Optimal Inventory Policies for Assembly Systems Under Random Demands 1: In Long-Run Balance, an Assembly System Has the Optimal Policies of an Equivalent Series SystemResearch Paper
Motivation
An assembly system must coordinate the production of components that meet at a common downstream item. A shortage of any required component can delay the finished product, while producing a component too early incurs holding cost. In Rosling's 1989 study, the central question is whether optimal decisions for such a tree can be understood using the simpler theory of a pure series inventory system. The paper proves an equivalence when the initial inventory positions are in a condition it calls long-run balance. That equivalence gives a precise route from an assembly network to serial inventory control without discarding its lead times or its discounted costs.
Setting
There are items in a tree rooted at end item . Every item has one immediate successor ; one unit of each component is needed for an end unit. Let be the production or delivery lead time of item . The total lead time is the sum of lead times on the path from to the end item, with , and the equivalent lead time is . Items are indexed so that is nondecreasing. These definitions and indexing conditions are in §§1–2 of the paper.
At the beginning of each period , outstanding orders arrive, the controller chooses the post-order echelon position , and then demand for the end item occurs. The pre-order position is , while is the position of predecessor from orders old enough to arrive after its lead time. A decision is feasible when for every immediate predecessor of . Decisions depend only on demands already observed. The demands are independent and identically distributed, nonnegative, and have a density and a finite positive mean.
The discounted Problem P charges echelon holding cost for item and a shortage coefficient for the end item. Its discount factor is . The objective is the expectation of the sum over periods of the holding charges and the expected end-item shortfall over demands, with a constant independent of the policy. The paper's Assumption requires every and . The system is in long-run balance in period when positions of adjacent items, compared at the same age relative to total lead time, satisfy equation (5):
Formalization targets
Equivalent series optimal policies
The equivalent series system has successor , lead time , the same demand law and shortage coefficient, and holding coefficient . Theorem 2 states that its optimal policies and those of the assembly system agree when the assembly system is initially in long-run balance. In the formal statement, the first inclusion is unconditional; the reverse inclusion is conditional on Problem P attaining an optimum:
The target includes Lemmas 1 and 2, Theorem 1, Corollary 1, and the cost identity displayed in the proof of Theorem 2. Lemma 1 limits excess production, Lemma 2 gives a production lower bound, Theorem 1 describes when long-run balance is reached and preserved, and Corollary 1 uses the adjacent series position in that result. Each is stated at the strength given on pp. 568–569 of the paper.
Significance
Theorem 2 identifies the same policy choices in a tree assembly problem and a series problem whose stages have modified lead times and holding coefficients. It makes the serial interpretation exact for initially balanced systems and supports the paper's later discussion of series-system calculations. The statement is an equivalence of optimal policies, rather than just an equality of numerical values, so both the feasible-policy comparison and the cost comparison matter.
The theorem and its supporting results are proved in the 1989 paper; they have not been machine-checked in this development. A complete formalization would supply a reusable account of finite-history inventory policies, random demand histories, echelon positions, and extended-real discounted objectives. The published serial model SupplyChainTheory_multiechelon represents a different stage-indexed system; the assembly tree, its initial pipeline, and Problem P still need their own definitions. The paper's order-up-to Corollary 2 relies on an extension of earlier serial results and is outside this target.
Difficulty
The first natural comparison is to replace the tree's predecessor constraints with adjacent-item constraints. Those feasible sets are not equal for arbitrary states: positions at different total lead times can cross, and initial orders placed before period 1 affect the earliest periods. Long-run balance controls the necessary position comparisons, but equation (5) is empty for an item with . The printed proof also uses a middle inequality outside the range covered by equation (5) when an equivalent lead time vanishes. A faithful statement must account for these boundary cases without defining the series problem through the assembly problem's optimal policies.
Formalization scope
Items use the paper's indices , with and . Lean period is paper period ; the policy sees exactly earlier demands. The common demand law is a probability measure on the reals, concentrated on nonnegative values, absolutely continuous with respect to Lebesgue measure, integrable, and of positive mean. The law of demand over periods is the pushforward of a finite product law under summation. Feasibility and the optimal-policy bounds are almost-sure statements, so changes on null histories do not alter them. Pathwise balance results quantify over one nonnegative demand path.
Initial positions include the orders placed before period 1. Their ages are monotone and obey the predecessor constraints inherited from that past. In addition to the paper's initial long-run balance, a separate boundary condition carries the missing comparison when . Discounting is restricted to : at the paper specifies average cost through a separate limiting prescription. The formal cost lies in the extended reals and is computed from its positive and negative parts; under the Assumption, feasible policies have a finite negative part. The policy-independent constant of equation (2) is omitted from both systems. “Optimal” means feasible and no more costly than every feasible policy, never a default value of an empty infimum.
The series system is built as a second instance of the same model, using the paper's successor, lead-time, and holding-coefficient transformations. Its cost and constraint (3) are then computed by the shared definitions. Contributions toward the lead-time identities, almost-sure policy comparisons, finite-time balance theorem, and extended-real cost identity are all part of the scope.
Selected references
- Kaj Rosling, Optimal Inventory Policies for Assembly Systems under Random Demands, Operations Research 37(4):565–579, 1989. DOI: 10.1287/opre.37.4.565.