Onderzoeksrapport Nr ~ 7817 A HEURISTIC METHOD FOR THE FACILITIES IN SERIES DYNAMIC LOT SIZE PROBLEM by H. R. LA1'1BRECHT J. VANDER EECKEN H. VANDERVEKEN Katholieke Universiteit Leuven, Department of Applie.d Economies De 1.:.i~nstraat B···JOOO 2 I~EUVEN BELGIUH IIJe::telijk Depot D/1978/2376/26. A HEURISTIC NETHOD FOR THE FACILITIES IN SERIES DYNAMIC LOT SIZE PROBLEM H.R. LM1BRECHT~ J. VANDER EECKEN H. VANDERVEKEN This paper focuses on heuristic procedures for the uncapacitated facilities in series dynamic lot size problem. Several multilevel and level-by-level procedures are compared with the optimal rrndels of \.J. ZANGWILL and S. LOVE. The best heuristic differs only marginally - on the average by no more than 1 .84 % - from the optimal solutiono Our computational expe.rience is based on a large set of simulation experiments. Io INTRODUCTION. There has been a widespread interest in the deterministic dynamic production and inventory models since the publication of the classic paper of Wagner and Whitin [ 12] , Their model deals with the search for optimal produc- tion (ordering) and inventory schedules for a single stage, single product system given a fluctuating deterministic demand pattern over a finite horizon o Presumed computational difficulties with Wagner-w'hitin's model have led to a number of heuristic approaches such as Part Period Balancing, Least Unit Cost, Least Total Costt Silver-Neal Heuristic, etc •••• In recent years various papers have appeared on production-inventory planning in multi-echelon or multistage systems. The seria~ arborescent and as- sembly structures are the best known production configurations. In this paper we will concentrate on the facilities in series dynamic lot ze problem. Because of the computational difficulties of the optimal so- lution algorithms we propose an efficient near-optimal heuristic procedure. ::1'1 Katholieke Universiteit Leuven, Department of Applied Economics. This work was supported by the Fonds Derde Cyclus under grant ,OT/V /19. The serial dynamic economic Jot size production model has been studied ~~he amoug others by d~fferent :o:ev,;::ral processes. Eaeh process is assumed to take place in a processing industries Serial <>ystctns ::.:::::::: facility. f:i.no..t product requires e.g. steel and chemical industry, A concave cost structure is assumed so that costs: may eTnbody a fixed charge. No bacl<logging is per·mitted so that requirements are to be met as they occur. It is also assumed that one of production at any facility requires as input one unit of production from the preceeding facility. t,et ~ ::::: r.' l l ' be the market demand for the finished product in period i, 0 lb <\)" • :II = 1, Define x. • as the production of faci H ty j, j n. in period i. Production is instantaneous. hl. ••• , m Let I . . he the inventory stored at facility j at the end of ],1 Let PJ,l . . (x) he the cost of producing x units and H. . (I) be the ],l. cost of holding I units stock. F . . (x) is a fixed charge function and period i. . J,l. we assume H. . (I) to be J ':!. The obj 1s to determine the production schedule in each facility that r:u.m.n:uzes total costs. HinimL"' The appropriate programming problem is as follows t (l) I.; j ""l Subject to (2) i=l, .••• ~ n i:=:1~ 0 I.J,U" { i L!- :1 = I.],n = 0 ••• , n (3) ¥(i,j) (4) ¥. (5) J has cleverly represented the constraints as floiV constraints in a single-source network (see figure 1). Equations (2) and (3) demonstrate 2. nodal conservation of flow in the network. The determination of the opti- to mal production schedule is the network optimal flow. n L: r. i=l l. -----~--~ I I I fac t I ------~-~) fac j ~---- "">Q-- -t fac m ! r J r. 1 FIGURE 1. r n 3. II. THE OPTD:1AL SOLUTION ALGORITHHS • Constraint (2) ·- (5) define a closed bounded convex set, and since the objective function is concave, it will attain its minimum at an extreme point of the convex set. An extreme flow is defined as the network flow equiva- lent of an extreme point of the convex set of feasible solutions. Zangwill demonstrates that) in the absence of capacity constraints) an extreme flow has the property that any node in the network can have at most one positive input, or : x J,~ •.• I ],~.. l =0 for all i and j As a consequence, the input into node (j,i) must satisfy demand over an in-, tegral number of periods. algorithm tions. Zangwill [ 14] developed a dynamic programming the above characteristic of. optimal solu- ting t-Ie refer to [ 14] for a detailed description of the algorithm. Love I 7 J considered the facilities in series model with the following cost assumptions : Production costs are non-increasing in t Inventory holding costs are non-decreasing in j : H. (I)~H._Ll t(I)~ j=l, •• .,m-1 ],t J .... ' As a consequence of the above assumptions, L.ove proves that if in a given period production starts in a duce~ facility~ then its successors must also pro- that is to say once production starts in a given period i, facility then production continues in i at all facilities j+l, ••• , m. tion schedules are called nested. tic reduction Such produc- The nested schedule case causes a dras- the number of computations required to find the optimal production schedule. We refer to [ 7] j~ for a detailed descripti'on of the 4. resulting The al thms of Zang><Till and Love \;rere programmed in FORTRAN IV. (on IBM ThE! 370/358 :Hodel 3) tr facilities and planning horizon. th the number of 1 tho::. 1Tu1nber o.f included in the Figures 2 and 3 illustrate these results graphically. III. HEURISTIC PROCEDURES. The heuristic procedures explained this section hold under the following cost assumptions : • The cost func o(x . • ) J~1 '"" 1 if X!~ the m~it ~" P . . (x . . ) ],1 ],1 S. o(x . . ) + b .• x . . with J ],1 J ],1 >0 and O(X,],1.) ""'0 if X.],1• ""0, is the same for J,~ each time per ~ but may differ from facility to facility. Since production <:ost is constant, it has no influence on the op- timal and may therefore be • The inventory holding cost fuaction h .• I", i J st::1n1 throngh but As a result of these two as non·~dr ~reasing linear and h. is conJ from star~ to successor staf?e. J ~. the production schedules w ~..rill be nested. A. THE }fOLTI-LEVEL HEURISTIC. The proposed heuris quantities are ass is of the multi-level type which means that production to Hn approach enhances the p·rac ties on a period by period basis. Such value of the method mainly because the current decisions can be bafed on near and thus accurate data. 5. Z3ec 7 Zangwill Love 6 4 3 2 -4 5 FIGURE 2. 6 7 9 6. n=:JO 6 U"'10 n -7 - - - - - - - - - - - - - - - - - - - - - - - n•) 4 5 FIGURE 3. 6 1() faciE tic 7o Define reorder period k as a period with positive production at all facili- > 0). For each 1 facility and each time period a coefficient will be calculated indicating ties (period one is always the reorder period if r rs whether a cost reduction 1s poss le by incorporating dem<1nds m, reorder period k. into t:he lot of facility j, j=l, cients turn out to be negative for a certain period i, i If all coeffi- >k then period i is considered as the new reorder period and the loading meachanism is repeated. The following coefficients will be used J 2.: Sa - C. - 1.-11 ;<, Q,=l h .• r. ( i -k) J 1 i "" k+1' k+2, ••• ¥. J ( i -p . ) r . ( h . - h . J !. J ) J- 1 . < jo i ¥. J with = k+2, k+3 (7) > jo C.1-1, as the cumulative inventory holding costs incurred from reorder period k up to period i-i. as the last period with positive production at facility j. p. J For each time period i, the fac:i.li ty which (6) Max {U . . j ],~ ~ is selected as the facility for O} Define the set A as follows A = {j \U • . is computed by (6)} • J,l h • • '1 • turns out tat I-f 1t J.KEA. we set J.o • J.K , e 1se J,Q k·eeps 1ts prev1ous.y determined value. 8. At the beginning of the loading process, i.e. at the start of each new . 1 we set J" reor d er per1oc We j t = 1, For ch<'~ck whether ••• m(=j 0 0 equa 1 to m. advantageous to it rk+l xj ,k' For this first step only formula (6) is evaluated. ). j"" l we have u1 ~k+l- "" s l - hl .rl·+' 'I j:=2 we have <::! u2,k+l "" ""1 + sz - s9., - h m··rk+l j=m we have 1.11 um~k+l ., The first component of in k, m L:~ 9,=1 Uj~k+l (Ck "" 0) h2.rk+1 represents the cost savings for not producing ties l , 2 ~ • • • j. The other terms represent inven- tory holding costs as the consequence of producing more than·the current requirements. Note also that for a specific facility j we treat the faciliJ ties 1, •.• ~ j as a single facili and h. as cost parameters. 2: with J £""1 • '!... t0e 1 Th e f ac1'1"1ty J.~ W1t•a last faci t coeffic pmn t .._p ty producing rk+l in period k, or, -~ J "" 1 ~ ••• J I .:l( J ,k = rk+l and xj~k+l "" rk+l Since for fhe t :JL J .~ 1 "" s ( j "" J.x+'• ' rk .o step J cA, we set J ~ .~ J • • E:! "" ' m selected to be tL.a k+2. rements of We next turn to the Both c effie (6) . . and (7 \J may no1.v be used (.dependJ.ng on the posJ.. t1on o f J. 0) • 1'. .n.gures 4 and 5 illustrate evaluated respectively by for- t:he a.l .o trary J • mula (6) and 0) for an 1 .o -~ J '"J -- ~1 ---- :eo l -> • L I v I .o .ox J ""J I ; l -·-----~>··· ' ~.!. I II ~~--J •'IIi I I 1 'lio i if l r --,1 ,.• k Ill ! ~ I - If "' ! 'k+l FIGURE il ~ alternatives evaluated by (6) FIGURE 5 : alternatives evaluated by (7) After the :;;;election of the highest positive coefficient the procedure is re- peated for the requirements of period k+3. The procedure ends if all coefficients turn out to be negative, indicating that a new reorder period is found. Notice that formula (6) computes the possible savings :resulting from not scheduling production facility j~ period i~ but adding r. to. the produc1 J ~ period ·:. li t; of tion Formula (7) or: the other hand lot of evaluates the possible Servings by adding r!, to ...lh: prod fc.-~ J.- ty j~ the last period tv-ith positive production for peeiod pj \vhich facility j ., Remember also that the production schedules must be nested, . se 1 ec:teo' proauct:ton ' . . that means that once ::;.s cont1.nues at j.'}t. + 1 , .... , m.. It is clear that the production quantitites must be adjusted after each step of the procedure. Because the production program is constructed on a period-by..;.period basis, it 1nay turn out that demand of the last all facil:i ties period n. period~ rn~ has to be produced at In this case a backtracking procedure examines v..rhether it is not better to incorporate rn into an earlier lot. We there- fore compare the saved set-up costs with the additi.onal inventory holding costs cau:.>ed production ( in inventory from the last period with positive n each facility) to period n. r A 7 facility, 7 problem will be used to illustrate the above proce- dure. Fad 4 80 l 3 100 100 4 2GO 5 300 200 !00 2 6 7 Reorder period 70 2 3 ~ " -~ l, ,. :J k~l. A'*'{l, 2~ ••• 7} 60 ~00 5 6 7 120 80 40 Formula (6) u12 "' 400 - 2 X 70 "" 260 500 - 2 X 70 "" 360 u32 = = 600 - 3 X 70"" 390 ut,2 = 800 - 3 X 70 "" 590 U,.,L2 u52 ""' llOO - 3 x 70 "" 890 u62 "" 1300 - l~ X 70 "" 1020 u72 = 1400 - 5 M~X {u j,2 } "' U72 = 1050 J c2 = s x 10 •o J X + J.~ 70 "" 1050 "' 7 = 350 • =7 A = {1 , 2, ••• , 7} = 400- 350- 2 X X 60 = -190 U23 "' U = 33 500 - 350 - 2 X 2 X 60 = - 90 = -110 u43 800 - 350 - 2x3x60= Formula (6) U13 2 600- 350- 2 X 3 X 60 90 u53 "' 1100 - 3.50 - 2 X 3 X 60 "" 390 u63 ""' 1300 - 350 - 2 x 4 x· 60 = l+70 u73 "" 1400 - 350 - 2 = 350 C3 • cnec. • k r 4 , + 2 X 4 X 60 3' 0 =6 Formula (6) u l t ~ ~ A X 5 X 60 '"' 450 = 830. = !J , 2 ~ ••• , 6 } u34 "' 400 - 830 - 3 X 2 X 100 "" -1030 500 - 830 - 3 X 2 X 100 "" - 930 600 - 830 - 3 X 3 X 100 = -1130 u44 "" 800 - 830 - 3 X 3 X 100 "" u24 "' =- 930 U 54 U 64 Formula (7) u 74 ~ 1100- 830- 3 X 3 X 100 = 1300 .., u 64 - 830 - 3 X 4 X 100 + s 7 -630 ~ -730 - (4-3) - 100 (5-4) "" -730 + ] 00 - 1.00 ... -7 30 • Since all coefficients are negative we turn to the next reorder period k=4. Reorder period k=4. Max {U. } j J, 5 • check r 6 , j 0 = 6, ], 6 '5 = 820 + j~ ~ 6, j~cA, j 0 =6 A~ {1, 2, ••• , 6} j"" U. = u6 1~2, •••• 6 is computed via (6) and U. J, 7 Max {U. } = U. . .h 6 J, 7 J = 200 + j:l'( ""' 7, j~A, j 0 "" via (7). 6 C "' 480 + 80 X 4 + 80 X 5 .,. 1200 6 • check r 7 , j 0 = 6, A = {1 ~ 2, ••• , 6} U. . , j"" 1, 2, ••• , 6 is computed by formula (6) and J, 7 uj,7 via formula (1) Since all U. J, 7 are negative we turn to the next reorder point k=7=n. 13., The production program for periods 4, 5,and 6 is repr.es0nted on figure 6. FIGURE 6. The demand r 7 has to be produced on all facilities.. We therefore examine whether it is not advantageous to incorporate r 7 into an earlier lot .. This is done by comparing the saved set-up cost with the additional in- ventory holding cost incurred by carrying r 7 in inventory from the last period with positive production to period 7. 14. = 160 X 2 X 2 "" 260 j "" 3 J "" 4 400 - 3 X 40 500 - 3 X 40 600 - 3 X 40 X 800 - 3 X 40 X j ... 5 1100- 3 X 40 X 3 "" 240 3 "" 440 3 "" 740 j "" 6 i300- 3 X 40 X ... 1400 - 2 X 40 X j l "" j ""' 2 J 7 4 "" 820 5 - l X 40 X 4 The greatest saving is obtained for j = 840 = 7. The resulting solution using the multi-level he,uristic is as follotvs x . . (I. . ) J.~ ],~ i 2 j 4 3 5 ·6 7 1 210(0) 0(0) 0(0) 340(0) 0(0) 0(0) 0(0) 2 210(0) 0(0) 0(0) 340(0) 0(0) 0(0) 0(0) 3 210(0) 0(0) 0(0) 340(0) ,0(0) 0(0) 0(0) 4 210(0) 0(0) 0(0) 340(0) 0(0) 0(0) 0(0) 5 210(0) 0(0) 0(0) 340(0) 0(0) 0(0) 0(0) 6 210(60) 0(60) 0(0) .340(240) 0(0) 0(0) 0(0) 7 150(70) 0(0) 60(0) 240(120) 0(40) 0(0) Total cost set-up costs 3000 Inventory costs 2590 100(0) 5590 The optimal solution found by Love • s algorithm is as follows 15. ~i 3 2 4 5 6 7 J 1 210(0) 0(0) 0(0) 340(0) 0(0) 0(0) 0(0) 2 210(0) 0(0) 0(0) 340{0) 0(0) 0(0) 0(0) 3 210(0) 0(0) 0(0) 340(0) 0(0) 0(0) 0(0) 4 210(0) 0(0) 0(0) 340(0) 0(0) 0(0) 0(0) 5 210(0) 0(0) 0(0) 340(120) 0(120) 0(0) 0(0) 6 210(130) 0(0) 0(0) 220( 120) 0(0} 120(0) 0(0) 80(0) 130(60) 0(0) 100(0) 120(40) 0(0) 7 120(0) Total costs of the optimal solution : 5520. The heuristic differs for this specific example by 1.27% from the optimal solutiono B. LEVEL-BY-LEVEL HEURISTICS A level-by-level heuristic assigns production quantities to a specific fa- cility over all periods and uses the resulting production program as demands for the preceeding facility. The level-by-level heuristics start with the last facility. Let rij) be the requirements for facility j, periods i, i = l, •.• ,n. These requirements are the production qua~~tities of facility j+l for all periodcq io For j=m we have that r~m) = r., i = 1, ••• , n. l. 1. Any single stage dynamic lot-size algorithm can be used such as Wagner-lifui tin Part Period Balancing Least Unit Cost Silver and Meal [ 9] Order ~foment [8 1 The cost parameters for each faci t 4 are given by and h .• J The level-by-level heuristics consist. in fact in nothing else than using m times one of the abovementioned sh1gle stage lot sizing procedures with the appropriate cost parameters. The recently developped Order ~Homent heuristic I 8 J needs more explanation .. Let Gk,p "" and W~ ~;rith J = ITBO. E(r).(t-1) + ITBO .• E(r). (TBO.- ITBO.] "L> J t=l E(r) = n J n r, i=l J J r.)_ 2 .. A. TBOj = J h, .E(r) J ITBOj = f TBOj 1~ , i.e. the greatest integer less than or equal TBO .. J The Order-Homent heuristic states to order for periods k through p-1) the first th11e thl< following inequality holds : G ''k ""> ,p ... w• J The other lot sizing algorithms are so well known that no further exy:lanation is needed. IV. COMPUTATIONAL l~XPERIENCE. The multi-level and level-by-level heuristics have been tested on a large sample of problems. Costs are expressed as percentages of the cost of the optimal solution which is set equal to 100. The average percent above the optimal solution for the heuristics is given in Table I. Procedure Cost Performance l1ulti-Level Heuristic 101.84 Level-by-Level Older Moment 1\lagner-lifni tin Part Period Balancing Silver-Meal ·,[,east Unit Cost 106.25 109.01 11 L 15 112.47 H7.92 TABLE 1. As can be seen from Table l. the mu ti-level heuristt is superior to the other procedures. In order to exp1it1y characterizing the sample (72 problems wit,h 4 and 4 ~ m ~ 10) 'l:ve ~ n ~ 10 introduce the follm.ring measures of problem complexity. I. The coefficient. of demand vari.'3don vD ""' where D is the average demand and crD is the standard deviation of demands The sample contains variable demand patterns as well as problems with inc1:easing, de..:reasing and const nt demand patterns 2. The coefficient of cost variation ,. "1-l --"'--)/m-1 s. J The change in inventory holding costs and set-up costs from facility to facility seems to be an important element for the effectiveness of the proposed heuristics. A large value of VC is an indi- cation that eosts are highly variable and as a consequence difficult to solve by means of a heuristic. Table 2 compares the multi-level heuristic (M..L.) and the level-by-level order moment (O.M.) procedure in function of VC and VD. " ~ 0 - 'J > 1.5- 3 r;_ • -' D H.L. O.M. M.L. O.M. M.L. 100.7.5 101.28 100. 7<:1, 105.91 101.27 H.L. o.M. I 08.25 H.L. 101.78 101 .52 OoM. 102.78 H.L. O.M. 102.87 103.33 0 - 0.15 o. 15 - 0.30 102.2 > 0.30 M.L. 101.14, ., O.M. M.L~ 102.5 I }f.L. 103.23 3 0.!1. 111 • 99 O.M. 108.33 O."M. 112.96 TABLE 2. The 72 problems were evenly spread over the 9 cells of Table 2. As can be seen from Table 2, the Multi-Level heuristic is superior to Order Moment for all values of VC and VD. The proposed Hulti-Level approach 19 .. is far more better than Order ~ioment for values of VC. The same conclusion holds by con1pa.ring the multi-level heuristic with the other level-by-level procedures. The Multi-Level heuristic resulted in the optimal solution for 34 out of the 72 problems. '11m 5 Level-by-Level heuristics were also tested using the following cost parameters. A. J = s. and J h. J The costs deviate from the optimal solution by 12 .. 2% to 17.9% depending on the heuristic used. Table 3 summarizes the CPU-times for a number of selected cases. The co~ puter times are considerately lower than the ones required for the optimal algorithm of S. Loveo Moreover, the computer time is approximately linear both with respect to the number of facilities and the number of periods, which is not the case for the optimal al.g<Yri thms. CPU-times in msec~; n""' 10, m = 4t 5, 6, 7, 8 4 5 6 7 8 164 195 239 263 299 938 1209 1471 1738 2028 m Multi-level Heuristic s. l,ove X CPU-times in msec ; m= 5, n "" 4, 5, 6. m Mul ti-Leve 1 Heuristic S. Love ~ On llU-1 370/358 Hodel 3 ... ,. 10 4 5 6 7 8 9 10 102 126 !37 149 174 H35 195 214 304 411 562 733 892 1209 20., Th~: CPU tim.: for the level-by~level procedures does not di.ffer significant- ly from. the computer time of the multi -level heur:l.stiiit., REFERENCES t 1J W.B. CRO\.JSTON & 1'1. \:i!AGNER : aDynamic Lot-Size Hodels for Multi-Stage Assembly Systems", Hanagement Science~ Vol. 20, No. 1 ~ September 1973 1 pp. 14-21. [ 2] W.B. 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