Inventory Control V: Joint Optimization of Reorder Point and Batch QuantityTextbook
Two decisions that are usually taken separately
An policy has two parameters. Chapter 4 of Axsäter's Inventory Control chooses the batch quantity from a deterministic model, and Chapter 5 chooses the reorder point from a stochastic one with held fixed; the book presents this two-step practice as an adequate approximation. Section 6.1 asks what is lost by it and shows how to optimize both parameters jointly in one stochastic model. For discrete demand the answer, due to Federgruen and Zheng (1992), is an algorithm of remarkable simplicity: increase one unit at a time, keep the reorder point optimal along the way by a one-line rule, and stop at the first for which the cost goes up. The claim that this stopping rule finds the global optimum over all pairs is the capstone of Sect. 6.1.1.1 and the goal of this mission. The same idea is reused in the book for policies (Sect. 6.1.1.2) and, in continuous form, for normally distributed demand (Sect. 6.1.2).
Setting
An item is controlled by a continuous review policy with integral reorder point and batch quantity . Demand is discrete and stationary; the lead-time demand takes values in the nonnegative integers with probabilities and has a finite mean . The average demand per unit of time is . Costs are a holding cost and a shortage cost , both per unit and time unit, and an ordering cost per batch.
The building block is the cost of an policy that keeps the inventory position at a fixed integer . By the standard argument of Sect. 5.3.2 the inventory level a lead-time later is , and the average holding and shortage cost rate is (Eq. 6.3)
Under the policy the inventory position is uniformly distributed on (Proposition 5.1), so the total average cost rate is (Eq. 6.4)
and (Eq. 6.5), attained at an optimal reorder point . The ready rate links the cost to service: raising the reorder point by one unit changes the cost by (Eq. 5.60).
Formalization targets
Goal — the Federgruen-Zheng stopping rule is optimal
Let be the smallest batch quantity with and let be an optimal reorder point for . Then
Supporting targets
The increment identity ; convexity of on together with as ; Eq. (5.60) and the convexity of in ; Eq. (5.61), that the largest with is optimal for its ; existence of an optimal for every ; the recursion (6.6)-(6.7), chosen by comparing with , and ; the equivalence and the monotonicity of that minimum in ; and the existence of some at which the costs stop decreasing.
Significance
The result itself. Joint optimization typically enlarges the batch and lowers the reorder point relative to the two-step procedure, and the book's Example 6.1 puts the resulting cost saving at a few percent. The Federgruen-Zheng procedure makes the exact joint optimum for discrete demand as cheap to compute as the two-step approximation, because each step of the recursion evaluates at two points. It is the exact benchmark against which the book's approximate techniques for normal demand (Sects. 6.1.2 and 6.1.3) are judged, and its structural core, that the optimal window of consecutive inventory positions grows one neighbour at a time, is the discrete-convexity fact behind the whole of Sect. 6.1.
Formalizing it. The mathematics is settled. What the mission produces is a Lean development in which the steps the book marks "evident" and "obvious" are separate statements: that the recursion preserves optimality, that the marginal cost of enlarging the batch is monotone, and that a minimum over exists at all. None of the statements has a machine-checked proof yet.
Difficulty
The obvious first idea, to argue that is convex in and stop at its first increase, does not work as stated: is a minimum over of a ratio and is not convex in general. What is true, and what the proof uses, is that the marginal cost is nondecreasing, because it equals the smaller of the two -values adjacent to the optimal window. Establishing the recursion (6.6) is where discrete convexity is needed: one must show that the best window of consecutive positions is obtained from the best window of by adding a neighbour, which fails for non-convex . The window sums are themselves convex in with increments , and the argument compares a competing window with the optimal one through the end terms. The remaining steps are finite algebra and an induction on from .
Formalization scope
A DiscreteDemand is a function with ,
and a summable first moment; is a finite sum over , empty for
. The reorder point ranges over and the batch quantity over ,
with assumed in every statement because Lean's division by is . Convexity of a
function on is stated as nondecreasing increments, and divergence as
Tendsto g (cocompact ℤ) atTop.
enters the goal as a function CQ together with the hypothesis that CQ Q is the least
value of ; the stopping index is characterized by the two conditions
that define "the smallest with ", and by optimality at .
That these objects exist is the content of two separate items, so the goal is not vacuous: a
minimum over exists for every because , and the costs cannot decrease
forever because the average of the smallest values of tends to infinity. The
positivity of and is the book's setting and is assumed where it appears.
The uniform inventory position of Proposition 5.1, which needs the book's assumption that not all demands are multiples of an integer larger than one, is taken as given in the cost formula (6.4), as the book does; the proposition itself is the subject of the next mission of this series. The definitions are reusable for the optimization of Sect. 6.1.1.2 and for the multi-echelon batch-ordering results of Sect. 10.5; contributions formalizing the Zheng-Federgruen algorithm on top of them are welcome.
Selected references
- Sven Axsäter, Inventory Control, 3rd edition, International Series in Operations Research & Management Science 225, Springer, 2015, Sects. 5.9.1 and 6.1.1. DOI 10.1007/978-3-319-15729-0
- Awi Federgruen and Yu-Sheng Zheng, An Efficient Algorithm for Computing an Optimal Policy in Continuous Review Stochastic Inventory Systems, Operations Research 40(4), 1992, pp. 808-813. DOI 10.1287/opre.40.4.808
- Yu-Sheng Zheng and Awi Federgruen, Finding Optimal Policies Is About as Simple as Evaluating a Single Policy, Operations Research 39(4), 1991, pp. 654-665. DOI 10.1287/opre.39.4.654
- Paul Zipkin, Foundations of Inventory Management, McGraw-Hill, 2000.