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Optimal integrated production and inventory control of an assemble-to-order system with multiple non-unitary demand classes

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  • ElHafsi, Mohsen

Abstract

We study a pure assemble-to-order system subject to multiple demand classes where customer orders arrive according to a compound Poisson process. The finished product is assembled from m different components that are produced on m distinct production facilities in a make-to-stock fashion. We show that the optimal production policy of each component is a state-dependent base-stock policy and the optimal inventory allocation policy is a multi-level state-dependent rationing policy. Using numerical experimentation, we first study the system behavior as a function of order size variability and order size. We show that the optimal average cost rate is more sensitive to order size variability than to order size. We also compare the optimal policy to the first-come first-serve policy and show that there is great benefit to inventory rationing. We also propose two simple heuristics and show that these can effectively mimic the optimal policy which is generally much more difficult to determine and, especially, to implement.

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Bibliographic Info

Article provided by Elsevier in its journal European Journal of Operational Research.

Volume (Year): 194 (2009)
Issue (Month): 1 (April)
Pages: 127-142

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Handle: RePEc:eee:ejores:v:194:y:2009:i:1:p:127-142

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Web page: http://www.elsevier.com/locate/eor

Related research

Keywords: Assemble-to-order Production and inventory control Compound demand Markov decision processes Make-to-stock queues;

References

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  1. Saif Benjaafar & Mohsen ElHafsi, 2006. "Production and Inventory Control of a Single Product Assemble-to-Order System with Multiple Customer Classes," Management Science, INFORMS, vol. 52(12), pages 1896-1912, December.
  2. Donald M. Topkis, 1968. "Optimal Ordering and Rationing Policies in a Nonstationary Dynamic Inventory Model with n Demand Classes," Management Science, INFORMS, vol. 15(3), pages 160-176, November.
  3. Feng Cheng & Markus Ettl & Grace Lin & David D. Yao, 2002. "Inventory-Service Optimization in Configure-to-Order Systems," Manufacturing & Service Operations Management, INFORMS, vol. 4(2), pages 114-132, December.
  4. Saif Benjaafar & Mohsen ElHafsi & Francis de VĂ©ricourt, 2004. "Demand Allocation in Multiple-Product, Multiple-Facility, Make-to-Stock Systems," Management Science, INFORMS, vol. 50(10), pages 1431-1448, October.
  5. de Kok, Ton G. & Visschers, Jeremy W. C. H., 1999. "Analysis of assembly systems with service level constraints," International Journal of Production Economics, Elsevier, vol. 59(1-3), pages 313-326, March.
  6. Morris A. Cohen & Paul R. Kleindorfer & Hau L. Lee, 1988. "Service Constrained (s, S) Inventory Systems with Priority Demand Classes and Lost Sales," Management Science, INFORMS, vol. 34(4), pages 482-499, April.
  7. Mohebbi, E. & Choobineh, F., 2005. "The impact of component commonality in an assemble-to-order environment under supply and demand uncertainty," Omega, Elsevier, vol. 33(6), pages 472-482, December.
  8. Savas Dayanik & Jing-Sheng Song & Susan H. Xu, 2003. "The Effectiveness of Several Performance Bounds for Capacitated Production, Partial-Order-Service, Assemble-to-Order Systems," Manufacturing & Service Operations Management, INFORMS, vol. 5(3), pages 230-251, December.
  9. Hausman, Warren H. & Lee, Hau L. & Zhang, Alex X., 1998. "Joint demand fulfillment probability in a multi-item inventory system with independent order-up-to policies," European Journal of Operational Research, Elsevier, vol. 109(3), pages 646-659, September.
  10. Francis de VĂ©ricourt & Fikri Karaesmen & Yves Dallery, 2002. "Optimal Stock Allocation for a Capacitated Supply System," Management Science, INFORMS, vol. 48(11), pages 1486-1501, November.
  11. Albert Y. Ha, 1997. "Inventory Rationing in a Make-to-Stock Production System with Several Demand Classes and Lost Sales," Management Science, INFORMS, vol. 43(8), pages 1093-1103, August.
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Cited by:
  1. Gao, Chunyan & Shen, Houcai & Cheng, T.C.E., 2010. "Order-fulfillment performance analysis of an assemble-to-order system with unreliable machines," International Journal of Production Economics, Elsevier, vol. 126(2), pages 341-349, August.
  2. Chen-Ritzo, Ching-Hua & Ervolina, Tom & Harrison, Terry P. & Gupta, Barun, 2011. "Component rationing for available-to-promise scheduling in configure-to-order systems," European Journal of Operational Research, Elsevier, vol. 211(1), pages 57-65, May.
  3. Kim, Eungab, 2012. "Centralized admission and production control in a two-stage supply chain with single component and customized products," International Journal of Production Economics, Elsevier, vol. 140(1), pages 530-540.

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