Lot Sizing Heuristics Performance

Each productive system manager knows that finding the optimal trade‐off between reducing inventory and decreasing the frequency of production/ replenishment orders allows a great cut‐back in operations costs. Several authors have focused their contributions, trying to demonstrate that among the various dynamic lot sizing rules there are big differences in terms of performance, and that these differences are not negligible. In this work, eight of the best known lot sizing algorithms have been described with a unique modelling approach and have then been exhaustively tested on several different scenarios, benchmarking versus Wagner and Whitin’s optimal solution. As distinct from the contributions in the literature, the operational behaviour has been evaluated in order to determine which one is more suitable to the characteristics of each scenario

Comparison of different approaches to multistage lot sizing with uncertain demand

We study a new variant of the classical lot sizing problem with uncertain demand where neither the planning horizon nor demands are known exactly. This situation arises in practice when customer demands arriving over time are confirmed rather lately during the transportation process. In terms of planning, this setting necessitates a rolling horizon procedure where the overall multistage problem is dissolved into a series of coupled snapshot problems under uncertainty. Depending on the available data and risk disposition, different approaches from online optimization, stochastic programming, and robust optimization are viable to model and solve the snapshot problems. We evaluate the impact of the selected methodology on the overall solution quality using a methodology-agnostic framework for multistage decision-making under uncertainty. We provide computational results on lot sizing within a rolling horizon regarding different types of uncertainty, solution approaches, and the value of available information about upcoming demands

Dynamic lot sizing for a warm/cold process: Heuristics and insights

Cataloged from PDF version of article.We consider the dynamic lot sizing problem for a warm/cold process where the process can be kept warm at a unit variable cost for the next period if more than a prespecified quantity has been produced. Exploiting the optimal production plan structures, we develop nine rule-based forward solution heuristics. Proposed heuristics are modified counterparts of the heuristics developed previously for the classical dynamic lot sizing problem. In a numerical study, we investigate the performance of the proposed heuristics and identify operating environment characteristics where each particular heuristic is the best or among the best. Moreover, for a warm/cold process setting, our numerical studies indicate that, when used on a rolling horizon basis, a heuristic may also perform better costwise than a solution obtained using a dynamic programming approach. & 2012 Elsevier B.V. All rights reserved

Approximation Algorithms for the Stochastic Lot-Sizing Problem with Order Lead Times

We develop new algorithmic approaches to compute provably near-optimal policies for multiperiod stochastic lot-sizing inventory models with positive lead times, general demand distributions, and dynamic forecast updates. The policies that are developed have worst-case performance guarantees of 3 and typically perform very close to optimal in extensive computational experiments. The newly proposed algorithms employ a novel randomized decision rule. We believe that these new algorithmic and performance analysis techniques could be used in designing provably near-optimal randomized algorithms for other stochastic inventory control models and more generally in other multistage stochastic control problems.National Science Foundation (U.S.) (Grant DMS-0732175)National Science Foundation (U.S.) (CAREER Award CMMI-0846554)United States. Air Force Office of Scientific Research (Award FA9550-08-1-0369)United States. Air Force Office of Scientific Research (Award FA9550-11-1-0150)Singapore-MIT AllianceSolomon Buchsbaum AT&T Research Fun

From Cost Sharing Mechanisms to Online Selection Problems

We consider a general class of online optimization problems, called online selection problems, where customers arrive sequentially, and one has to decide upon arrival whether to accept or reject each customer. If a customer is rejected, then a rejection cost is incurred. The accepted customers are served with minimum possible cost, either online or after all customers have arrived. The goal is to minimize the total production costs for the accepted customers plus the rejection costs for the rejected customers. These selection problems are related to online variants of offline prize collecting combinatorial optimization problems that have been widely studied in the computer science literature. In this paper, we provide a general framework to develop online algorithms for this class of selection problems. In essence, the algorithmic framework leverages any cost sharing mechanism with certain properties into a poly-logarithmic competitive online algorithm for the respective problem; the competitive ratios are shown to be near-optimal. We believe that the general and transparent connection we establish between cost sharing mechanisms and online algorithms could lead to additional online algorithms for problems beyond the ones studied in this paper.National Science Foundation (U.S.) (CAREER Award CMMI-0846554)United States. Air Force Office of Scientific Research (FA9550-11-1-0150)United States. Air Force Office of Scientific Research (FA9550-08-1-0369)Solomon Buchsbaum AT&T Research Fun

A Digital Twin Framework for Production Planning Optimization: Applications for Make-To-Order Manufacturers

In this dissertation, we develop a Digital Twin framework for manufacturing systems and apply it to various production planning and scheduling problems faced by Make-To-Order (MTO) firms. While this framework can be used to digitally represent a particular manufacturing environment with high fidelity, our focus is in using it to generate realistic settings to test production planning and scheduling algorithms in practice. These algorithms have traditionally been tested by either translating a practical situation into the necessary modeling constructs, without discussion of the assumptions and inaccuracies underlying this translation, or by generating random instances of the modeling constructs, without assessing the limitations in accurately representing production environments. The consequence has been a serious gap between theory advancement and industry practice. The major goal of this dissertation is to develop a framework that allows for practical testing, evaluation, and implementation of new approaches for seamless industry adoption. We develop this framework as a modular software package and emphasize the practicality and configurability of the framework, such that minimal modelling effort is required to apply the framework to a multitude of optimization problems and manufacturing systems. Throughout this dissertation, we emphasize the importance of the underlying scheduling problems which provide the basis for additional operational decision making. We focus on the computational evaluation and comparisons of various modeling choices within the developed frameworks, with the objective of identifying models which are both effective and computationally efficient. In Part 1 of this dissertation, we consider a class of Production Planning and Execution problems faced by job shop manufacturing systems. In Part 2 of this dissertation, we consider a class of scheduling problems faced by manufacturers whose production system is dominated by a single operation

Supply Chain Management with Online Customer Selection

We consider new online variants of supply chain management models, where in addition to production decisions, one also has to actively decide on which customers to serve. Specifically, customers arrive sequentially during a selection phase, and one has to decide whether to accept or reject each customer upon arrival. If a customer is rejected, then a lost-sales cost is incurred. Once the selection decisions are all made, one has to satisfy all the accepted customers with minimum possible production cost. The goal is to minimize the total cost of lost sales and production. A key feature of the model is that customers arrive in an online manner, and the decision maker does not require any information about future arrivals. We provide two novel algorithms for online customer selection problems, which are based on repeatedly solving offline subproblems that ignore previously made decisions. For many important settings, our algorithms achieve small constant competitive ratio guarantees. That is, for any sequence of arriving customers, the cost incurred by the online algorithm is within a fixed constant factor of the cost incurred by the respective optimal solution that has full knowledge upfront on the sequence of arriving customers. Finally, we provide a computational study on the performance of these algorithms when applied to the economic lot sizing and joint replenishment problems with online customer selection.National Science Foundation (U.S.) (CMMI-0846554)United States. Air Force Office of Scientific Research (FA9550-11-1-0150)United States. Air Force Office of Scientific Research (FA9550-08-1-0369

Meta-Heuristics for Dynamic Lot Sizing: a review and comparison of solution approaches

Proofs from complexity theory as well as computational experiments indicate that most lot sizing problems are hard to solve. Because these problems are so difficult, various solution techniques have been proposed to solve them. In the past decade, meta-heuristics such as tabu search, genetic algorithms and simulated annealing, have become popular and efficient tools for solving hard combinational optimization problems. We review the various meta-heuristics that have been specifically developed to solve lot sizing problems, discussing their main components such as representation, evaluation neighborhood definition and genetic operators. Further, we briefly review other solution approaches, such as dynamic programming, cutting planes, Dantzig-Wolfe decomposition, Lagrange relaxation and dedicated heuristics. This allows us to compare these techniques. Understanding their respective advantages and disadvantages gives insight into how we can integrate elements from several solution approaches into more powerful hybrid algorithms. Finally, we discuss general guidelines for computational experiments and illustrate these with several examples

The dynamic lot-sizing problem with convex economic production costs and setups

In this work the uncapacitated dynamic lot-sizing problem is considered. Demands are deterministic and production costs consist of convex costs that arise from economic production functions plus set-up costs. We formulate the problem as a mixed integer, non-linear programming problem and obtain structural results which are used to construct a forward dynamic-programming algorithm that obtains the optimal solution in polynomial time. For positive setup costs, the generic approaches are found to be prohibitively time-consuming; therefore we focus on approximate solution methods. The forward DP algorithm is modified via the conjunctive use of three rules for solution generation. Additionally, we propose six heuristics. Two of these are single-stepSilver–Meal and EOQ heuristics for the classical lot-sizing problem. The third is a variant of the Wagner–Whitin algorithm. The remaining three heuristics are two-step hybrids that improve on the initial solutions of the first three by exploiting the structural properties of optimal production subplans. The proposed algorithms are evaluated by an extensive numerical study. The two-step Wagner–Whitin algorithm turns out to be the best heuristic

Lagrangian duality for robust problems with decomposable functions: the case of a robust inventory problem

We consider a class of min-max robust problems in which the functions that need to be “robustified” can be decomposed as the sum of arbitrary functions. This class of problems includes many practical problems, such as the lot-sizing problem under demand uncertainty. By considering a Lagrangian relaxation of the uncertainty set, we derive a tractable approximation, called the dual Lagrangian approach, that we relate with both the classical dualization approximation approach and an exact approach. Moreover, we show that the dual Lagrangian approach coincides with the affine decision rule approximation approach. The dual Lagrangian approach is applied to a lot-sizing problem, in which demands are assumed to be uncertain and to belong to the uncertainty set with a budget constraint for each time period. Using the insights provided by the interpretation of the Lagrangian multipliers as penalties in the proposed approach, two heuristic strategies, a new guided iterated local search heuristic, and a subgradient optimization method are designed to solve more complex lot-sizing problems in which additional practical aspects, such as setup costs, are considered. Computational results show the efficiency of the proposed heuristics that provide a good compromise between the quality of the robust solutions and the running time required in their computation.publishe