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Production Economics 155 (2014) 82–90

Contents lists available at ScienceDirect

**Int. J. Production Economics
**

journal homepage: www.elsevier.com/locate/ijpe

**Economic Order Quantities in production: From Harris to Economic Lot
**

Scheduling Problems

Martin Holmbom 1, Anders Segerstedt n

Industrial logistics, ETS, Luleå university of Technology, SE-971 87 Luleå, Sweden

art ic l e i nf o

a b s t r a c t

Article history:

Received 30 May 2013

Accepted 31 March 2014

Available online 8 April 2014

This article provides a short historical overview from Harris and his Economic Order Quantity (EOQ)

formula to the Economic Lot Scheduling Problem (ELSP). The aim is to describe the development of the

ELSP ﬁeld from the EOQ formula to the advanced methods of today in a manner that suits master and

graduate students. The article shows the complexities, difﬁculties and possibilities of scheduling and

producing several different items in a single production facility with constrained capacity. The items

have different demand, cost, operation time and set-up time. Set-up time consumes capacity and makes

the scheduling more complicated. Idle time makes the scheduling easier but is bad from a practical point

of view since it creates unnecessary costs due to low utilisation of the facility. A heuristic solution

method is used on a small numerical example to illustrate different solution approaches. The solution

method creates a detailed schedule and estimates the correct set-up and inventory holding cost even if

the facility works close to its capacity.

& 2014 Elsevier B.V. All rights reserved.

Keywords:

Economic Order Quantities

Economic Production Lots

Economic Lot Scheduling Problems

1. Introduction

The Economic Order Quantity (EOQ) has been a known concept in

the manufacturing industry for 100 years. Over the years numerous

methods for calculating economic order quantities have been

developed and these methods have become increasingly advanced

as their creators have aimed to solve more intricate problems. One

of these problems is the Economic Lot Scheduling Problem (ELSP)

which is about calculating economic order quantities and constructing a feasible production schedule for several products that are

produced in the same machine or production facility. This may

sound like a trivial problem but it is indeed intricate and even

classiﬁed as NP-hard (Gallego and Shaw, 1997). Due to the complexity of the problem, the reader of ELSP literature must often be wellread in mathematics to fully understand the solution methods and

apply them to real cases. Therefore, this article aims to describe the

development of the ELSP ﬁeld from the EOQ formula to the

advanced methods of today in a manner that suits master and

graduate students. The article focuses on the development of the

EOQ formula and the three main approaches in previous literature

that most ELSP methods are based upon, the common cycle solution,

the basic period approach and the extended basic period approach. To

illustrate these approaches, we solve a small numerical example

n

**Corresponding author. Tel.: þ 46 920491212.
**

E-mail addresses: Martin.Holmbom@ltu.se (M. Holmbom),

Anders.Segerstedt@ltu.se (A. Segerstedt).

1

Tel.: þ46 920492427.

http://dx.doi.org/10.1016/j.ijpe.2014.03.024

0925-5273/& 2014 Elsevier B.V. All rights reserved.

**with our own heuristic method. Using this example, we will show
**

and argue where the research frontier concerning deterministic

ELSP is. We will also show that the traditional inventory holding

cost approximation may not always hold.

The ELSP problem is found in countless practical applications,

e.g. milling of gear houses, painting of metal rolls, welding of rear

axles, painting of truck components, moulding of brackets, paper

production, etc.; reaching from process industries with more

or less continuous ﬂow to work shops. In many cases it is

ﬁnancially beneﬁcial for companies to purchase and run one

ﬂexible high-speed machine capable of processing many types of

items, compared to purchase and run many dedicated machines

(Gallego and Roundy, 1992; Segerstedt, 1999). Hence, many

machines produce more than one item. Typically, such machines

are capable only of processing one type of item at a time, and a

set-up is usually required each time the production switch from

one type to another (Gallego and Roundy, 1992). Thus, the

dominant characteristics of a single-machine multi-item ELSP

system are the following: multiple items are processed; only one

item can be produced at a time; the machine has limited but

sufﬁcient capacity; a set-up is required between the processing of

different items; items may differ in cost structure and require

different machine capacity; backorders are not allowed; Item

demand rates are deterministic and constant over time; set-up

and operation times are deterministic and constant over time;

set-up costs and set-up times are independent of production

sequence; inventory holding costs are determined by the value

of stocks held.

Erlenkotter (1990) explains why the EOQ formula also is known as the Wilson lot size formula and Camp's formula. calculates the cost per unit instead of the cost per time interval (day or year) and includes the set-up cost of the average stock (S/2) 1 S ðCX þ SÞ þ þ C: 240M X ð1Þ Harris states that ﬁnding the order size X that minimises Eq. Segerstedt / Int. which is independent of q and thus constant. The article has the following outline: Section 2 provides a short resume on the early history of EOQ and the Economic Production Lot (EPL). In Section 7 we present the Bomberger problem and provide a complete scheduled solution to it. except when the expression inside the square is zero. For further information about these confusing citations up to the 1970s the reader is referred to Erlenkotter (1990). in a handbook on cost and production. 8–182). that is best from an economic perspective. Grubbströ m (1995) points out that Eq. if the production rate is ﬁnite. in Section 8 we summarise the article and discuss ELSP from a practical point of view. Alford (1934) referenced Camp (1922) for a general formula to determine the EOQ. to the best of our knowledge not presented in the same way before. Suppose that we have a machine that produces three different items. followed by a short review of the literature from Bomberger to present time. q ¼order quantity of the item. I¼ the unit charge for interest and depreciation on stock. (3) we can see that the cost per unit is A q1 C q ðqÞ ¼ þ h : q 2d ð4Þ The resemblances to Harris' equation are h ¼0. The .g. Hence. and Silver et al. can be written as rﬃﬃﬃﬃﬃﬃﬃﬃﬃ!2 rﬃﬃﬃﬃﬃﬃﬃﬃﬃ h 2dA 2Ah q : ð5Þ C q ðqÞ ¼ þ 2dq h d In Eq. the EPL formula is well-known and commonly described in textbooks for undergraduate and graduate students in operations management and logistics. in money units (a ﬁxed cost per order or production lot). We now introduce our own notations that we will use in the rest of the article d ¼demand rate of the item. is CðqÞ ¼ dA q ðκ dÞ þh : q 2 κ ð7Þ The order quantity corresponding to the minimum cost is derived through differential calculus on Eq. The second term. q ¼ κ t.e. through algebraic rearrangements. However. the cost per time unit can be written as a function of q CðqÞ ¼ dA q þh : q 2 ð3Þ From Eq. and he formulates a total-cost function that. 1956. Like the EOQ formula. which is smaller than the order quantity. with production and demand data as in Table 1. (5). Ford Whitman Harris published the ﬁrst ideas about the EOQ in “Factory. B and C. (In the early 1970s the formula was known as the Wilson-formula in Sweden. Erlenkotter (1990)). (8). Bomberger's 10-items problem became a “milestone” concerning ELSP.) Moreover. Sections 4–6 treat the common cycle solution. (1998) use Economic Production Quantity. (3) and the algebraic expression in Eq. corresponds to the lowest possible cost per unit of the order quantity. t ¼ q=κ so the maximum inventory can be written q ðκ dÞ=κ . which coincides with the minimum point of the cost function. was according to Erlenkotter (1990) ﬁrst derived in Taft (1918). d ¼12M and A¼S.M. we let κ be the production rate in units per day and assume that the production is on-going during the time t. A. Different terms for EPL are used by different authors. and since the demand is constant at all time (even during the production) the maximum inventory is ðκ dÞt. W. X¼the unknown order size. Finally. e. A. Harris (1913) uses the following notations: M ¼the number of units used per month. S¼ the set-up cost of an order ($). 2. in units per day. in contrast to most textbooks of today. The Magazine of Management”. (1) involves higher mathematics. Buffa (1969) uses minimum cost Production Order Quantity. the problem has been the test example(s) new suggestions and methods have tried to solve and compete with. the basic period approach and the extended basic period approach respectively. Then. in money units per unit and day. the assumption of the average inventory (q/2) changes since the maximum inventory become less than the order quantity. 3. the ﬁrst term is always positive. In the ﬁrst edition of the “Industrial Engineering Handbook” published by McGraw-Hill (Maynard. Production Economics 155 (2014) 82–90 Bomberger (1966) presents a problem and a solution method from the characteristics of a metal stamping facility producing different stampings on the same press line. But in the next edition of the same handbook another author attributed the EOQ formula to Camp (1922). Holmbom. A¼set-up cost or order cost. Then. The early history of EOQ and Economic Production Lot (EPL) In 1913. Section 3 introduces our small numerical example. However. (5) can be used to derive the EOQ formula rﬃﬃﬃﬃﬃﬃﬃﬃﬃ 2dA qn ¼ EOQ ¼ : ð6Þ h It is not known how Harris ﬁrst derived the EOQ formula but it is an interesting question due to the fact that Harris had limited education in mathematics (cf. 83 h¼inventory holding cost of the item.1C. Harris assumes that the annual interest and depreciation cost is 10%. or lot size. Up to now we have assumed that all replenishments happen instantly. To handle this. Wilson (1934) made the EOQ formula famous when he created and sold an inventory control scheme based on Harris' ideas. (4). Eq. (7) rﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ sﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ 2dA κ 2dA 1 n ð8Þ ¼ q ¼ EPL ¼ h κ d h 1 d=κ This quantity is usually called the Economic Production Lot (EPL) and the formula. i. Harris further continues that “sufﬁce it to say that the value for X that will give the minimum value […] reduces to the square root of 240MS divided by C”. he acted according to the old tradition and did not cite earlier work. J. The average inventory is half the maximum inventory and hence the cost function. C ¼the cost of a unit ($).W. T ¼the manufacturing interval in months. the production rate is inﬁnite. A small numerical example We will now introduce a small numerical example with a single machine and multiple items that we will use throughout this article. Because of that we present the problem and a totally scheduled solution of it. in money units per time unit. who extends Harris EOQ formula by incorporating a ﬁnite production rate. pp. an equation now known as the classic EOQ formula rﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ rﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ 240MS 2 12MS ¼ : ð2Þ C 0:1C Erlenkotter (1990) presents a compilation of early EOQ literature and describes Harris' complete career from a production engineer to a patent lawyer and a founder of a law ﬁrm. both differential calculus on Eq. Hannon correctly identiﬁed Harris' work and Taft (1918).

i. and according to Eq. However. it is not certain that the order quantities will cover the demand during the total time of both production and set-up. An operation time. the cost cannot be reduced any further.e. in money units (depending on chosen frequencies and time interval) Adjusted early start of item i in period j.8696 105 0. 54) state that “It is permissible to study each item individually only as long as there are no interactions among the items”. In this example. According to his conclusions.g. Holmbom. in days. in units per day Set-up time of item i. we assume that there are 14 working hours available per day. during which all items are produced once.….2174 840 10 230 84 0. consider a machine where several items are produced ði ¼ 1. and that “There can be many sorts of interactions among the items”. which only consider one product at the time. qnA ¼ ð2 10:5 500=0:2174Þð1=1 ð0:0119 10:5ÞÞ 235. (9) sﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ 2∑N i ¼ 1 Ai : ð10Þ Tn ¼ N ∑i ¼ 1 hi di ð1 oi di Þ Eqs. as the set-up time is not considered in the EPL formula.5 10 30 500 500 0. depends on the number of working hours available. in money units per production lot Order quantity for replenishment of item i. and do not consider the possibility that the available capacity may be too small to satisfy the required demand. To calculate economic order quantities in a single-machine multiitem system and avoid interferences between the items. T. Hadley and Whitin (1963.e.0714 0. 2. Then. Hence. since two or more items would have to be produced at the same time to avoid demand shortages. NÞ and assume ﬁnite production rates and instant set-ups. in units per day. in this particular example the demand for 230 days can be produced during less than 192 days with set-ups included. which means that we can produce 84 pieces of A in one day if we do not make any set-ups. is also added so that oi ¼ 1=κ i . (8) and (9) are often presented in textbooks to introduce a discussion of cyclic policies (e. Operation time of item i.6957 17 20 30 1000 2000 0. Rogers (1958) discusses the problem of inventory control in a single-machine multi-item system and applies the EPL formula to the items individually. in money units per unit and day Set-up cost for item i. J. we need to handle the items jointly. in which all items can be produced with the chosen frequencies f i (T inf r T min ) Total cost per day.) All notations used in the following calculations are gathered in Table 2. in days per unit Production cycle time. p. in which all items can be produced with frequencies all equal to one The shortest possible production cycle time in days. qnB ¼ 246. di hi Ai qi κi si oi T fi Tinf Tmin C(f. holding cost (money units/day and unit) di o0i s0i Ai ci hi K r D κ i ¼ K=o0i oi ¼ 1=κ i si ¼ s0i =K hi ¼ ci r=D A B C 10. in days per production lot ¼ 1=κ i . However. ….2174 30 8 60 500 1600 0.0357 0. Hence. (An index i is added to distinguish the items. A.6957 42 0. i¼ 1. The problem with such interference between the items is also discussed and illustrated by Brander (2006). This solution is a lower bound. The capacity of the machine. (7) the total cost is ∑i ððdi Ai =qni Þ þ hi ðqni =2Þð1 oi di ÞÞ ¼299. it is usually impossible to construct a feasible production schedule from these calculated order quantities. and qnC ¼ 256.T) tij ii f^ Demand rate for item i. But. Production Economics 155 (2014) 82–90 machine can only produce one item at a time and there is a set-up time that precedes every start of a new item.8696 Table 2 The notations used in this article. the cost per time unit is 0 1 setup cost inventory holding cost zﬄﬄﬄﬄﬄﬄﬄﬄﬄﬄ}|ﬄﬄﬄﬄﬄﬄﬄﬄﬄﬄ{ z}|{ N B d T ðκ i di Þ C B Ai C CðTÞ ¼ ∑ B þ hi i C @ A 2 T κi i¼1 N ¼ ∑ i¼1 Ai dT þ hi i ð1 oi di Þ : 2 T ð9Þ The optimal T that corresponds to the lowest cost is found through differential calculus on Eq. the EOQ and EPL formulas.0119 0. for every set-up) Cost/value (money units/unit) (money units/day and unit) Shift factor (min/day) Interest rate (%/year) Production days (days/year) Production rate (units/day) Actual capacity (days/unit) Set-up time (days) Inv. (8) on the pﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ data presented in Table 1. Table 1 Data for the numerical example. are limited from a practical point of view.40 money units per day. i. oi .0357 0. To calculate the EPL of the items we apply Eq. in production time (days) per produced item i. the number of items that can be produced per day.0238 0.0095 0. They mention items competing for ﬂoor space and investments in inventory. Demand rate (units/day) Machine capacity (min/unit) Set-up time (min) Set-up cost (money units.84 M. maxi f i . those equations only ﬁnd a common cycle length that minimises the set-up cost and inventory holding cost. in units Production rate for item i. before the inventory reaches zero Current inventory of item i The highest frequency used. the number of times that item i is produced during a production cycle T The shortest possible production cycle time in days. in days (time interval in which all items are produced at least once) Frequency. Segerstedt / Int.2. for a common time interval.N Inventory holding cost of item i. Nahmias (2009) and Segerstedt (2009)).

since facilities and workforce cost money even during idle time (cf.564 3. During each cycle the machine is idle for 12.1 1. the production of item i is repeated every T i units of time. A.1428 10. (10) and (12) are combined to ﬁnd the cycle time that corresponds to the lowest cost T n ¼ max sﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ ! 2∑N i ¼ 1 Ai . was introduced in Table 3. and he introduces an item-speciﬁc cycle time. the ratio between setup cost and inventory holding cost of each item should be as close to 1 as possible. 2. By making the ratios close to “1” we can expect to ﬁnd a solution close to the lower bound solution (calculated from Taft's EPL formula) in which the ratio is equal to 1 for all items. the frequency of item A can hardly be reduced since it is equal to 1. J. 1.0357 1. TÞ ¼ ∑ i i þ hi i ð1 oi di Þ : 2f i T i ∑ðsi þ oi di TÞ r T: ð11Þ i Eq. T inf ∑N i ¼ 1 hi di ð1 oi di Þ ð13Þ and the optimal order quantities are calculated from qni ¼ di T n . which is the number of times that the item is produced during T. Brander and Segerstedt (2009)). so instead we increase the frequency of items B and C to 2. item A would probably beneﬁt from less frequent production than items B and C. which is 9. Bomberger constrains the cycle times T i to be integer multiples ki of a basic period. With different frequencies for different items the total cost function (Eq. However.22 0. the cycle time. T. and he restricts the basic period to be large enough to accommodate production of all items once.049 5. According to Eqs. Thus. (14) is the total set-up cost and the second part is the total inventory holding cost. and it allows the items to be produced with different frequencies.88 212. from a practical point of view it seems strange to let the machine be idle for approximately 1/6 of the total time.085 80. We will come back to the use of f i later in this article. We use the method presented in Holmbom et al. However. Each time the cycle is ﬁnished it immediately starts over again.32 320. and si and oi would increase to such extent that no positive T could satisfy Eq. The common cycle solution to the numerical example is presented in Table 3 and illustrated in Fig.2 0.32 160. Since the ratio of item A is large. where we deﬁned it as the number of times that an item is produced during the cycle time T. holding cost/day (5) þ(6) Σ qni ¼ di T n =f i Ratio: (5)/(6) 1/Ratio: 1/(9) B 1 0.16 54. With different frequencies for different items the cycle time. According to Bomberger's restriction. The solution method guaranties feasible solutions in the sense that the production can be scheduled without interferences and that the machine capacity is sufﬁcient. it is presented in Table 4 and illustrated in Fig.16 days. Tb. since the capacity would become too small to meet the demand. Thus.32 1 0.0 3. Notice that qi ¼ di T=f i .M. The main principle of that method was ﬁrst developed by Segerstedt (1999). The principle is to reduce the total cost by ﬁnding an even balance between the set-up cost and the inventory holding cost of each item. Bomberger in 1966 when he presented his 10-item problem instance that has been cited extensively in the literature ever since. We assume that the inventories are replenished immediately after they become empty. The total set-up cost per day is calculated from ∑i f i Ai =T n and the total inventory holding cost per day is calculated from ∑i hi ð1 oi di Þdi T n = ð2f i Þ. (11). This new solution corresponding to a new set of frequencies (1. T i . The total cost is 320. When there is much idle time it could be a good idea to reduce the number of shifts per day and thus reduce the available production time.27 money units less than the total cost of the common cycle solution. the shortest possible time where the expected demand rates can be satisﬁed is Σ C 1 0. and that the ﬁrst part in Eq.0714 3. must be large enough to cover the set-up and operation times for all items of the demand during the cycle Hanssmann's article about the common cycle solution from 1962 was followed by a large amount of articles that treated similar problems.43 2.0357 5. Probably the most wellknown ELSP publication was made by Earl E. A (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Frequency: f i Set-up time: f i si Operation time: oi di T n (2) þ(3) Σ Set-up cost/day Inv.315 160.172 10. (11) can be rearranged to ﬁnd the shortest possible cycle time T inf ¼ ∑i si : 1 ∑ i oi di ð12Þ Eqs. Bomberger (1966) uses dynamic programming to calculate order quantities. with given frequencies.46 131. which would increase the order quantity of item A and hence reduce its ratio.98 374. (9)) becomes f A dT ð14Þ Cðf. To illustrate the basic period approach we return to our numerical example (in Table 1). f i . In Table 3 we have introduced a frequency. f i . 2) and a new calculated cycle time T n that minimises the total cost. (12) and (13) T inf ¼ 0:77 and T n ¼ 12:475.64 ∑i f i si ¼ 1:35 1 ∑i oi di ð16Þ and consequently the time corresponding to the lowest cost. is 2∑i f i Ai .37 money units per day. This solution method was showed by Hanssmann (1962) and is known as the common cycle solution. the basic period must be . T min ¼ 22:48: ð17Þ T n ¼ max ∑i hi di ð1 oi di Þ=f i The total cost is 311.475 10. 2. The common cycle solution 5.635 40. T. so that T i ¼ ki T b . must be large enough to cover the set-up and operation times for all items of the demand during the cycle ∑ðf i si þ oi di TÞ r T: ð15Þ i Table 3 The common cycle solution of the numerical example.08 92. The basic period approach To take both capacity constraints and interferences between the items into account.08 12.595 40. If we look at the common cycle solution in Table 3 we can see that the largest ratio or inverted ratio (lines 9 and 10 in Table 3) belongs to item A. and the inventory would therefore increase with every cycle.46 0. But in this particular example it is not possible to reduce the number of shifts from two to one (K¼ 420). The idle time is necessary since the output per day would exceed the demand rate if the machine would run non-stop. B and C are produced during a common cycle that is repeated successively. we assume that the items A.68 T min ¼ 0.559 1.31 Therefore. Segerstedt / Int. Production Economics 155 (2014) 82–90 85 4.64 money units per day. Holmbom. Bomberger's extension of the common cycle solution is called the basic period approach. Thus. which we now know as ELSPs. which is the time from one production start of the ith item to the next production start of that item. The frequency. (2013).315¼ 2.

all items can be produced during the basic period and the restriction is fulﬁlled. (19) is.69 311.01 Σ C 2 0. In the extended basic period approach Bomberger's restriction on the basic period is relaxed so that the “period” only must cover the average set-up times and operation times of all items (Stankard and Gupta.171 88.846 22. (2013).99 1. But Eq. a detailed production schedule is created. The solution in Table 4 is the best basic period solution our method can ﬁnd. By reworking Eq. the solution that was infeasible with the basic period approach is now feasible.171/2 E10. The common cycle solution. 1973. Thus T n ∑i ðf i si þ oi di T n Þ Z : f^ f^ ð19Þ Cðf. Holmbom et al. item B requires 8. our method here ﬁrst decides the frequency of each item and then calculates the optimal cycle time. In this case the basic period is 22. This is the best extended basic period solution that can be found with the current method.566/2 þ 9. Second.583 155.810 2. Therefore an extra inventory holding cost is created.71.109 days of the total 29. Production Economics 155 (2014) 82–90 Fig. if we increase the frequency of item B one step (i. A.45 0. However. Unlike Bomberger's method. J.e.24 22. The schedule of the solution in Table 5 is presented in Table 6 and illustrated in Fig. Doll and Whybark.27 money units less than the cost of the common cycle solution.78 337.333 18. since the costs are unchanged. Therefore.250 18.201 days and item C requires 12. holding cost/day (5)þ (6) qni ¼ di T n =f i Ratio: (5)/(6) 1/Ratio: 1/(9) B 1 0. 1969. T n =f^ . Observe that the machine is idle during 5. The idle time and early .45 236. Thus.56 large enough to accommodate production of all items once.816 (Eq. The extended basic period approach According to Table 4 and to the largest ratio or inverted ratio.1 1. The total cost is 1.24. Holmbom. The inequalities force the production of item B and item C to start before the inventories reach zero to avoid shortages. must satisfy Tn o d Tn Z ∑ si þ i i ð18Þ fi f^ i where f^ ¼ maxi ðf i Þ.48/2 ¼11.805/4¼2. To ﬁnd a better solution we need to consider another approach. the schedule would be like Table 7. time schedule and the inventory of item B. A (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Frequency: f i Set-up time: f i si Operation time: oi di T n (2)þ (3) Set-up cost/day Inv.070¼8.37 191. and the basic period. (17)). and hence the real total cost is more than the 301.48 83. Early starts are necessary for item B in periods 1 and 3. Elmaghraby. and the time for producing all items once is 2. the same as for the common cycle solution. The “optimal” cycle time and the economical frequencies are still the same. The early starts depend on the difference between the actual period length and the theoretical period length if all periods would have been equal. In two of the four periods both item B and item C needs to be scheduled and therefore those periods must be at least 2. The extended basic period solution is presented in Table 5. Hence.143 6. the machine is idle during 17% of the total time. (2013)) 6. Segerstedt / Int. The set-up times in the numerical example are relatively short. (19) we end up with the same restriction on the cycle time as we presented in Eq.846 þ6. fB ¼4.85 money units shown in Table 5. in contrast to Eq.88 2 0. will not fulﬁl Eq.070 days.140/2¼ 6. The production of item A requires 3.100 9.566 44. If they are multiplied with a factor 4 to 2 h for item A and C and 4 h for item B.816 days to keep the inventory levels stationary over time. (18). ﬁrst ﬁnding a basic period and then deciding the frequency of each item. (15).80 0. However. which is longer than T n =4 7:45. With the extra inventory the total cost becomes (cf.271 days.69 155. 1978).2 0. If all periods have the same length there is no extra inventory and the preliminary cost estimation in Table 5 is correct. the basic period is a result of the chosen frequencies and the calculated optimal cycle time. (18). Bomberger solved the problem with dynamic programming. 1. T n =4 7:46.763 days. Thus. Hence. it might be preferable to increase the frequency of item B. Hence.423 6. How to calculate the extra cost is described in Holmbom et al. When we cannot schedule the production in equally long periods the traditional inventory holding cost approximation and the cost calculations in Table 5 does not hold (cf. Table 4 The basic period solution to the numerical example. Haessler and Hogue.036 2.96 49.53 1. and 10.1 0. (16)) and T n becomes 29.071 9. Nilsson and Segerstedt (2008)). relaxing the period length restriction gives us a new problem. the basic period. 3. the potential “early starts” are calculated. T n Þ ¼ ∑ i ^ f dt f i Ai di T n i ij ð1 oi di Þ þ hi ∑ n þ hi 2f i T j ¼1 fi ! ¼ 310:37: ð20Þ The extra inventory cost is ∑i hi ∑j ðdi t ij =f i Þ ¼ 8:53 money units per day. satisfactory even if we increase the frequency of item B to “4” as we discussed earlier.201þ6. 1976.00 money units less than the cost of the basic period solution. all four periods cannot be equally long.13 (Eq. using a power-of-two policy justiﬁed in forthcoming Section 7) T min becomes 2. First. The scheduling procedure aims to make the four periods as equal as possible.86 M.

Goyal (1975) and Segerstedt (1999). If we assume a complementary facility cost of 300 money units per hour (5 MU/min.56 67. In that respect it is quite surprising that the production of all items ﬁt into 8 equal periods.271 4.140 65.475 4200þ 12.64)/ 12.4 0.069 12.21 0.817 2. Production Economics 155 (2014) 82–90 87 Fig. ci . Table 5 The extended basic period solution to the numerical example. delays and more work in process (WIP).673 6. we end up with a .6 0.37 MU/day.98 1.475¼4200 þ320. but too high utilisation will transform the process to a bottleneck (cf.M.08 223.315 24.78 0. and hence many small pieces of the puzzle to put together. and in the common cycle solution of this modiﬁed example the idle time is 14%. it is ﬁnancially beneﬁcial to produce the demand with a minor K given that T inf is larger than zero but not too large (approximately o15). (Segerstedt (1999) contains another printing mistake concerning hi .201 Early start – 6. so it is surely a printing mistake.1175 instead of 0.908 23.286 8. The ﬁrst comment may be in Cooke et al. the original article contains a printing mistake where c2 is presented as 0. still a better solution than the common cycle solution. Hence.77 313. The common cycle solution that Bomberger presents in the same article.92 150. high delivery precision and short throughput times. holding cost/day (5) þ (6) qni ¼ di T n =f i Ratio: (5)/(6) 1/Ratio: 1/(9) B 1 0.696 (30 1.036 3. In the Bomberger problem the utilisation is high and the machine is idle only during 4.816 starts have changed and the total cost is now 301.436 6. we will here present a scheduled solution to it. Hopp (2011)) and create costs such as queuing. The Bomberger problem is presented in Table 8. Production B Production C Production A Idle: Period 1 Early start Period 2 2.02 Table 6 The schedule of the extended basic period solution. The shift factor will not inﬂuence the frequencies.000 8. The basic period solution.708 150.64¼ 4520.727 3.56 Σ C 4 0. High utilisation is preferred from a total cost perspective.201 0. A. multiplied with 0.92 301.271 Early start – 0.271 length Equal 7.64 MU/day.454 length – Period 3 Early start Period 4 2.115/4)¼ 313. The holding cost per unit and day. Holmbom. The shift factor.201 0.071 12.763 29.070 – Cumulated: Actual 8.08 2 0. The machine is idle during 13% of the time.1775.1 (inventory interest rate) and divided by 240 (days per year) (cf. (2004) but unfortunately some earlier published articles are based on the wrong numbers. 7.179 29. T ¼ 41:17. (2013) method strictly. J. but it seems like no one commented upon it. Bomberger (1966)).201 6.78 16. a signiﬁcant cost reduction can be achieved if it is possible to produce the demand in fewer hours and thus in fewer shifts per day. can only be replicated if c2 ¼ 0:1775.817 2. We have inverted the production rates in the Bomberger problem to “capacity” ðoi ¼ 1=κ i Þ.908 22.519 8.475 320.1 1.85þ2 0. Unfortunately. It can perhaps partly be explained by the fact that there are many different items to schedule.036 24.805 55. For the extended basic period solution the increase is 4200 þ 310. and thus we do not need to consider any early starts or extra inventory.37 ¼4510.475 4200 þ 12. beginning with the item that has highest frequency and longest production time. The schedule in Table 10 cannot be found if we apply the scheduling rules of the Holmbom et al. the overall total cost of the common cycle solution increases to (12. is the variable that creates costs.85 253. time schedule and the inventory of item B.6% of the time. too high utilisation must be avoided to facilitate short delivery times. The items are scheduled in descending order according to (1) frequency and (2) production time.362 29. K. The Bomberger problem Due to the importance of the Bomberger problem instance in this research ﬁeld. hi . The Bomberger problem is possible to schedule in 8 equal periods.) Table 9 shows the best known solution to the Bomberger problem found by Doll and Whybark (1973).637 14. In cases where the idle time is large.637 0. is calculated from an original labour and material cost per unit. see Table 10. Segerstedt / Int. Thus. the economical frequencies only depend on the set-up costs and inventory holding costs.816 14.070 – 3.000 8. If we follow that allocation method strictly. 4200 MU/day) independent of the machine is idle or not.763 0. 2. A (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Frequency: f i Set-up time: f i si Operation time: oi di T n (2) þ (3) Set-up cost/day Inv.59 67.49. In the early 1970s the printing mistake must have been known.83 1.

667 10 5 0. Among the more recent publications are Khoury et al. then period 4 contains 23. The total cost per day increases from 32. or the . Remanufacturing is a production and problem area where ELSP is also applied.313 10 5 1600 7500 1.637 0. 2010).0400 1.392 – 3.07 to 32.000 10 4 0. 5 and 7 instead of periods 2.333 10 4 0.115 – Early start – 2. Zipkin (1991).250 10 4 0. Tang and Teunter (2006).692 10 4 0.333 10 5 0.177 1. 5 and 7.g. (2004) and Yao (2005).9000 2. Goyal (1973. Elmaghraby (1978). Item i 1 2 3 4 5 6 7 8 9 10 di κi oi Si Ai ci hi 400 30.458 10 3 340 2000 5.9000 3. The allocation method can be modiﬁed with complementary scheduling rules to ﬁnd the exact schedule shown in Table 10.09%. (2013) who summarise the ELSP research during the last 15 years (1997–2012).667 10 4 0. Zanoni et al.053 10 4 0.392 Table 8 The Bomberger problem (time unit: days). the ratio between the set-up cost and the inventory holding cost of each item should be as close as possible to “1”.000 8. In such situations the EOQ and EPL formulas do not guarantee that the order quantities will cover demand. They argue that the “power-of-two policy”.177 Early start Period 4 1.1775 7.947 6.816 29. time schedule and the inventory of B. with longer set-up times. Segerstedt (2004) shows that the same principle can be extended to several machines and multi-level production.667 10 5 slightly different schedule where all periods are not equal. (From a practical point of view the cost difference is negligible.25 30 0.1000 4. of the basic period.167 10 4 1 310 1.88 M.077 6. 2007) and the One Warehouse N-retailer Problem (Abdul-Jalbar et al. We have also discussed the limitations of these formulas when many different items are produced in the same machine. 4. If we put item 10 in periods 1. Some well-known references.50 110 2. A.569 7. þ0.0065 2. 3.750 10 4 400 15.) After Bomberger's publication many researchers and authors have made different contributions to the ELSP area.392 6.10.115 – Idle: 0. The extended basic period solution. A recent review is made by Chan et al.250 10 4 340 1300 7. are Doll and Whybark (1973).816 Cumulated: Actual length Equal length Period 2 Early start 2.5 130 5..708 10 6 400 8000 1. This is because the method suggests that item 10 should be scheduled in periods 1.g.477 22. Table 7 The extended basic period solution.. Segerstedt / Int. Teunter et al. 3.66 days of production. the Joint Replenishment Problem (Nilsson et al. 1975).000 8. Elmaghraby (1978) presents an overview of earlier research.870 – Period 3 2. which is required to achieve period equality. 6 and 8.7850 1. is a requirement for achieving schedule feasibility in practice. Haessler and Hogue (1976).75 200 0.908 14. Lopez and Kingsman (1991) make a review and compare different solution methods.125 10 0.637 8. (2001).125 20 0.125 5 0. Hsu (1983).000 6.5000 6. (2009) and Zanoni et al. 8.908 23.000 3. Axsäter (1987).000 10 4 0.115 10 4 24 2400 4.160 10 3 80 6000 1. Yao and Elmaghraby (2001) also show that the power-of-two policy simpliﬁes the construction of feasible cyclic schedules. which in turn force items 8 and 4 to start 0.569 3.167 10 5 80 2000 5. e. (2004).392 6.569 0. Holmbom.25 50 0. Period 1 Early start Production B Production C Production A 2.1275 5. Production Economics 155 (2014) 82–90 Fig.125 15 0.396 10 5 800 9500 1.2675 1.454 14. (2012) use the same principle as shown in this article. Gallego and Roundy (1992) and Bourland and Yano (1997). We have discussed the early history of EOQ and EPL and showed the related formulas. some already mentioned. The same principle has also been applied to other problems than ELSP with good results. J.24 days early. (2012). Summary and practical implications The aim of this article was to describe the development of the ELSP ﬁeld from the EOQ formula to the solution methods of today.362 29. Cooke et al. e. Soman et al. 3.

86 8.425 22.374 1.197 2. set-up times and operation times are often stable but expected demand rates can change.10 2. The set-up time is sometimes dependent of the sequence of the production.37 money units. Time-varying lot sizes are not compatible with philosophies such as lean production that strives to eliminate all kinds of variation and promotes standardised working routines.64 (the common cycle solution) to 311. with inspiration from Leachman and Gascon (1988).197 2. during the total time of both production and set-up.85 as the traditional inventory holding cost approximation suggested.336 0.374 6. e.39 6. with this relaxed restriction there is no guarantee that the periods will be equally long and therefore the production of some items must start before the inventory is empty.160 1.40 16.M.626 5.40 day.425 23.160 1.40 Holmbom et al. In a practical situation it is sensible to have a production schedule that is repeated at regular time intervals to create a production pattern.121 8.55 7. which can enable better utilisation of the capacity and less idle time. This production schedule was further improved when we used the basic period approach to solve the example. but it can be handled by creating a schedule based on the average set-up time. A.498 22.91 5. which is a bit awkward and cumbersome time frame. The basic period approach allows the items to be produced with different frequencies. the cost calculation depends on the scheduling and requires a solution method that creates a detailed production schedule. the extended basic period solution came closer to the lower bound solution on 299.374 0. However.962 1.265 23.265 23. Item i 1 2 3 4 5 6 7 8 9 10 fi Tn si þ oi di T n =f i f i Ai =T n hi ð1 oi di Þdi T n =ð2f i Þ 1 4 4 8 4 2 1 8 4 4 2.04 16. a signiﬁcant difference that previous ELSP literature has paid little attention to.468 0. However. (2013) is easy to adapt to different time intervals. die-casting of plastic products (the set-up time is shorter if the item has the same colour as the previous produced item) or manufacturing of pinions and gears (the set-up time is shorter if the item has the same module or the same size of the gear tooth as the previous item). a decision rule can be based on the current inventory.874 1.715 3 6. Holmbom. while items with low demand and frequency (produced once per sixth month or less) can be scheduled in a buffer every period. Hence.425 2. (2002).07 Table 10 The extended basic period solution to the Bomberger problem.41 2. which will lead to a higher average inventory.463 23. In practical situations the scheduling may be done explicitly for the items with the highest recommended frequencies.121 4.626 5.121 8 6. (2005) show that deterministic models can be used even if the demand is stochastic.960 0.40 (derived from the EPL formula) then the common cycle solution and the basic period solution.160 1.500 2.425 22.48 1.425 22.160 1.425 capacity will be enough. Production Economics 155 (2014) 82–90 89 Table 9 The best known solution to the Bomberger problem. further develop such decision rules.03 32.468 2.197 2. Levén and Segerstedt (2007).374 2. it should be produced in the current period.626 5.23 8.715 4. Therefore.374 1. For example. They emphasise the importance of rules to decide whether the production should start or not. J. Dobson (1987) and Moon et al.374 5 6.121 8. if the inventory of an item does not cover expected demand until the next possibility to produce the item. and if the demand changes over time there is a risk for obsolete overstock.626 5. In our example the basic period approach reduced the total cost per day from 320. The method of 21.61 2.425 178.465 23.35 2.37 money units/day.265 23.g. Therefore a too long cycle time should be avoided.374 1. But despite that extra inventory holding cost. With the common cycle solution we computed a feasible production schedule for a small numerical example with three items. The cover time.374 1.715 4.121 4 6. even though time-varying lot sizes work satisfactory in theory there may be considerable practical disadvantages such as variations in the material supply and inventory ﬂoor space. Segerstedt / Int. In the solution of the Bomberger problem the schedule would be repeated every 187.54 187.089 23.468 2.121 0.715 4.27 2.64 0.626 5. can be used to prioritise the items to avoid shortages.715 4. In the extended basic period approach the restriction on the “period” is relaxed.43 0.43 0.874 21.65 1.626 5. Therefore the ELSP analysis and calculation must be done regularly. and not 301.66 4. Brander et al. In a practical situation everything is not deterministic.623 0.626 5.121 8.626 5.500 0.374 1. The cost of the extended basic period approach solution was shown to be 310. The model presented here does not explicitly consider sequence dependent set-up times.626 5.g.463 23.425 22. which often can be costeffective.468 2.197 2.265 23. This cost was even further reduced when we applied the extended basic period approach.11 0.468 2. ii =di . The production of items 7 and 3 would almost cover the demand of a whole year. where ii is the current inventory of item i.08 0. Item Period 1 8 4 9 3 2 5 10 6 7 1 Σ Idle ΣΣ 2 6.121 6 6.15 187.09 1. we had to consider the items jointly and we introduced the common cycle solution.121 8.53 0.374 1.197 0. This may be an explanation to the larger .500 7 6.962 1. Time-varying lot sizes have been studied and suggested by e.

Soman. (Ed.. Sci. 42 (1).. 2008. Int. This work has been supported by Kolarctic Project. Holmbom. Hanssmann. A computational approach to the economic lot scheduling problem. D. New York.. S. M. An application of cyclical master production scheduling in a multi-stage. Roundy. S. C. 147–164.. 729–739. Analysis of Inventory Systems. van den Broecke. 2002. Hybrid genetic algorithm for the economic lotscheduling problem. Comput. 2011. Silver. Sci. Oper. Prod.. 2005. Res.. F. Appl. New York.. Production Economics 155 (2014) 82–90 interest for ﬁxed order quantities. Yano.. stochastic demands..-L. Gallego. E. single-machine production systems with timevarying. J. G. Malmö (in Swedish). New York. 4 (3). 35 (5). Int. 179–189. J. Dobson. 1141–1154. P. R. 796–809. Taj.E. 2004. 6th ed. 193–205. 265–272. 2004.. O...E. J.K.. W. L.). 13 (5).F.. Harris. J. 41 (10–11). Oper.. 487–493. J.. Hadley.L. Mag.. 1973. How many parts to make at once. IIE Trans. Res. 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