Theory and Practice of Supply Chain Synchronization

In this dissertation, we develop strategies to synchronize component procurement in assemble-to-order (ATO) production and overhaul operations. We focus on the high-tech and mass customization industries which are not only considered to be very important to create or keep U.S. manufacturing jobs, but also suffer most from component inventory burden. In the second chapter, we address the deterministic joint replenishment inventory problem with batch size constraints (JRPB). We characterize system regeneration points, derive a closed-form expression of the average product inventory, and formulate the problem of finding the optimal joint reorder interval to minimize inventory and ordering costs per unit of time. Thereafter, we discuss exact solution approaches and the case of variable reorder intervals. Computational examples demonstrate the power of our methodology. In the third chapter, we incorporate stochastic demand to the JRPB. We propose a joint part replenishment policy that balances inventory and ordering costs while providing a desired service level. A case study and guided computational experiments show the magnitudes of savings that are possible using our methodology. In the fourth chapter, we show how lack of synchronization in assembly systems with long and highly variable component supply lead times can rapidly deteriorate system performance. We develop a full synchronization strategy through time buffering of component orders, which not only guarantees meeting planned production dates but also drastically reduces inventory holding costs. A case study has been carried out to prove the practical relevance, assess potential risks, and evaluate phased implementation policies. The fifth chapter explores the use of condition information from a large number of distributed working units in the field to improve the management of the inventory of spare parts required to maintain those units. Synchronization is again paramount here since spare part inventory needs to adapt to the condition of the engine fleet. All needed parts must be available to complete the overhaul of a unit. We develop a complex simulation environment to assess the performance of different inventory policies and the value of health monitoring. The sixth chapter concludes this dissertation and outlines future research plans as well as opportunities

Cooperation in stochastic inventory models with continuous review

Consider multiple companies that continuously review their inventories and face Poisson demand. We study cooperation strategies for these companies and analyse if there exist allocations of the joint cost such that any company has lower costs than on its own; such allocations are called stable cost allocations. We start with two companies that jointly place an order for replenishment if their joint inventory position reaches a certain reorder level. This strategy leads to a simple expression of the joint costs. However, these costs exceed the costs for non-cooperating companies. Therefore, we examine another cooperation strategy. Namely, the companies reorder as soon as one of them reaches its reorder level. This latter strategy has lower costs than for non-cooperating companies. Numerical experiments show that the gametheoretical distribution rule — a cost allocation in which the companies share the procurement cost and each pays its own holding cost — is a stable cost allocation. These results also hold for situations with multiple companies

Analysis and comparison of two strategies for multi-item inventory systems with joint replenishment costs

Inventory Control;business economics

Strongly Polynomial Primal-Dual Algorithms for Concave Cost Combinatorial Optimization Problems

We introduce an algorithm design technique for a class of combinatorial optimization problems with concave costs. This technique yields a strongly polynomial primal-dual algorithm for a concave cost problem whenever such an algorithm exists for the fixed-charge counterpart of the problem. For many practical concave cost problems, the fixed-charge counterpart is a well-studied combinatorial optimization problem. Our technique preserves constant factor approximation ratios, as well as ratios that depend only on certain problem parameters, and exact algorithms yield exact algorithms. Using our technique, we obtain a new 1.61-approximation algorithm for the concave cost facility location problem. For inventory problems, we obtain a new exact algorithm for the economic lot-sizing problem with general concave ordering costs, and a 4-approximation algorithm for the joint replenishment problem with general concave individual ordering costs

Computing (R, S) policies with correlated demand

This paper considers the single-item single-stocking non-stationary stochastic lot-sizing problem under correlated demand. By operating under a nonstationary (R, S) policy, in which R denote the reorder period and S the associated order-up-to-level, we introduce a mixed integer linear programming (MILP) model which can be easily implemented by using off-theshelf optimisation software. Our modelling strategy can tackle a wide range of time-seriesbased demand processes, such as autoregressive (AR), moving average(MA), autoregressive moving average(ARMA), and autoregressive with autoregressive conditional heteroskedasticity process(AR-ARCH). In an extensive computational study, we compare the performance of our model against the optimal policy obtained via stochastic dynamic programming. Our results demonstrate that the optimality gap of our approach averages 2.28% and that computational performance is good

Leader-follower Game in VMI System with Limited Production Capacity Considering Wholesale and Retail Prices

VMI (Vendor Managed Inventory) is a widely used cooperative inventory policy in supply chains in which each enterprise has its autonomy in pricing. This paper discusses a leader-follower Stackelberg game in a VMI supply chain where the manufacturer, as a leader, produces a single product with a limited production capacity and delivers it at a wholesale price to multiple different retailers, as the followers, who then sell the product in dispersed and independent markets at retail prices. An algorithm is then developed to determine the equilibrium of the Stackelberg game. Finally, a numerical study is conducted to understand the influence of the Stackelberg equilibrium and market related parameters on the profits of the manufacturer and its retailers. Through the numerical example, our research demonstrates that: (a) the market related parameters have significant influence on the manufacturer’ and its retailers’ profits; (b) a retailer’s profit may not be necessarily lowered when it is charged with a higher inventory cost by the manufacturer; (c) the equilibrium of the Stackelberg equilibrium benefits the manufacturer.Stackelberg Game;Supply Chain;Vendor Managed Inventory