A comparison between the order and the volume fill rates for a base-stock inventory control system under a compound renewal demand process

The order fill rate is less commonly used than the volume fill rate (most often just denoted fill rate) as a performance measure for inventory control systems. However, in settings where the focus is on filling customer orders rather than total quantities, the order fill rate should be the preferred measure. In this paper we consider a continuous review, base-stock policy, where all replenishment orders have the same constant lead time and all unfilled demands are backordered. We develop exact mathematical expressions for the two fill-rate measures when demand follows a compound renewal process. We also elaborate on when the order fill rate can be interpreted as the (extended) ready rate. Furthermore, for the case when customer orders are generated by a negative binomial distribution, we show that it is the size of the shape parameter of this distribution that determines the relative magnitude of the two fill rates. In particular, we show that when customer orders are generated by a geometric distribution, the order fill rate and the volume fill rate are equal (though not equivalent when considering sample paths). For the case when customer inter-arrival times follow an Erlang distribution, we show how to compute the two fill rates.Backordering; continuous review; compound renewal process; inventory control; negative binomial distribution; service levels

Computation of order and volume fill rates for a base stock inventory control system with heterogeneous demand to investigate which customer class gets the best service

We consider a base stock inventory control system serving two customer classes whose demands are generated by two independent compound renewal processes. We show how to derive order and volume fill rates of each class. Based on assumptions about first order stochastic dominance we prove when one customer class will get the best service. That theoretical result is validated through a series of numerical experiments which also reveal that it is quite robust.Base stock policy; service measures; two customer classes; compound renewal processes

An inventory control project in a major Danish company using compound renewal demand models

We describe the development of a framework to compute the optimal inventory policy for a large spare-parts’ distribution centre operation in the RA division of the Danfoss Group in Denmark. The RA division distributes spare parts worldwide for cooling and A/C systems. The warehouse logistics operation is highly automated. However, the procedures for estimating demands and the policies for the inventory control system that were in use at the beginning of the project did not fully match the sophisticated technological standard of the physical system. During the initial phase of the project development we focused on the fitting of suitable demand distributions for spare parts and on the estimation of demand parameters. Demand distributions were chosen from a class of compound renewal distributions. In the next phase, we designed models and algorithmic procedures for determining suitable inventory control variables based on the fitted demand distributions and a service level requirement stated in terms of an order fill rate. Finally, we validated the results of our models against the procedures that had been in use in the company. It was concluded that the new procedures were considerably more consistent with the actual demand processes and with the stated objectives for the distribution centre. We also initiated the implementation and integration of the new procedures into the company’s inventory management systemBase-stock policy; compound distribution; fill rate; inventory control; logistics; stochastic processes

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

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

Satisfying multiproduct demand with a FPR-based inventory system featuring expedited rate and scraps

Facing stiff competition in worldwide markets, capability of meeting timely demands of multiproduct and satisfying customer’s desired product quality are essential to present-day manufacturers. Motivated by achieving the aforementioned goals, this research intends to find most economic common cycle length for a multiproduct finite production rate (FPR)-based inventory system, wherein, imperfect production process with expedited fabrication rate and random scrap is assumed. Extra setup and unit costs are associated with the adjusted rate, and imperfect products are screened and scrapped. A mathematical model is cautiously constructed to examine and resolve the problem. A numerical illustration is employed to exhibit the applicability of the proposed method. Except finding the most economic common cycle time for the problem, core contribution of this study also is associated with the individual and combined impact(s) of important factors to the problem, and hence, enabling management of manufacturing firms to make efficient/cost-effective decision and gain competitive advantages

Projected Inventory Level Policies for Lost Sales Inventory Systems: Asymptotic Optimality in Two Regimes

We consider the canonical periodic review lost sales inventory system with positive lead-times and stochastic i.i.d. demand under the average cost criterion. We introduce a new policy that places orders such that the expected inventory level at the time of arrival of an order is at a fixed level and call it the Projected Inventory Level (PIL) policy. We prove that this policy has a cost-rate superior to the equivalent system where excess demand is back-ordered instead of lost and is therefore asymptotically optimal as the cost of losing a sale approaches infinity under mild distributional assumptions. We further show that this policy dominates the constant order policy for any finite lead-time and is therefore asymptotically optimal as the lead-time approaches infinity for the case of exponentially distributed demand per period. Numerical results show this policy also performs superior relative to other policies

Inventory Control at AQ Electric Suzhou

This report details the process and result of developing a mathematical inventory control model to be use by AQ Electric Suzhou. The mathematical model was written in Microsoft Excels inherent programming language Visual Basic and utilizes printouts such as sales history, bill of materials, component data etc. from AQ Electric Suzhous ERP system Monitor to derive a demand history for each component. Each component is then given a compound Poisson lead time demand distribution with an optimization of reorder point in a (R,Q) continuous review inventory system with regards to service level and maximum inventory constraints. The results were that AQ Electric Suzhou would find it difficult to achieve the target on time delivery and target inventory turn rate simultaneously without changing input parameters such as minimum order quantities and lead times

Stock keeping unit fill rate specification

The fill rate is the most widely applied service level measure in industry and yet there is minimal advice available on how it should be differentiated on an individual Stock Keeping Unit (SKU) basis given that there is an overall system target service level. The typical approach utilized in practice, and suggested in academic textbooks, is to set the individual service levels equal to the targeted performance required across an entire stock base or a certain class of SKUs (e.g., in ABC classification). In this paper it is argued that this approach is far from optimal and a simple methodology is proposed that is shown (on real life datasets) to be associated with reductions in stock investments. In addition, the new approach is intuitive, very easy to implement and thus highly likely to be positively received by practitioners and software manufacturer