Dynamic lotsizing with a finite production rate

Abstract

The dynamic lotsizing problem concerns the determination of optimally produced/delivered batch quantities, when demand, which is to be satisfied, is distributed over time in different amounts at different times. The standard formulation assumes that these batches are provided instantaneously, i.e. that the production rate is infinite.Using a cumulative geometrical representation for demand and production, it has previously been demonstrated that the inner-corner condition for an optimal production plan reduces the number of possible optimal replenishment times to a finite set of given points, at which replenishments can be made. The problem is thereby turned into choosing from a set of zero/one decisions, whether or not to replenish each time there is a demand. If n is the number of demand events, this provides 2n−1 alternatives, of which at least one solution must be optimal. This condition applies, whether an Average Cost approach or the Net Present Value principle is applied, and the condition is valid in continuous time, and therefore in discrete time.In the current paper, the assumption of an infinite production rate is relaxed, and consequences for the inner-corner condition are investigated. It is then shown that the inner-corner condition needs to be modified to a tangency condition between cumulative requirements and cumulative production.Also, we have confirmed the additional restriction for feasibility in the finite production case (provided by Hill, 1997), namely the production rate restriction. Furthermore, in the NPV case, one further necessary condition for optimality, the distance restriction concerning the proximity between adjacent production intervals, has been derived. In an example this condition has shown to reduce the number of candidate solutions for optimality still further. An algorithm leading to the optimal solution is presented.