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Computationally Efficient Optimal Solutions to the Lot-Sizing Problem in Multistage Assembly Systems

Author

Listed:
  • Panayotis Afentakis

    (Syracuse University)

  • Bezalel Gavish

    (University of Rochester)

  • Uday Karmarkar

    (University of Rochester)

Abstract

The scheduling of lot sizes in multistage production environments is a fundamental problem in many Material Requirements Planning Systems. Many heuristics have been suggested for this problem with varying degrees of success. Research to date on obtaining optimal solutions has been limited to small problems. This paper presents a new formulation of the lot-sizing problem in multistage assembly systems which leads to an effective optimization algorithm for the problem. The problem is reformulated in terms of "echelon stock" which simplifies its decomposition by a Lagrangean relaxation method. A Branch and Bound algorithm which uses the bounds obtained by the relaxation was developed and tested. Computational results are reported on 120 randomly generated problems involving up to 50 items in 15 stages and up to 18 time periods in the planning horizon.

Suggested Citation

  • Panayotis Afentakis & Bezalel Gavish & Uday Karmarkar, 1984. "Computationally Efficient Optimal Solutions to the Lot-Sizing Problem in Multistage Assembly Systems," Management Science, INFORMS, vol. 30(2), pages 222-239, February.
  • Handle: RePEc:inm:ormnsc:v:30:y:1984:i:2:p:222-239
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    File URL: http://dx.doi.org/10.1287/mnsc.30.2.222
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    Cited by:

    1. Voros, Jozsef, 1995. "Setup cost stability region for the multi-level dynamic lot sizing problem," European Journal of Operational Research, Elsevier, vol. 87(1), pages 132-141, November.
    2. Dellaert, N. & Jeunet, J. & Jonard, N., 2000. "A genetic algorithm to solve the general multi-level lot-sizing problem with time-varying costs," International Journal of Production Economics, Elsevier, vol. 68(3), pages 241-257, December.
    3. Xiao, Yiyong & Kaku, Ikou & Zhao, Qiuhong & Zhang, Renqian, 2011. "A reduced variable neighborhood search algorithm for uncapacitated multilevel lot-sizing problems," European Journal of Operational Research, Elsevier, vol. 214(2), pages 223-231, October.
    4. Chu, Chi-Leung & Leon, V. Jorge, 2009. "Scalable methodology for supply chain inventory coordination with private information," European Journal of Operational Research, Elsevier, vol. 195(1), pages 262-279, May.
    5. Dellaert, N. P. & Jeunet, J., 2003. "Randomized multi-level lot-sizing heuristics for general product structures," European Journal of Operational Research, Elsevier, vol. 148(1), pages 211-228, July.
    6. Erenguc, S. Selcuk & Simpson, N. C. & Vakharia, Asoo J., 1999. "Integrated production/distribution planning in supply chains: An invited review," European Journal of Operational Research, Elsevier, vol. 115(2), pages 219-236, June.
    7. Escudero, L. F. & Galindo, E. & Garcia, G. & Gomez, E. & Sabau, V., 1999. "Schumann, a modeling framework for supply chain management under uncertainty," European Journal of Operational Research, Elsevier, vol. 119(1), pages 14-34, November.
    8. Kimms, Alf & Drexl, Andreas, 1996. "Multi-level lot sizing: A literature survey," Manuskripte aus den Instituten für Betriebswirtschaftslehre der Universität Kiel 405, Christian-Albrechts-Universität zu Kiel, Institut für Betriebswirtschaftslehre.
    9. Degraeve, Z. & Jans, R.F., 2003. "A New Dantzig-Wolfe Reformulation And Branch-And-Price Algorithm For The Capacitated Lot Sizing Problem With Set Up Times," ERIM Report Series Research in Management ERS-2003-010-LIS, Erasmus Research Institute of Management (ERIM), ERIM is the joint research institute of the Rotterdam School of Management, Erasmus University and the Erasmus School of Economics (ESE) at Erasmus University Rotterdam.
    10. Xiao, Yiyong & Zhang, Renqian & Zhao, Qiuhong & Kaku, Ikou & Xu, Yuchun, 2014. "A variable neighborhood search with an effective local search for uncapacitated multilevel lot-sizing problems," European Journal of Operational Research, Elsevier, vol. 235(1), pages 102-114.
    11. dos Santos-Meza, Elisangela & Oliveira dos Santos, Maristela & Nereu Arenales, Marcos, 2002. "A lot-sizing problem in an automated foundry," European Journal of Operational Research, Elsevier, vol. 139(3), pages 490-500, June.
    12. Kimms, Alf, 1997. "Ablauforganisation bei Serienproduktion in Fließfertigungssystemen," Manuskripte aus den Instituten für Betriebswirtschaftslehre der Universität Kiel 431, Christian-Albrechts-Universität zu Kiel, Institut für Betriebswirtschaftslehre.
    13. Kimms, Alf, 1998. "Short-term management of lot production," Manuskripte aus den Instituten für Betriebswirtschaftslehre der Universität Kiel 480, Christian-Albrechts-Universität zu Kiel, Institut für Betriebswirtschaftslehre.
    14. Anantaram Balakrishnan & Joseph Geunes, 2000. "Requirements Planning with Substitutions: Exploiting Bill-of-Materials Flexibility in Production Planning," Manufacturing & Service Operations Management, INFORMS, vol. 2(2), pages 166-185, January.
    15. Grubbström, Robert W. & Tang, Ou, 2012. "The space of solution alternatives in the optimal lotsizing problem for general assembly systems applying MRP theory," International Journal of Production Economics, Elsevier, vol. 140(2), pages 765-777.
    16. Sazvar, Z. & Mirzapour Al-e-hashem, S.M.J. & Govindan, K. & Bahli, B., 2016. "A novel mathematical model for a multi-period, multi-product optimal ordering problem considering expiry dates in a FEFO system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 93(C), pages 232-261.
    17. Lee, S. D. & Rung, J. M., 2000. "Production lot sizing in failure prone two-stage serial systems," European Journal of Operational Research, Elsevier, vol. 123(1), pages 42-60, May.
    18. Simpson, N. C., 1999. "Multiple level production planning in rolling horizon assembly environments," European Journal of Operational Research, Elsevier, vol. 114(1), pages 15-28, April.
    19. Jans, Raf & Degraeve, Zeger, 2007. "Meta-heuristics for dynamic lot sizing: A review and comparison of solution approaches," European Journal of Operational Research, Elsevier, vol. 177(3), pages 1855-1875, March.

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