IDEAS home Printed from https://ideas.repec.org/a/bla/popmgt/v21y2012i4p668-681.html
   My bibliography  Save this article

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

Author

Listed:
  • Feng Cheng*
  • Markus Ettl
  • Yingdong Lu
  • David D. Yao

Abstract

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.

Suggested Citation

  • Feng Cheng* & Markus Ettl & Yingdong Lu & David D. Yao, 2012. "A Production–Inventory Model for a Push–Pull Manufacturing System with Capacity and Service Level Constraints," Production and Operations Management, Production and Operations Management Society, vol. 21(4), pages 668-681, July.
    • Handle: RePEc:bla:popmgt:v:21:y:2012:i:4:p:668-681
    DOI: 10.1111/j.1937-5956.2011.01303.x
    as

    Download full text from publisher

    File URL: https://doi.org/10.1111/j.1937-5956.2011.01303.x
    Download Restriction: no
    File URL: https://libkey.io/10.1111/j.1937-5956.2011.01303.x?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    References listed on IDEAS

    as
    1. Philip Kaminsky & Jayashankar M. Swaminathan, 2001. "Utilizing Forecast Band Refinement for Capacitated Production Planning," Manufacturing & Service Operations Management, INFORMS, vol. 3(1), pages 68-81, August.
    2. Jing-Sheng Song & David D. Yao, 2002. "Performance Analysis and Optimization of Assemble-to-Order Systems with Random Lead Times," Operations Research, INFORMS, vol. 50(5), pages 889-903, October.
    3. Bennett Fox, 1966. "Discrete Optimization Via Marginal Analysis," Management Science, INFORMS, vol. 13(3), pages 210-216, November.
    4. 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.
    5. Warren H. Hausman & Rein Peterson, 1972. "Multiproduct Production Scheduling for Style Goods with Limited Capacity, Forecast Revisions and Terminal Delivery," Management Science, INFORMS, vol. 18(7), pages 370-383, March.
    6. A. Federgruen & P. Zipkin, 1986. "An Inventory Model with Limited Production Capacity and Uncertain Demands II. The Discounted-Cost Criterion," Mathematics of Operations Research, INFORMS, vol. 11(2), pages 208-215, May.
    7. James R. Bradley & Bruce C. Arntzen, 1999. "The Simultaneous Planning of Production, Capacity, and Inventory in Seasonal Demand Environments," Operations Research, INFORMS, vol. 47(6), pages 795-806, December.
    8. A. Federgruen & P. Zipkin, 1986. "An Inventory Model with Limited Production Capacity and Uncertain Demands I. The Average-Cost Criterion," Mathematics of Operations Research, INFORMS, vol. 11(2), pages 193-207, May.
    9. Xiangwen Lu & Jing-Sheng Song & Amelia Regan, 2006. "Inventory Planning with Forecast Updates: Approximate Solutions and Cost Error Bounds," Operations Research, INFORMS, vol. 54(6), pages 1079-1097, December.
    10. Yingdong Lu & Jing-Sheng Song & David D. Yao, 2003. "Order Fill Rate, Leadtime Variability, and Advance Demand Information in an Assemble-to-Order System," Operations Research, INFORMS, vol. 51(2), pages 292-308, April.
    11. Philip Kaminsky & Jayashankar M. Swaminathan, 2004. "Effective Heuristics for Capacitated Production Planning with Multiperiod Production and Demand with Forecast Band Refinement," Manufacturing & Service Operations Management, INFORMS, vol. 6(2), pages 184-194, March.
    12. Yossi Aviv & Awi Federgruen, 2001. "Capacitated Multi-Item Inventory Systems with Random and Seasonally Fluctuating Demands: Implications for Postponement Strategies," Management Science, INFORMS, vol. 47(4), pages 512-531, April.
    13. Jayashankar M. Swaminathan & Sridhar R. Tayur, 1998. "Managing Broader Product Lines through Delayed Differentiation Using Vanilla Boxes," Management Science, INFORMS, vol. 44(12-Part-2), pages 161-172, December.
    14. Retsef Levi & Robin O. Roundy & David B. Shmoys & Van Anh Truong, 2008. "Approximation Algorithms for Capacitated Stochastic Inventory Control Models," Operations Research, INFORMS, vol. 56(5), pages 1184-1199, October.
    15. Roman Kapuściński & Sridhar Tayur, 1998. "A Capacitated Production-Inventory Model with Periodic Demand," Operations Research, INFORMS, vol. 46(6), pages 899-911, December.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Liu, Liming & Xu, He & Zhu, Stuart X., 2020. "Push verse pull: Inventory-leadtime tradeoff for managing system variability," European Journal of Operational Research, Elsevier, vol. 287(1), pages 119-132.
    2. Hong Fu & Yongkai Ma & Debing Ni & Xiaoqiang Cai, 2017. "Coordinating a decentralized hybrid push–pull assembly system with unreliable supply and uncertain demand," Annals of Operations Research, Springer, vol. 257(1), pages 537-557, October.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. 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.
    2. Han Zhu, 2022. "A simple heuristic policy for stochastic inventory systems with both minimum and maximum order quantity requirements," Annals of Operations Research, Springer, vol. 309(1), pages 347-363, February.
    3. Wang, Xun & Disney, Stephen M. & Ponte, Borja, 2023. "On the stationary stochastic response of an order-constrained inventory system," European Journal of Operational Research, Elsevier, vol. 304(2), pages 543-557.
    4. Hernan Caceres & Dongchen Yu & Alexander Nikolaev, 2018. "Evaluating shortfall distributions in periodic inventory systems with stochastic endogenous demands and lead-times," Annals of Operations Research, Springer, vol. 271(2), pages 405-427, December.
    5. Weidong Chen & Cong Shi & Izak Duenyas, 2020. "Optimal Learning Algorithms for Stochastic Inventory Systems with Random Capacities," Production and Operations Management, Production and Operations Management Society, vol. 29(7), pages 1624-1649, July.
    6. Robert N. Boute & Marc R. Lambrecht & Benny Van Houdt, 2007. "Performance evaluation of a production/inventory system with periodic review and endogenous lead times," Naval Research Logistics (NRL), John Wiley & Sons, vol. 54(4), pages 462-473, June.
    7. Xiuli Chao & Sridhar Seshadri & Michael Pinedo, 2008. "Optimal capacity in a coordinated supply chain," Naval Research Logistics (NRL), John Wiley & Sons, vol. 55(2), pages 130-141, March.
    8. Erica L. Plambeck, 2008. "Asymptotically Optimal Control for an Assemble-to-Order System with Capacitated Component Production and Fixed Transport Costs," Operations Research, INFORMS, vol. 56(5), pages 1158-1171, October.
    9. Susan H. Xu & Zhaolin Li, 2007. "Managing a Single-Product Assemble-to-Order System with Technology Innovations," Management Science, INFORMS, vol. 53(9), pages 1467-1485, September.
    10. Qingkai Ji & Lijun Sun & Xiangpei Hu & Jing Hou, 2016. "Optimal policies of a two-echelon serial inventory system with general limited capacities," International Journal of Production Research, Taylor & Francis Journals, vol. 54(20), pages 6142-6155, October.
    11. Retsef Levi & Robin O. Roundy & David B. Shmoys & Van Anh Truong, 2008. "Approximation Algorithms for Capacitated Stochastic Inventory Control Models," Operations Research, INFORMS, vol. 56(5), pages 1184-1199, October.
    12. Willem van Jaarsveld & Alan Scheller-Wolf, 2015. "Optimization of Industrial-Scale Assemble-to-Order Systems," INFORMS Journal on Computing, INFORMS, vol. 27(3), pages 544-560, August.
    13. Ioannis Ch. Paschalidis & Yong Liu, 2003. "Large Deviations-Based Asymptotics for Inventory Control in Supply Chains," Operations Research, INFORMS, vol. 51(3), pages 437-460, June.
    14. Xiuli Chao & Xiting Gong & Cong Shi & Chaolin Yang & Huanan Zhang & Sean X. Zhou, 2018. "Approximation Algorithms for Capacitated Perishable Inventory Systems with Positive Lead Times," Management Science, INFORMS, vol. 64(11), pages 5038-5061, November.
    15. Jian Yang & Zhaoqiong Qin, 2007. "Capacitated Production Control with Virtual Lateral Transshipments," Operations Research, INFORMS, vol. 55(6), pages 1104-1119, December.
    16. Xinxin Hu & Izak Duenyas & Roman Kapuscinski, 2008. "Optimal Joint Inventory and Transshipment Control Under Uncertain Capacity," Operations Research, INFORMS, vol. 56(4), pages 881-897, August.
    17. Rodney P. Parker & Roman Kapuściński, 2011. "Managing a Noncooperative Supply Chain with Limited Capacity," Operations Research, INFORMS, vol. 59(4), pages 866-881, August.
    18. Jing-Sheng Song & Yao Zhao, 2009. "The Value of Component Commonality in a Dynamic Inventory System with Lead Times," Manufacturing & Service Operations Management, INFORMS, vol. 11(3), pages 493-508, March.
    19. Klosterhalfen, Steffen T. & Holzhauer, Falk & Fleischmann, Moritz, 2018. "Control of a continuous production inventory system with production quantity restrictions," European Journal of Operational Research, Elsevier, vol. 268(2), pages 569-581.
    20. Wenjing Shen & Izak Duenyas & Roman Kapuscinski, 2014. "Optimal Pricing, Production, and Inventory for New Product Diffusion Under Supply Constraints," Manufacturing & Service Operations Management, INFORMS, vol. 16(1), pages 28-45, February.

    More about this item

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:bla:popmgt:v:21:y:2012:i:4:p:668-681. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Wiley Content Delivery (email available below). General contact details of provider: http://onlinelibrary.wiley.com/journal/10.1111/(ISSN)1937-5956 .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.