On multi-stage production/inventory systems under stochastic demand

This paper was presented at the 1992 Conference of the International Society of Inventory Research in Budapest, as a tribute to professor Andrew C. Clark for his inspiring work on multi-echelon inventory models both in theory and practice. It reviews and extends the work of the authors on periodic review serial and convergent multi-echelon systems under stochastic stationary demand. In particular, we highlight the structure of echelon cost functions which play a central role in the derivation of the decomposition results and the optimality of base stock policies. The resulting optimal base stock policy is then compared with an MRP system in terms of cost effectiveness, given a predefined target customer service level. Another extension concerns an at first glance rather different problem; it is shown that the problem of setting safety leadtimes in a multi-stage production-to-order system with stochastic lead times leads to similar decomposition structures as those derived for multi-stage inventory systems. Finally, a discussion on possible extensions to capacitated models, models with uncertainty in both demand and production lead time as well as models with an aborescent structure concludes the paper

Effective medical surplus recovery

We analyze not-for-profit Medical Surplus Recovery Organizations (MSROs) that manage the recovery of surplus (unused or donated) medical products to fulfill the needs of underserved healthcare facilities in the developing world. Our work is inspired by an award-winning North American non-governmental organization (NGO) that matches the uncertain supply of medical surplus with the receiving parties’ needs. In particular, this NGO adopts a recipient-driven resource allocation model, which grants recipients access to an inventory database, and each recipient selects products of limited availability to fill a container based on its preferences. We first develop a game theoretic model to investigate the effectiveness of this approach. This analysis suggests that the recipient-driven model may induce competition among recipients and lead to a loss in value provision through premature orders. Further, contrary to the common wisdom from traditional supply chains, full inventory visibility in our setting may accelerate premature orders and lead to loss of effectiveness. Accordingly, we identify operational mechanisms to help MSROs deal with this problem. These are: (i) appropriately selecting container capacities while limiting the inventory availability visible to recipients and increasing the acquisition volumes of supplies, (ii) eliminating recipient competition through exclusive single-recipient access to MSRO inventory, and (iii) focusing on learning recipient needs as opposed to providing them with supply information, and switching to a provider-driven resource allocation model. We use real data from the NGO by which the study was inspired and show that the proposed improvements can substantially increase the value provided to recipients

A Neuroevolutionary Approach to Stochastic Inventory Control in Multi-Echelon Systems

Stochastic inventory control in multi-echelon systems poses hard problems in optimisation under uncertainty. Stochastic programming can solve small instances optimally, and approximately solve larger instances via scenario reduction techniques, but it cannot handle arbitrary nonlinear constraints or other non-standard features. Simulation optimisation is an alternative approach that has recently been applied to such problems, using policies that require only a few decision variables to be determined. However, to find optimal or near-optimal solutions we must consider exponentially large scenario trees with a corresponding number of decision variables. We propose instead a neuroevolutionary approach: using an artificial neural network to compactly represent the scenario tree, and training the network by a simulation-based evolutionary algorithm. We show experimentally that this method can quickly find high-quality plans using networks of a very simple form

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

Warehousing and Inventory Management in Dual Channel and Global Supply Chains

More firms are adopting the dual-channel supply chain business model where firms offer their products to customers using dual-channel sales (to offer the item to customers online and offline). The development periods of innovative products have been shortened, especially for high-tech companies, which leads to products with short life cycles. This means that companies need to put their new products on the market as soon as possible. The dual-channel supply chain is a perfect tool to increase the customer’s awareness of new products and to keep customers’ loyalty; firms can offer new products online to the customer faster compared to the traditional retail sales channel. The emergence of dual-channel firms was mainly driven by the expansion in internet use and the advances in information and manufacturing technologies. No existing research has examined inventory strategies, warehouse structure, operations, and capacity in a dual-channel context. Additionally, firms are in need to integrate their global suppliers base; where the lower parts costs compensate for the much higher procurement and cross-border costs; in their supply chain operations. The most common method used to integrate the global supplier base is the use of cross-dock, also known as Third Party Logistic (3PL). This study is motivated by real-world problem, no existing research has considered the optimization of cross-dock operations in terms of dock assignment, storage locations, inventory strategies, and lead time uncertainty in the context of a cross-docking system. In this dissertation, we first study the dual-channel warehouse in the dual-channel supply chain. One of the challenges in running the dual-channel warehouse is how to organize the warehouse and manage inventory to fulfill both online and offline (retailer) orders, where the orders from different channels have different features. A model for a dual-channel warehouse in a dual-channel supply chain is proposed, and a solution approach is developed in the case of deterministic and stochastic lead times. Ending up with numerical examples to highlight the model’s validity and its usefulness as a decision support tool. Second, we extend the first problem to include the global supplier and the cross-border time. The impact of global suppliers and the effect of the cross-border time on the dual-channel warehouse are studied. A cross-border dual-channel warehouse model in a dual-channel supply chain context is proposed. In addition to demand and lead time uncertainty, the cross-border time is included as stochastic parameter. Numerical results and managerial insights are also presented for this problem. Third, motivated by a real-world cross-dock problem, we perform a study at one of the big 3 automotive companies in the USA. The company faces the challenges of optimizing their operations and managing the items in the 3PL when introducing new products. Thus, we investigate a dock assignment problem that considers the dock capacity and storage space and a cross-dock layout. We propose an integrated model to combine the cross-dock assignment problem with cross-dock layout problem so that cross-dock operations can be coordinated effectively. In addition to lead time uncertainty, the cross-border time is included as stochastic parameter. Real case study and numerical results and managerial insights are also presented for this problem highlighting the cross-border effect. Solution methodologies, managerial insights, numerical analysis as well as conclusions and potential future study topics are also provided in this dissertation

Dual-Channel Warehouse and Inventory Management with Stochastic Demand

This study examines the inventory policy for the emerging dual-channel warehouse, which has a unique structure where the warehouse is divided into two areas: one for fulfilling online orders and the other for storing products and fulfilling offline orders. A multi-item inventory model was developed considering the warehouse capacity constraint, demand, and lead time uncertainty. Solution methods are provided for both uniform and normal distributions. Adopting the proposed inventory policy for a dual warehouse is cost effective and adds flexibility to the warehouse and supply chain. The study also offers managerial insights on some critical issues faced by companies operating in a dual-channel context

Demand Prediction and Inventory Management of Surgical Supplies

Effective supply chain management is critical to operations in various industries, including healthcare. Demand prediction and inventory management are essential parts of healthcare supply chain management for ensuring optimal patient outcomes, controlling costs, and minimizing waste. The advances in data analytics and technology have enabled many sophisticated approaches to demand forecasting and inventory control. This study aims to leverage these advancements to accurately predict demand and manage the inventory of surgical supplies to reduce costs and provide better services to patients. In order to achieve this objective, a Long Short-Term Memory (LSTM) model is developed to predict the demand for commonly used surgical supplies. Moreover, the volume of scheduled surgeries influences the demand for certain surgical supplies. Hence, another LSTM model is adopted from the literature to forecast surgical case volumes and predict the procedure-specific surgical supplies. A few new features are incorporated into the adopted model to account for the variations in the surgical case volumes caused by COVID-19 in 2020. This study then develops a multi-item capacitated dynamic lot-sizing replenishment model using Mixed Integer Programming (MIP). However, forecasting is always considered inaccurate, and demand is hardly deterministic in the real world. Therefore, a Two-Stage Stochastic Programming (TSSP) model is developed to address these issues. Experimental results demonstrate that the TSSP model provides an additional benefit of $2,328.304 over the MIP model

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

Demand Prediction and Inventory Management of Surgical Supplies

Effective supply chain management is critical to operations in various industries, including healthcare. Demand prediction and inventory management are essential parts of healthcare supply chain management for ensuring optimal patient outcomes, controlling costs, and minimizing waste. The advances in data analytics and technology have enabled many sophisticated approaches to demand forecasting and inventory control. This study aims to leverage these advancements to accurately predict demand and manage the inventory of surgical supplies to reduce costs and provide better services to patients. In order to achieve this objective, a Long Short-Term Memory (LSTM) model is developed to predict the demand for commonly used surgical supplies. Moreover, the volume of scheduled surgeries influences the demand for certain surgical supplies. Hence, another LSTM model is adopted from the literature to forecast surgical case volumes and predict the procedure-specific surgical supplies. A few new features are incorporated into the adopted model to account for the variations in the surgical case volumes caused by COVID-19 in 2020. This study then develops a multi-item capacitated dynamic lot-sizing replenishment model using Mixed Integer Programming (MIP). However, forecasting is always considered inaccurate, and demand is hardly deterministic in the real world. Therefore, a Two-Stage Stochastic Programming (TSSP) model is developed to address these issues. Experimental results demonstrate that the TSSP model provides an additional benefit of $2,328.304 over the MIP model