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Inventory and Production Decisions for an Assemble-to-Order System with Uncertain Demand and Limited Assembly Capacity

Author

Listed:
  • Ke Fu

    (Lingnan College, Sun Yat-sen University, Guangzhou, China 510275)

  • Vernon Ning Hsu

    (School of Management, George Mason University, Fairfax, Virginia 22030)

  • Chung-Yee Lee

    (Department of Industrial Engineering and Logistics Management, Hong Kong University of Science and Technology, Clear Water Bay, Kowloon, Hong Kong, China)

Abstract

This paper considers an inventory and production-planning problem for a contract manufacturer who anticipates an order of a single product, but with uncertain quantity. To meet the challenges of long component procurement lead times and limited assembly capacity, which may render production time insufficient to assemble total order quantity, the manufacturer may need to procure components or even assemble some quantities of the final product before receiving the confirmation of the actual order quantity. We present profit-maximization models that make optimal inventory and production decisions in the above assemble-to-order environment. We also consider the option of outsourcing, so that the manufacturer can outsource part of his production to an external facility that also has limited capacity. We establish structural properties of optimal solutions and develop efficient solution procedures for the proposed problems. We also provide sensitivity analysis of the optimal decisions, and some managerial insights.

Suggested Citation

  • Ke Fu & Vernon Ning Hsu & Chung-Yee Lee, 2006. "Inventory and Production Decisions for an Assemble-to-Order System with Uncertain Demand and Limited Assembly Capacity," Operations Research, INFORMS, vol. 54(6), pages 1137-1150, December.
    • Handle: RePEc:inm:oropre:v:54:y:2006:i:6:p:1137-1150
    DOI: 10.1287/opre.1060.0335
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    References listed on IDEAS

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    1. Vernon Ning Hsu & Chung Yee Lee & Kut C. So, 2006. "Optimal Component Stocking Policy for Assemble-to-Order Systems with Lead-Time-Dependent Component and Product Pricing," Management Science, INFORMS, vol. 52(3), pages 337-351, March.
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    Cited by:

    1. Jun Tong & Xiaotao Zhou & Lei Lei, 2024. "Priority-Based Capacity Allocation for Hierarchical Distributors with Limited Production Capacity," Mathematics, MDPI, vol. 12(14), pages 1-17, July.
    2. de Kok, Ton & Grob, Christopher & Laumanns, Marco & Minner, Stefan & Rambau, Jörg & Schade, Konrad, 2018. "A typology and literature review on stochastic multi-echelon inventory models," European Journal of Operational Research, Elsevier, vol. 269(3), pages 955-983.
    3. Ke Fu & Vernon N. Hsu & Chung-Yee Lee, 2009. "Note--Optimal Component Acquisition for a Single-Product, Single-Demand Assemble-to-Order Problem with Expediting," Manufacturing & Service Operations Management, INFORMS, vol. 11(2), pages 229-236, December.
    4. Vernon Ning Hsu & Chung Yee Lee & Kut C. So, 2007. "Managing components for assemble‐to‐order products with lead‐time‐dependent pricing: The full‐shipment model," Naval Research Logistics (NRL), John Wiley & Sons, vol. 54(5), pages 510-523, August.
    5. Song, Zhe & Kusiak, Andrew, 2010. "Mining Pareto-optimal modules for delayed product differentiation," European Journal of Operational Research, Elsevier, vol. 201(1), pages 123-128, February.
    6. Süleyman Demirel & Izak Duenyas & Roman Kapuscinski, 2015. "Production and Inventory Control for a Make-to-Stock/Calibrate-to-Order System with Dedicated and Shared Resources," Operations Research, INFORMS, vol. 63(4), pages 823-839, August.
    7. Oh, Yosep & Behdad, Sara, 2017. "Simultaneous reassembly and procurement planning in assemble-to-order remanufacturing systems," International Journal of Production Economics, Elsevier, vol. 184(C), pages 168-178.
    8. Xiang Fang & Kut C. So & Yunzeng Wang, 2008. "Component Procurement Strategies in Decentralized Assemble-to-Order Systems with Time-Dependent Pricing," Management Science, INFORMS, vol. 54(12), pages 1997-2011, December.
    9. Tang, Dong, 2011. "Managing finished-goods inventory under capacitated delayed differentiation," Omega, Elsevier, vol. 39(5), pages 481-492, October.
    10. Fan, Di & Liang, Tianheng & Yeung, Andy C.L. & Zhang, Haomin, 2020. "The impact of capacity-reduction initiatives on the stock market value of Chinese manufacturing firms," International Journal of Production Economics, Elsevier, vol. 223(C).
    11. Yeu-Shiang Huang & Hau-Wen Lo & Jyh-Wen Ho, 2021. "Effects of component commonality and perishability on inventory control in assemble-to-order systems," Operational Research, Springer, vol. 21(1), pages 205-229, March.
    12. Atan, Zümbül & Ahmadi, Taher & Stegehuis, Clara & Kok, Ton de & Adan, Ivo, 2017. "Assemble-to-order systems: A review," European Journal of Operational Research, Elsevier, vol. 261(3), pages 866-879.
    13. Kai Huang, 2014. "Benchmarking non-first-come-first-served component allocation in an assemble-to-order system," Annals of Operations Research, Springer, vol. 223(1), pages 217-237, December.
    14. Xiao, Yongbo & Chen, Jian & Lee, Chung-Yee, 2010. "Optimal decisions for assemble-to-order systems with uncertain assembly capacity," International Journal of Production Economics, Elsevier, vol. 123(1), pages 155-165, January.
    15. Fernando Bernstein & Gregory A. DeCroix & Yulan Wang, 2011. "The Impact of Demand Aggregation Through Delayed Component Allocation in an Assemble-to-Order System," Management Science, INFORMS, vol. 57(6), pages 1154-1171, June.
    16. Svoboda, Josef & Minner, Stefan & Yao, Man, 2021. "Typology and literature review on multiple supplier inventory control models," European Journal of Operational Research, Elsevier, vol. 293(1), pages 1-23.
    17. Zhang, Guoquan & Shang, Jennifer & Li, Wenli, 2011. "Collaborative production planning of supply chain under price and demand uncertainty," European Journal of Operational Research, Elsevier, vol. 215(3), pages 590-603, December.

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