Optimal control of an inventory-production system with state-dependent random yield

Abstract

In this paper we study a single stage, periodic-review inventory problem for a single item with stochastic demand. The inventory manager determines order sizes according to an order-up-to logic and observes a random yield due to quality problems in the production. We distinguish between two different states of the production process combined with different probabilities to produce a defective unit. In order to improve the production process, periodic inspections are conducted and in case of a failure the machine is repaired. Approximations are developed to evaluate the average cost for a given order-up-to level and a given inspection interval and we illustrate the existence of optimal policy parameters. The approximations are tested in a simulation study and reveal an excellent performance as they lead to near optimal policy parameters. Moreover, we decompose the problem and test different methods to compute the policy parameters either sequentially or separately. Our results show that a joint optimization of the inventory and maintenance policy leads to a better system performance and reduced costs.