Lot sizing with learning and forgetting in setups: Analytical results and insights

This article considers the dynamic lot sizing problem when there is learning and forgetting in setups. Learning in setups takes place with repetition when additional setups are made and forgetting takes place when there is a break between two successive setups. We allow the amount forgotten over a break to depend both on the length of the break and the amount of learning at the beginning of the break. The learning and forgetting functions we use are realistic. We present several analytical results and use these in developing computationally efficient algorithms for solving the problem. Some decision/forecast horizon results are also developed, and finally we present managerial insights based on our computational results. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 93–108, 2016

[1]  Suresh P. Sethi,et al.  Forecast, Solution, and Rolling Horizons in Operations Management Problems: A Classified Bibliography , 2001, Manuf. Serv. Oper. Manag..

[2]  I. Steedman SOME IMPROVEMENT CURVE THEORY , 1970 .

[3]  Huan Neng Chiu,et al.  Discrete time-varying demand lot-sizing models with learning and forgetting effects , 1997 .

[4]  Ali Allahverdi,et al.  The significance of reducing setup times/setup costs , 2008, Eur. J. Oper. Res..

[5]  Jeffrey D. Camm,et al.  Capacitated lot sizing under setup learning , 1994 .

[6]  Maurice Bonney,et al.  Lot sizing with learning and forgetting in set-ups and in product quality , 2003 .

[7]  Shlomo Globerson,et al.  Incorporating Forgetting into Learning Curves , 1987 .

[8]  J. R. De Jong,et al.  THE EFFECTS OF INCREASING SKILL ON CYCLE TIME AND ITS CONSEQUENCES FOR TIME STANDARDS , 1957 .

[9]  T.C.E. Cheng,et al.  AN ECONOMIC PRODUCTION QUANTITY MODEL WITH LEARNING AND FORGETTING CONSIDERATIONS , 1994 .

[10]  Suresh P. Sethi,et al.  A Dynamic Lot Sizing Model with Learning in Setups , 1990, Oper. Res..

[11]  Avraham Shtub,et al.  Learning and forgetting industrial skills: An experimental model , 1993 .

[12]  Salah E. Elmaghraby,et al.  Economic manufacturing quantities under conditions of learning and forgetting (EMQ/LaF) , 1990 .

[13]  Robert E. Ployhart,et al.  Learning by Doing Something Else: Variation, Relatedness, and the Learning Curve , 2003, Manag. Sci..

[14]  C. Bailey Forgetting and the learning curve: a laboratory study , 1989 .

[15]  Suresh Chand,et al.  Lot sizes and setup frequency with learning in setups and process quality , 1989 .

[16]  David A. Nembhard,et al.  An empirical comparison of forgetting models , 2001, IEEE Trans. Engineering Management.

[17]  Evan L. Porteus Investing in Reduced Setups in the EOQ Model , 1985 .

[18]  Ram Rachamadugu,et al.  PERFORMANCE OF A MYOPIC LOT SIZE POLICY WITH LEARNING IN SETUPS , 1994 .

[19]  Jason Chao-Hsien Pan,et al.  The Learning Effect on setup Cost Reduction for Mixture inventory Models with Variable lead Time , 2008, Asia Pac. J. Oper. Res..

[20]  James E. Ward,et al.  Effect of Learning and Forgetting on Batch Sizes , 2011 .

[21]  Michal Tzur,et al.  Learning in setups: analysis, minimal forecast horizons, and algorithms , 1996 .

[22]  T. P. Wright,et al.  Factors affecting the cost of airplanes , 1936 .

[23]  Henry Mintzberg,et al.  Strategy Formulation---Introduction to a Grouping on Strategy Formulation , 1978 .

[24]  Sven Axsäter,et al.  A Note on EMQ under Learning and Forgetting , 1981 .

[25]  Ram Rachamadugu,et al.  Optimal and heuristic policies for lot sizing with learning in setups , 1995 .

[26]  T. Morton,et al.  The Effects of Learning on Optimal Lot Sizes: Further Developments on the Single Product Case , 1985 .

[27]  Huan Neng Chiu,et al.  DETERMINISTIC TIME‐VARYING DEMAND LOT‐SIZING MODELS WITH LEARNING AND FORGETTING IN SETUPS AND PRODUCTION , 2003 .

[28]  Huan Neng Chiu,et al.  An optimal algorithm for solving the dynamic lot-sizing model with learning and forgetting in setups and production , 2005 .

[29]  Maurice Bonney,et al.  Production breaks and the learning curve: The forgetting phenomenon , 1996 .

[30]  E. C. Keachie,et al.  Effects of Learning on Optimal Lot Size , 1966 .

[31]  Ezey M. Dar-El,et al.  A dual-phase model for the individual learning process in industrial tasks , 1995 .