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Simultaneous optimization of capacity and planned lead time in a two-stage production system with different customer due dates

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  • Altendorfer, Klaus
  • Minner, Stefan

Abstract

We consider a two-stage make-to-order manufacturing system with random demands, processing times, and distributed customer due dates. The work to each stage is released based on a planned lead time. A general approach to minimize total inventory holding and customer order tardiness cost is presented to find the optimal manufacturing capacities and planned lead times for each manufacturing stage. Expressions are derived for work-in process inventories, finished-goods-inventory and expected backorders under the assumption of a series of M/M/1 queuing systems and exponentially distributed customer required lead times. We prove that the distribution of customer required lead time has no influence on the optimal planned lead times whenever capacity is predefined but it influences the optimal capacity to invest into. For the simultaneous optimization of capacity and planned lead times we present a numerical study that shows that only marginal cost decreases can be gained by setting a planned lead time for the upstream stage and that a considerable cost penalty is incurred if capacity and planned lead time optimization are performed sequentially.

Suggested Citation

  • Altendorfer, Klaus & Minner, Stefan, 2011. "Simultaneous optimization of capacity and planned lead time in a two-stage production system with different customer due dates," European Journal of Operational Research, Elsevier, vol. 213(1), pages 134-146, August.
    • Handle: RePEc:eee:ejores:v:213:y:2011:i:1:p:134-146
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    1. Altendorfer, Klaus & Minner, Stefan, 2015. "Influence of order acceptance policies on optimal capacity investment with stochastic customer required lead times," European Journal of Operational Research, Elsevier, vol. 243(2), pages 555-565.
    2. Altendorfer, Klaus, 2015. "Influence of lot size and planned lead time on service level and inventory for a single-stage production system with advance demand information and random required lead times," International Journal of Production Economics, Elsevier, vol. 170(PB), pages 478-488.
    3. Öner-Közen, Miray & Minner, Stefan, 2017. "Impact of priority sequencing decisions on on-time probability and expected tardiness of orders in make-to-order production systems with external due-dates," European Journal of Operational Research, Elsevier, vol. 263(2), pages 524-539.
    4. Gansterer, Margaretha & Almeder, Christian & Hartl, Richard F., 2014. "Simulation-based optimization methods for setting production planning parameters," International Journal of Production Economics, Elsevier, vol. 151(C), pages 206-213.
    5. Vahdani, Behnam & Mohammadi, M., 2015. "A bi-objective interval-stochastic robust optimization model for designing closed loop supply chain network with multi-priority queuing system," International Journal of Production Economics, Elsevier, vol. 170(PA), pages 67-87.
    6. Klaus Altendorfer & Thomas Felberbauer & Herbert Jodlbauer, 2018. "Effects of forecast errors on optimal utilisation in aggregate production planning with stochastic customer demand," Papers 1812.00773, arXiv.org.

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