-splitting model in the multi-echelon system, and formulate the problem in a Mixed Integer Nonlinear Programming (MINLP) model. To demonstrate the solvability and the effectiveness of the model, we conduct several numerical analyses, and further conduct simulation models to verify the correctness of the proposed mathematical model

Two-echelon spare parts inventory system subject to a service constraint

Department of Logistics2004-2005 > Academic research: refereed > Publication in refereed journalAccepted ManuscriptPublishe