Component ordering strategies in assembly systems with uncertain capacity and random yield

Abstract

Sourcing components in a complex global supplier network may lead to a high degree of supply uncertainty. Events, such as unexpected production defects or insufficient supplier capacity, can cause unexpected shortages of required components and halt the assembly of final products. Accordingly, the assembly enterprises must effectively manage various supply uncertainties in their component ordering decisions to avoid such component shortfalls. These issues have guided this research to investigate the optimal ordering strategies of an assembler facing the following two types of supply uncertainty: the uncertain production capacity of a standard component (component 1) and the random production yield of a core component (component 2). The assembler makes the component ordering decisions before these supply uncertainties are realized. We characterize the optimal ordering decision and find that the assembler should order components 1 and 2 according to a fixed ratio, which only depends on the random yield of component 2 and the production cost of component 1, but not on the uncertain capacity of component 1. A case study is presented to further explore the intertwined effects of these two uncertainties in an assembly system. Finally, the model is extended to consider a secondary option of buying additional component 1 s after observing some or all of the supply uncertainties, and this secondary option endows the firm with different capabilities in counteracting the supply uncertainties.