Optimal Production and Admission Policies in Make‐to‐Stock/Make‐to‐Order Manufacturing Systems

In this article, we study optimal production and admission control policies in manufacturing systems that produce two types of products: one type consists of identical items that are produced to stock, while the other has varying features and is produced to order. The model is motivated by applications from various industries, in particular, the automobile industry, where a part supplier receives orders from both an original equipment manufacturer and the aftermarket. The product for the original equipment manufacturer is produced to stock, it has higher priority, and its demands are fully accepted. The aftermarket product is produced to order, and its demands can be either accepted or rejected. We characterize the optimal production and admission policies with a partial‐linear structure, and using computational analysis, we provide insights into the benefits of the new policies. We also investigate the impact of production capacity, cost structure, and demand structure on system performance.     

TIME‐BASED PRICING AND LEADTIME POLICIES FOR A BUILD‐TO‐ORDER MANUFACTURER

We studied time‐based policies on pricing and leadtime for a build‐to‐order and direct sales manufacturer. It is assumed that the utility of the product varies among potential customers and decreases over time, and that a potential customer will place an order if his or her utility is higher than the manufacturer's posted price. Once an order is placed, it will be delivered to the customer after a length of time called “leadtime.” Because of the decrease in a customer's utility during leadtime, a customer will cancel the order if the utility falls below the ordering price before the order is received. The manufacturer may choose to offer discounted prices to customers who would otherwise cancel their orders. We discuss two price policies: common discounted price and customized discounted price. In the common discounted price policy, the manufacturer offers a single lower price to the customers; in the customized discounted price policy, the manufacturer offers the customers separately for individual new prices. Our analytical and numerical studies show that the discounted price policies results in higher revenue and that the customized discounted price policy significantly outperforms the common discounted price policy when product utility decreases rapidly. We also study two leadtime policies when production cost decreases over time. The first uses a fixed leadtime, and the second allows the leadtime to vary dynamically over time. We find that the dynamic leadtime policy significantly outperforms the fixed leadtime policy when the product cost decreases rapidly.     

End‐of‐Life Inventory Problem with Phaseout Returns

We consider the service parts end‐of‐life inventory problem of a capital goods manufacturer in the final phase of its life cycle. The final phase starts as soon as the production of parts terminates and continues until the last service contract expires. Final order quantities are considered a popular tactic to sustain service fulfillment obligations and to mitigate the effect of obsolescence. In addition to the final order quantity, other sources to obtain serviceable parts are repairing returned defective items and retrieving parts from phaseout returns. Phaseout returns happen when a customer replaces an old system platform with a next‐generation one and returns the old product to the original equipment manufacturer (OEM). These returns can well serve the demand for service parts of other customers still using the old generation of the product. In this study, we study the decision‐making complications as well as cost‐saving opportunities stemming from phaseout occurrence. We use a finite‐horizon Markov decision process to characterize the structure of the optimal inventory control policy. We show that the optimal policy consists of a time‐varying threshold level for item repair. Furthermore, we study the value of phaseout information by extending the results to cases with an uncertain phaseout quantity or an uncertain schedule. Numerical analysis sheds light on the advantages of the optimal policy compared to some heuristic policies.     

The Impact of Revenue‐Maximizing Priority Pricing on Customer Delay Costs

Speed is an increasingly important determinant of which suppliers will be given customers' business and is defined as the time between when an order is placed by the customer and when the product is delivered, or as the amount of time customers must wait before they receive their desired service. In either case, the speed a customer experiences can be enhanced by giving priority to that particular customer. Such a prioritization scheme will necessarily reduce the speed experienced by lower‐priority customers, but this can lead to a better outcome when different customers place different values on speed. We model a single resource (e.g., a manufacturer) that processes jobs from customers who have heterogeneous waiting costs. We analyze the price that maximizes priority revenue for the resource owner (i.e., supplier, manufacturer) under different assumptions regarding customer behavior. We discover that a revenue‐maximizing supplier facing self‐interested customers (i.e., those that independently minimize their own expected costs) charges a price that also minimizes the expected total delay costs across all customers and that this outcome does not result when customers coordinate to submit priority orders at a level that seeks to minimize their aggregate costs of priority fees and delays. Thus, the customers are better off collectively (as is the supplier) when the supplier and customers act independently in their own best interests. Finally, as the number of priority classes increases, both the priority revenues and the overall customer delay costs improve, but at a decreasing rate.     

An Analysis of Dual‐Kanban Just‐In‐Time Systems in a Non‐Repetitive Environment

Recent advances in approaches and production technologies for the production of goods and services have made just‐in‐time (JIT) a strong alternative for use in intermittent and small batch production systems, especially when time‐based competition is the norm and a low inventory is a must. However, the conventional JIT system is designed for mass production with a stable master production schedule. This paper suggests supplementing the information provided by production kanbans with information about customer waiting lines to be used by operators to schedule production in each work‐station of intermittent and small batch production systems. This paper uses simulation to analyze the effect of four scheduling policy variables—number of kanbans, length of the withdrawal cycle, information about customer waiting lines, and priority rules on two performance measures—customer wait‐time and inventory. The results show that using information about customer waiting lines reduces customer wait‐time by about 30% while also reducing inventory by about 2%. In addition, the effect of information about customer waiting lines overshadows the effect of priority rules on customer wait‐time and inventory.     

Electricity Time‐of‐Use Tariff with Stochastic Demand

In this article, we study the electricity time‐of‐use (TOU) tariff for an electricity company with stochastic demand. The electricity company offers the flat rate (FR) and TOU tariffs to customers. Under the FR tariff, the customer pays a flat price for electricity consumption in both the peak and non‐peak periods. Under the TOU tariff, the customer pays a high price for electricity consumption in the peak period and a low price for electricity consumption in the non‐peak period. The electricity company uses two technologies, namely the base‐load and peak‐load technologies, to generate electricity. We derive the optimal capacity investment and pricing decisions for the electricity company. Furthermore, we use real data from a case study to validate the results and derive insights for implementing the TOU tariff. We show that in almost all the cases, the electricity company needs less capacity for both technologies under the TOU tariff than under the FR tariff, even though the expected demand in the non‐peak period increases. In addition, except for some extreme cases, there is essentially no signicant reduction in the total demand of the two periods, although the TOU tariff can reduce the demand in the peak period. Under the price‐cap regulation, the customer may pay a lower price on average under the TOU tariff than under the FR tariff. We conduct an extensive numerical study to assess the impacts of the model parameters on the optimal solutions and the robustness of the analytical results, and generate managerial implications of the research findings.     

Revenue Management with End‐of‐Period Discounts in the Presence of Customer Learning

Consider a firm that sells identical products over a series of selling periods (e.g., weekly all‐inclusive vacations at the same resort). To stimulate demand and enhance revenue, in some periods, the firm may choose to offer a part of its available inventory at a discount. As customers learn to expect such discounts, a fraction may wait rather than purchase at a regular price. A problem the firm faces is how to incorporate this waiting and learning into its revenue management decisions. To address this problem we summarize two types of learning behaviors and propose a general model that allows for both stochastic consumer demand and stochastic waiting. For the case with two customer classes, we develop a novel solution approach to the resulting dynamic program. We then examine two simplified models, where either the demand or the waiting behavior are deterministic, and present the solution in a closed form. We extend the model to incorporate three customer classes and discuss the effects of overselling the capacity and bumping customers. Through numerical simulations we study the value of offering end‐of‐period deals optimally and analyze how this value changes under different consumer behavior and demand scenarios.     

Using Frontier Portfolios to Improve Make‐to‐Order Operations

Make‐to‐order (MTO) manufacturers face a common problem of maintaining a desired service level for delivery at a reasonable cost while dealing with irregular customer orders. This research considers a MTO manufacturer who produces a product consisting of several custom parts to be ordered from multiple suppliers. We develop procedures to allocate orders to each supplier for each custom part and calculate the associated replenishment cost as well as the probability of meeting the delivery date, based on the suppliers' jobs on hand, availability, process speed, and defective rate. For a given delivery due date, a frontier of service level and a replenishment cost frontier are created to provide a range of options to meet customer requirements. This method can be further extended to the case when the delivery due date is not fixed and the manufacturer must “crash” its delivery time to compete for customers.     

Take‐Back Legislation: Consequences for Remanufacturing and Environment

In the last two decades, many countries have enacted product take‐back legislation that holds manufacturers responsible for the collection and environmentally sound treatment of end‐of‐use products. In an industry regulated by such legislation, we consider a manufacturer that also sells remanufactured products under its brand name. Using a stylized model, we consider three levels of legislation: no take‐back legislation, legislation with collection targets, and legislation with collection and reuse targets. We characterize the optimal solution for the manufacturer and analyze how various levels of legislation affect manufacturing, remanufacturing, and collection decisions. First, we explore whether legislation with only collection targets causes an increase in remanufacturing levels, which is argued to be an environmentally friendlier option for end‐of‐use treatment than other options such as recycling. While increased remanufacturing alone is usually perceived as a favorable environmental outcome, if one considers the overall environmental impact of new and remanufactured products, this might not be the case. To study this issue, we model the environmental impact of the product following a life cycle analysis–based approach. We characterize the conditions under which increased remanufacturing due to take‐back legislation causes an increase in total environmental impact. Finally, we model the impact of legislation on consumer surplus and manufacturer profits and identify when total welfare goes down because of legislation.     

COMPONENT COMMONALITY: MODELS WITH PRODUCT‐SPECIFIC SERVICE CONSTRAINTS*

Common components are used extensively for reasons including product postponement and expediting new product development. We consider a two‐stage assemble‐to‐order system with two products having uniformly distributed demand, one common component, and product‐specific components. We develop optimization models in which the cost‐minimizing inventory of the components must be determined and allocated to products in order to meet product‐specific service level constraints. We compare two different commonality models based on whether or not the products are prioritized. A distinctive feature of our study is the use of product‐specific service levels. We compare our results with models using aggregate service levels.     

On Optimal Expediting Policy for Supply Systems with Uncertain Lead‐Times

We examine the role of expediting in dealing with lead‐time uncertainties associated with global supply chains of “functional products” (high volume, low demand uncertainty goods). In our developed stylized model, a retailer sources from a supplier with uncertain lead‐time to meet his stable and known demand, and the supply lead‐time is composed of two random duration stages. At the completion time of the first stage, the retailer has the option to expedite a portion of the replenishment order via an alternative faster supply mode. We characterize the optimal expediting policy in terms of if and how much of the order to expedite and explore comparative statics on the optimal policy to better understand the effects of changes in the cost parameters and lead‐time properties. We also study how the expediting option affects the retailer's decisions on the replenishment order (time and size of order placement). We observe that with the expediting option the retailer places larger orders closer to the start of the selling season, thus having this option serve as a substitute for the safety lead‐time and allowing him to take increased advantages of economies of scale. Finally we extend the basic model by looking at correlated lead‐time stages and more than two random lead‐time stages.     

Managing the Reverse Channel with RFID‐Enabled Negative Demand Information

We analyze the inventory decisions of a manufacturer who has ample production capacity and also uses returned products to satisfy customer demand. All returned items go through an evaluation process, at the end of which the decision of disposal, direct reselling, or rework is made for each unit according to a predetermined procedure. We quantify the value of information/visibility on the reverse channel for the manufacturer by making comparisons among three approaches: No information‐naive; no visibility‐enlightened; and full visibility. We find the value of visibility increases with the comparative length of the reverse channel and volume, volatility, and usability of returns. Furthermore, the smarter the manufacturer, the less benefit visibility brings to the system. By this analysis, we quantify the visibility savings of radio frequency identification (RFID) in the reverse channel as a candidate enabler technology. We also provide numerical examples to show that practical approximations in inventory management may have acceptable penalties to the manufacturer with visibility.     

Retailer's Response to Alternate Manufacturer's Incentives Under a Single‐Period,Price‐Dependent,Stochastic‐Demand Framework*

This article considers the joint development of the optimal pricing and ordering policies of a profit‐maximizing retailer, faced with (i) a manufacturer trade incentive in the form of a price discount for itself or a rebate directly to the end customer; (ii) a stochastic consumer demand dependent upon the magnitude of the selling price and of the trade incentive, that is contrasted with a riskless demand, which is the expected value of the stochastic demand; and (iii) a single‐period newsvendor‐type framework. Additional analysis includes the development of equal profit policies in either form of trade incentive, an assessment of the conditions under which a one‐dollar discount is more profitable than a one‐dollar rebate, and an evaluation of the impact upon the retailer‐expected profits of changes in either incentive or in the degree of demand uncertainty. A numerical example highlights the main features of the model. The analytical and numerical results clearly show that, as compared to the results for the riskless demand, dealing with uncertainty through a stochastic demand leads to (i) (lower) higher retail prices if additive (multiplicative) error, (ii) lower (higher) pass throughs if additive (multiplicative) error, (iii) higher claw backs in both error structures wherever applicable, and (iv) higher rebates to achieve equivalent profits in both error structures.     

Optimal Dynamic Order Scheduling under Capacity Constraints Given Demand‐Forecast Evolution

We consider a manufacturer without any frozen periods in production schedules so that it can dynamically update the schedules as the demand forecast evolves over time until the realization of actual demand. The manufacturer has a fixed production capacity in each production period, which impacts the time to start production as well as the production schedules. We develop a dynamic optimization model to analyze the optimal production schedules under capacity constraint and demand‐forecast updating. To model the evolution of demand forecasts, we use both additive and multiplicative versions of the martingale model of forecast evolution. We first derive expressions for the optimal base stock levels for a single‐product model. We find that manufacturers located near their market bases can realize most of their potential profits (i.e., profit made when the capacity is unlimited) by building a very limited amount of capacity. For moderate demand uncertainty, we also show that it is almost impossible for manufacturers to compensate for the increase in supply–demand mismatches resulting from long delivery lead times by increasing capacity, making lead‐time reduction a better alternative than capacity expansion. We then extend the model to a multi‐product case and derive expressions for the optimal production quantities for each product given a shared capacity constraint. Using a two‐product model, we show that the manufacturer should utilize its capacity more in earlier periods when the demand for both products is more positively correlated.     

A Production–Inventory Model for a Push–Pull Manufacturing System with Capacity and Service Level Constraints

We study a hybrid push–pull production system with a two‐stage manufacturing process, which builds and stocks tested components for just‐in‐time configuration of the final product when a specific customer order is received. The first production stage (fabrication) is a push process where parts are replenished, tested, and assembled into components according to product‐level build plans. The component inventory is kept in stock ready for the final assembly of the end products. The second production stage (fulfillment) is a pull‐based assemble‐to‐order process where the final assembly process is initiated when a customer order is received and no finished goods inventory is kept for end products. One important planning issue is to find the right trade‐off between capacity utilization and inventory cost reduction that strives to meet the quarter‐end peak demand. We present a nonlinear optimization model to minimize the total inventory cost subject to the service level constraints and the production capacity constraints. This results in a convex program with linear constraints. An efficient algorithm using decomposition is developed for solving the nonlinear optimization problem. Numerical results are presented to show the performance improvements achieved by the optimized solutions along with managerial insights provided.     

Static and Dynamic Pricing of Excess Capacity in a Make‐to‐Order Environment

We consider a make‐to‐order manufacturer that serves two customer classes: core customers who pay a fixed negotiated price, and “fill‐in” customers who make submittal decisions based on the current price set by the firm. Using a Markovian queueing model, we determine how much the firm can gain by explicitly accounting for the status of its production facility in making pricing decisions. Specifically, we examine three pricing policies: (1) static, state‐independent pricing, (2) constant pricing up to a cutoff state, and (3) general state‐dependent pricing. We determine properties of each policy, and illustrate numerically the financial gains that the firm can achieve by following each policy as compared with simpler policies. Our main result is that constant pricing up to a cutoff state can dramatically outperform a state‐independent policy, while at the same time achieving most of the increase in revenue achievable from general state‐dependent pricing. Thus, we find that constant pricing up to a cutoff state presents an attractive tradeoff between ease of implementation and revenue gain. When the costs of policy design and implementation are taken into account, this simple heuristic may actually out‐perform general state‐dependent pricing in some settings.     

A Queueing Theoretic Approach to Set Staffing Levels in Time‐Dependent Dual‐Class Service Systems*

This article addresses the optimal staffing problem for a nonpreemptive priority queue with two customer classes and a time‐dependent arrival rate. The problem is related to several important service settings such as call centers and emergency departments where the customers are grouped into two classes of “high priority” and “low priority,” and the services are typically evaluated according to the proportion of customers who are responded to within targeted response times. To date, only approximation methods have been explored to generate staffing requirements for time‐dependent dual‐class services, but we propose a tractable numerical approach to evaluate system behavior and generate safe minimum staffing levels using mixed discrete‐continuous time Markov chains (MDCTMCs). Our approach is delicate in that it accounts for the behavior of the system under a number of different rules that may be imposed on staff if they are busy when due to leave and involves explicitly calculating delay distributions for two customer classes. Ultimately, we embed our methodology in a proposed extension of the Euler method, coined Euler Pri, that can cope with two customer classes, and use it to recommend staffing levels for the Welsh Ambulance Service Trust (WAST).     

An Evaluation of the NERJIT Priority Rule in a Kanban‐Controlled Flowshop

Significant progress in production and information technologies and innovations in management of operations during the last couple of decades have made the production of small lots and deployment of Just‐In‐Time (JIT) concepts in flowshops possible. As a result, some researchers and practitioners have been seeking to improve the performance of non‐repetitive systems using JIT concepts. In this process, the JIT concepts that were originally designed for mass production have been modified to adapt JIT to non‐repetitive systems. This article uses a priority rule that is based on real‐time demand and production information for sequencing jobs in a kanban‐controlled flowshop. The analysis of the effect of this priority rule; the number of kanbans; the length of the withdrawal cycle; First‐Come, First‐Served (FCFS); and Shortest Processing Time (SPT) on four performance measures—customer wait time, total inventory, input stock‐point inventory, and output stock‐point inventory, shows that the use of this priority rule results in a significant reduction of customer wait time and a slight decrease in inventory.     

OPTIMAL ORDERING IN A DUAL‐SUPPLIER SYSTEM WITH DEMAND FORECAST UPDATES

We study how an updated demand forecast affects a manufacturer's choice in ordering raw materials. With demand forecast updates, we develop a model where raw materials are ordered from two suppliers—one fast but expensive and the other cheap but slow—and further provide an explicit solution to the resulting dynamic optimization problem. Under some mild conditions, we demonstrate that the cost function is convex and twice‐differentiable with respect to order quantity. With this model, we are able to evaluate the benefit of demand information updating which leads to the identification of directions for further improvement. We further demonstrate that the model applies to multiple‐period problems provided that some demand regularity conditions are satisfied. Data collected from a manufacturer support the structure and conclusion of the model. Although the model is described in the context of in‐bound logistics, it can be applied to production and out‐bound logistics decisions as well.     

Pareto‐Improving Contracts for Express Package Delivery Services

We address the problem of an express package delivery company in structuring a long‐term customer contract whose terms may include prices that differ by day‐of‐week and by speed‐of‐service. The company traditionally offered speed‐of‐service pricing to its customers, but without day‐of‐week differentiation, resulting in customer demands with considerable day‐of‐week seasonality. The package delivery company hoped that using day‐of‐week and speed‐of‐service price differentiation for contract customers would induce these customers to adjust their demands to become counter‐cyclical to the non‐contract demand. Although this usually cannot be achieved by pricing alone, we devise an approach that utilizes day‐of‐week and speed‐of‐service pricing as an element of a Pareto‐improving contract. The contract provides the lowest‐cost arrangement for the package delivery company while ensuring that the customer is at least as well off as he would have been under the existing pricing structure. The contract pricing smoothes the package delivery company's demand and reduces peak requirements for transport capacity. The latter helps to decrease capital costs, which may allow a further price reduction for the customer. We formulate the pricing problem as a biconvex optimization model, and present a methodology for designing the contract and numerical examples that illustrate the achievable savings.