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Applying simheuristics to minimize overall costs of an MRP planned production system

Abstract

Looking at current enterprise resource planning systems shows that material requirements planning (MRP) is one of the main production planning approaches implemented there. The MRP planning parameters lot size, safety stock, and planned lead time, have to be identified for each MRP planned material. With increasing production system complexity, more planning parameters have to be defined. Simulation-based optimization is known as a valuable tool for optimizing these MRP planning parameters for the underlying production system. In this article, a fast and easy-to-apply simheuristic was developed with the objective to minimize overall costs. The simheuristic sets the planning parameters lot size, safety stock, and planned lead time for the simulated stochastic production systems. The developed simheuristic applies aspects of simulation annealing (SA) for an efficient metaheuristic-based solution parameter sampling. Additionally, an intelligent simulation budget management (SBM) concept is introduced, which skips replications of not promising iterations. A comprehensive simulation study for a multi-item and multi-staged production system structure is conducted to evaluate its performance. Different simheuristic combinations and parameters are tested, with the result that the combination of SA and SBM led to the lowest overall costs. The contributions of this article are an easy implementable simheuristic for MRP parameter optimization and a promising concept to intelligently manage simulation budget.

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Applying simheuristics to minimize overall costs of an MRP planned production system

Author: Seiringer, Wolfgang,Castañeda Jiménez, Juliana,Altendorfer, Klaus,Panadero Martínez, Javier,Juan, Angel A.
Publisher: Multidisciplinary Digital Publishing Institute (MDPI)
Year: 2022
DOI: 10.3390/a15020040
Source: https://upcommons.upc.edu/bitstream/2117/384637/1/mrp.pdf


Ci a ion: Sei inge , W.; Cas aneda, J.;
Al endo e , K.; Panade o J.; Juan,
A.A. Applying Simheu is ics o
Minimize O e all Cos s o an MRP
Planned P oduc ion Sys em.
Algo i hms 2022,15, 40. h ps://
doi.o g/10.3390/a15020040
Academic Edi o : Meng Liu
Recei ed: 13 Decembe 2021
Accep ed: 25 Janua y 2022
Published: 27 Janua y 2022
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algo i hms
A icle
Applying Simheu is ics o Minimize O e all Cos s o an MRP
Planned P oduc ion Sys em
Wol gang Sei inge 1,* , Juliana Cas aneda 2, Klaus Al endo e 1, Ja ie Panade o 2and Angel A. Juan 3
1School o Business and Managemen , Uni e si y o Applied Sciences Uppe Aus ia, Weh g abengasse 1-3,
4400 S ey , Aus ia; klaus.al endo e @ h-s ey .a
2IN3—Compu e Science Depa men , Uni e si a Obe a de Ca alunya, Rambla Poblenou 156,
08018 Ba celona, Spain; [email p o ec ed] (J.C.); jpanade [email p o ec ed] (J.P.)
3Depa men o S a is ics and OR, Uni e si a Poli ècnica de València, Plaza Fe andiz y Ca bonell,
03801 Alcoy, Spain; [email p o ec ed]
*Co espondence: wol gang.sei inge @ h-s ey .a
Abs ac :
Looking a cu en en e p ise esou ce planning sys ems shows ha ma e ial equi emen s
planning (MRP) is one o he main p oduc ion planning app oaches implemen ed he e. The MRP
planning pa ame e s lo size, sa e y s ock, and planned lead ime, ha e o be iden i ied o each MRP
planned ma e ial. Wi h inc easing p oduc ion sys em complexi y, mo e planning pa ame e s ha e o
be de ined. Simula ion-based op imiza ion is known as a aluable ool o op imizing hese MRP
planning pa ame e s o he unde lying p oduc ion sys em. In his a icle, a as and easy- o-apply
simheu is ic was de eloped wi h he objec i e o minimize o e all cos s. The simheu is ic se s
he planning pa ame e s lo size, sa e y s ock, and planned lead ime o he simula ed s ochas ic
p oduc ion sys ems. The de eloped simheu is ic applies aspec s o simula ion annealing (SA) o an
e icien me aheu is ic-based solu ion pa ame e sampling. Addi ionally, an in elligen simula ion
budge managemen (SBM) concep is in oduced, which skips eplica ions o no p omising i e a ions.
A comp ehensi e simula ion s udy o a mul i-i em and mul i-s aged p oduc ion sys em s uc u e
is conduc ed o e alua e i s pe o mance. Di e en simheu is ic combina ions and pa ame e s a e
es ed, wi h he esul ha he combina ion o SA and SBM led o he lowes o e all cos s. The
con ibu ions o his a icle a e an easy implemen able simheu is ic o MRP pa ame e op imiza ion
and a p omising concep o in elligen ly manage simula ion budge .
Keywo ds: MRP; planning pa ame e ; op imiza ion; simula ion budge ; heu is ic
1. In oduc ion
Fo manu ac u ing companies, an en e p ise esou ce planning sys em (ERP) is he
cen al sys em o plan and con ol p oduc ion- ela ed esou ces. Compa ed o he ech-
nological de elopmen o ERP sys ems, he used planning algo i hms ha e no changed
ha much du ing he las decade. Mos comme cial ERP sys ems s ill use he hie a chical
p oduc ion planning app oach o ma e ial equi emen s planning (MRP) o gene a e p o-
duc ion o de s [
1
]. The applicabili y in di e en indus ies and he s aigh o wa d and
scalable logic—independen om he p oduc complexi y— os e ed MRP’s impo ance
in indus y and also science. The h ee planning pa ame e s o con ol MRP a e lo size,
planned lead ime, and sa e y s ock. Many o he pa ame e s mus be se up and de ined
o ge a p oduc ion sys em on which an MRP can be applied, such as a bill o ma e ial
(BOM), p ocessing ime, se up ime, planning pe iod, machine a ailabili y, and many mo e.
The mas e p oduc ion schedule (MPS), which is based on he cus ome demands, de ines
he quan i ies and ime pe iods o he o de ed ma e ials and speci ies he g oss equi e-
men s o he MRP algo i hm. E en hough he MRP logic is no complica ed, keeping
an MRP sys em up o da e is a challenging ask. Suppose aw ma e ial is a ailable in
he ERP sys em, bu canno be handed o p oduc ion. This ype o misin o ma ion can
Algo i hms 2022,15, 40. h ps://doi.o g/10.3390/a15020040 h ps://www.mdpi.com/jou nal/algo i hms
Algo i hms 2022,15, 40 2 o 18
equi e upda ing he comple e MRP sys em wi h e-planning, including scheduled eceip s
and planned o de eleases [
1
]. Howe e , hese a e no sophis ica ed asks compa ed o
selec ing op imal MRP planning pa ame e s. To o e come a wo sening se ice le el, i is,
o example, possible o inc ease planned lead ime wi h he consequence o inc easing
s ocking le el [
2
]. Conside ing he e ec s o changing he alue o one MRP planning
pa ame e is manageable, bu doing his in a sys ema ic way o lo size, planned lead ime,
and sa e y s ock need o be suppo ed by me hods om he ield o p oduc ion sys em
simula ion and heu is ics. Using p oduc ion sys em simula ion o e alua e he pe o -
mance o a p oduc ion sys em elying on an MRP p o ides in e es ing insigh s in o he
beha io o he p oduc ion sys em pe o mance. In pa icula , he sys ema ic explo a ion
o sui able MRP pa ame e combina ions will help ind op imal alues wi h espec o
gi en pe o mance indica o s, such as in en o y and a diness cos s. P oduc ion sys ems
a e cha ac e ized by a high unce ain y le el, which is associa ed wi h hei planning.
This may be due o in e nal ac o s, such as s ochas ic p ocessing imes, machine ailu es,
limi ed a ailabili y o esou ces—ei he wo ke s o aw ma e ials—e c. I can also be
due o ex e nal ac o s associa ed wi h cus ome s’ demand, such as equi ed lead imes,
changes in o de s eques ed, o cancella ions [
3
]. Gi en his complexi y, he planning o
he MRP pa ame e s in a p oduc ion sys em equi es he de elopmen o me hodologies
capable o dealing wi h sys ems unde unce ain y. The implemen a ion o op imiza ion
echniques based on hyb id me hods be ween me aheu is ic and simula ion echniques
has p o en o be a me hodology wi h he po en ial o es ablish he s ochas ic MRP pa-
ame e s a nea op imal le els [
4
]. The e o e, his pape p oposes a simula ion heu is ic
(simheu is ic) o es ablish he alues o he MRP pa ame e s in a mul i-s age, mul i-i em
p oduc ion sys em. A disc e e e en simula ion model simula ing a s ochas ic MRP sys em
is combined wi h a me aheu is ic using a daemon-like p ocedu al c i e ion and simula ion
budge managemen (SBM). The s ochas ic MRP mimics a p oduc ion plan exposed o
he unce ain ies associa ed wi h s ochas ic o de amoun s, he cus ome - equi ed lead
imes, and machine se up imes. He eby, he ocus o his a icle is o in es iga e how o
apply di e en simheu is ic app oaches o sys ema ically ind he bes MRP pa ame e
se ings in o de o minimize o e all cos s. F om an algo i hmic pe spec i e, he challenge
is o in eg a e he simheu is ics in o he used simula ion amewo k. Da a om he ac ual
i e a ion mus be s o ed and p o ide he ounda ion o subsequen i e a ions. Fo SBM, i
is necessa y o keep ack o p e ious solu ion quali y. This in o ma ion is used o decide
i he emaining eplica ions o an i e a ion a e consumed. P oduc ion sys em modeling
associa ed challenges a e he selec ion o app op ia e s a ing pa ame e s including he
anges o he MRP pa ame e s. The ackled p oblem is o iden i y he combina ion o MRP
pa ame e s p o iding he lowes o e all cos s by applying he de eloped simheu is ics.
Hence, he pe o med simula ion s udy is used o answe he ollowing h ee esea ch
ques ions. To answe hese ques ions he de eloped simheu is ics a e e alua ed using an
MRP-based p oduc ion sys em:
Q1: Does he applica ion o an in elligen simula ion budge managemen (SBM)
p o ide lowe o e all cos s compa ed o a ixed numbe o eplica ions?
Q2: In he con ex o MRP pa ame e s se ing, can he use o simula ed annealing (SA)
help a oid ge ing apped in a local minimum ela ed o he o e all cos s?
Q3: Is he combina ion o SBM and SA leading o lowe minimum o e all cos s and, i
so, wha is he e ec o inc easing simula ion budge ?
The emainde o he a icle is s uc u ed as ollows: Sec ion 2p esen s a li e a u e
e iew on he use o simula ion and simula ion-based op imiza ion me hods o deal wi h
s ochas ic MRP sys ems. Sec ion 3in oduces he simula ion-based op imiza ion heu is ic
used o sol e he p oblem. Sec ion 4explains he cha ac e is ics o he s ochas ic MRP
sys em used in his wo k o es ou me hodology. Sec ion 5desc ibes he simula ion-
op imiza ion expe imen s pe o med. Sec ion 6discusses he esul s ob ained. Finally,
Sec ion 7concludes on he indings o his wo k and discusses u u e lines o esea ch.
Algo i hms 2022,15, 40 3 o 18
2. Rela ed Wo k
P oduc ion sys ems a e cha ac e ized by a high complexi y gi en by he la ge numbe
o pa ame e s in ol ed in hei wo king p ocesses. In gene al, MRP sys ems calcula e
he lo size o be p oduced o o de ed o each componen in each pe iod based on he
i ems’ demand. The e is a BOM in which hey a e o ganized hie a chically as componen s,
and i also includes he numbe o each pa pe inal p oduc [
3
]. This sec ion p esen s a
e iew o some o he wo ks ca ied ou abou he op imiza ion o he pa ame e s s udied
in his wo k, which a e associa ed wi h MRP. The objec i e is o iden i y he mos s udied
pa ame e s, hei combina ion, and he analysis o solu ion me hods. Please no e, ha he
objec i e unc ion o he op imiza ion p oblem discussed in his pape includes in en o y
and backo de cos s. This includes se ice and ime pe o mance e ec s, i.e., low se ice
le el leads o high backo de cos s and high p oduc ion lead imes lead o high in en o y
cos s (and p obably o highe backo de cos s). Consequen ly, he objec i e unc ion in his
a icle is in line wi h a lo o MRP pa ame e op imiza ion p oblems om he p esen ed
li e a u e.
The MRP in a p oduc ion line is modeled o simpli y he sys em wi h a se o as-
sump ions. They include all hose pa ame e s ha allow us o model he unce ain y
and complexi y o he sys em i sel . The op imiza ion o hese models—ei he wi h exac ,
heu is ic, me aheu is ic, o e en hyb id me hods—enables us o ind nea -op imal and
e icien solu ions o he sys em. Among he mos s udied pa ame e s unde unce ain y
in he MRP li e a u e a e he sa e y s ock and he planned lead ime [
5
]. The app oach
employed o manage an MRP unde unce ain y depends on he ype o unce ain y, he
signi icance o i s e ec , and he manage s’ p e e ences [
6
]. Table 1p esen s some o he
op imiza ion wo ks on one o mo e o he MRP pa ame e s s udied in his pape , wi h
hei espec i e solu ion echniques. F om he li e a u e e iew, i can be concluded ha
his a icle ackles he MRP pa ame e op imiza ion p oblem, which is al eady ea ed by
o he au ho s.
Table 1. Rela ed wo k e iewed.
Au ho App oach Pa ame e s Me hod o Analysis
Lead Time Sa e y S ock Lo Size Demand
Whyba k and Williams [7], Buzaco
and Shan hikuma [8], Enns [9]X X X Simula ion
Molinde [10] X X X X Hyb id: simula ed
annealing & simula ion
Al endo e [2] X X Heu is ic
Al endo e e al. [11] X X Simula ion
Teo e al. [12] X X Non-linea op imiza ion
Libe opoulos and Koukoumialos
[13] X X Simula ion
Al endo e and Minne [14] X X Gene al op imiza ion
model
Al endo e [15] X X X Heu is ic
Ba ios e al. [4] X Hyb id: heu is ic &
simula ion
Gans e e e al. [5] X X X
Hyb id: Va iable neighbo
sea ch & simula ion
Ka de e al. [16] X X X Hyb id: Gene ic
Algo i hm & simula ion
Among he ela ed wo k analyzed, i is ound ha simula ion echniques ha e been
widely applied in MRP models since hey allow us o obse e he beha io o he supply
Algo i hms 2022,15, 40 4 o 18
chain h ough he c ea ion o expe imen s based on he model o he sys em unde s udy.
A he same ime, i allows us o obse e he e ec s o changes in MRP pa ame e s. I
o e s he possibili y o planning and con olling he p oduc ion sys ems and imp o ing
s a egies a di e en o ganiza ional le els. Likewise, disc e e-e en simula ion mimics
he dynamics o sys ems in he eal wo ld, which has made i a e y popula me hod o
MRP modeling [
17
]. Whyba k and Williams
[7]
ha e been among he i s o p opose a
amewo k o cha ac e ize and s udy he unce ain y ha can a ec in en o y in es men
and se ice le el pe o mance in an MRP sys em. They used simula ion o compa e wo
pa ame e s, sa e y s ock and sa e y lead ime. They also es ed whe he he e is be e
in en o y con ol ha mee s ma ke unce ain y. In he same di ec ion, Buzaco and
Shan hikuma
[8]
, Enns
[9]
s udied he in luence o sa e y s ock size and planned lead ime.
Likewise, hese au ho s de eloped models ha simul aneously decide on he lo size and
planned lead ime in an en i onmen wi h cons an cus ome demand and s ochas ic lead
imes [
18
]. O he models a e de eloped o add ess he isk gene a ed by unce ain y in
lead imes and demand, while ocusing on deciding which o hese wo pa ame e s should
be used o make decisions [
10
]. The design o hese simula ion models o explo e he e ec
o demand unce ain y on he sys em pe o mance also a ies depending on whe he we
a e conside ing a single-s age manu ac u ing sys em [
2
] o a mul i-i em, mul i-s age MRP
p oduc ion sys em [11].
Typically, MRP simula ion models a e s udied o know he esponses (o ou pu s o
he sys em) o he ini ially de ined pa ame e s [
19
,
20
]. Howe e , his echnique does no
allow de e mining he op imal alues o he pa ame e s o achie e a gi en objec i e [
21
].
Pa ame e op imiza ion o con igu e he sys ems and ope a e as e icien ly as possible is
ecommended [
10
]. In he li e a u e, some models es ablish planned lead imes based on
capaci y equi emen s planning, using nonlinea op imiza ion o ind he op imal alues
o he planning pa ame e s minimizing p oduc ion- ela ed cos s [
12
]. O he models ely
on simula ion-based op imiza ion o pe o m nume ical explo a ions. The in eg a ion o
op imiza ion me hods and simula ion allows us o calib a e he pa ame e s o he s ochas ic
model. In his op imiza ion p ocess, he objec i e unc ion has an associa ed measu e o he
expe imen al simula ion ha is op imized [
22
]. Fo ins ance, i includes he op imiza ion o
planned s ock le els and lead ime in p oduc ion, as well as he op imiza ion o in en o y
sys ems wi h ad anced demand in o ma ion and some se ice le el equi emen s [
13
].
The e a e also analy ical models o he simul aneous op imiza ion o capaci y and planned
deli e y ime in a wo-s age p oduc ion sys em wi h di e en cus ome due da es [
14
].
Ano he wo k in es iga ing he applica ion o analy ical me hods and heu is ics was
p esen ed in [
15
]. The in en o y and he a diness cos s we e analyzed. In addi ion,
a heu is ic-based app oach o sol e he associa ed op imiza ion p oblem was used. All
h ee MRP pa ame e s wi h he limi a ion o only one p oduc ion s age and capaci y, we e
in es iga ed.
One o he me hods o simula ion-based op imiza ion is simheu is ics. I is a solu ion
me hod based on algo i hms combining simula ion me hods wi hin a heu is ic/me aheu is ic
op imiza ion amewo k. I allows o deal wi h s ochas ic combina o ial op imiza ion p ob-
lems [
23
,
24
]. Ba ios e al.
[4]
demons a ed ha simheu is ics a e a p omising app oach
o sol e a wo-s age s ochas ic MRP. They iden i ied he sa e y s ock le el o each i em
o minimize he o al expec ed manu ac u ing cos . Thei esul s demons a e ha he
use o simheu is ics p o ides ad an ages o e he use o simula ion app oaches alone.
Some app oaches a y be ween hem because o he p oposed op imiza ion heu is ics and
me aheu is ics. Fo example, Molinde
[10]
p oposed o de e mine he sa e y lead ime
wi h a hyb id app oach combining simula ion wi h op imiza ion based on he simula ed an-
nealing algo i hm. Gans e e e al.
[5]
p esen ed a simula ion-based op imiza ion app oach
wi h a sea ch p ocedu e based on a iable neighbo hood sea ch wi h a obus p oduc ion
planning as a esul . They ocused on he simul aneous op imiza ion o h ee pa ame e s,
planned lead ime, sa e y s ock, and lo sizes. In addi ion, Ka de e al.
[16]
op imized
he MRP pa ame e s, applied, and compa ed wo di e en e sions o e icien global
Algo i hms 2022,15, 40 5 o 18
op imiza ion o single-objec i e and mul i-objec i e unc ions. Thei esul s demons a e
how bo h app oaches a e compe i i e wi h each o he .
Thus, some o he wo ks ela ed o he op imiza ion o he MRP sys em ha e ocused
mainly on pa ame e s such as lead ime, ollowed by sa e y s ock and lo size. The li e -
a u e ha has analyzed he h ee pa ame e s has always used hyb id simula ion-based
op imiza ion app oaches o analyze and sol e he model. I is because inc easing he
numbe o pa ame e s inc eases he complexi y. The simples analysis me hods usually
in ol e only one o a mos wo pa ame e s. Simula ion is he mos widely used analysis
me hod, ollowed by hyb id simula ion-based op imiza ion me hods. Mo eo e , he la e
is also one o he mos ecen solu ion me hods in he li e a u e. Conside ing he end o
ela ed wo ks, his pape p esen s a simula ion-based op imiza ion me hodology o ind
he alues o he s udied pa ame e s o MRP ha gua an ee an e icien pe o mance o
he p oduc ion sys em, wi h he op imiza ion a ge o minimum o e all cos s.
3. Simula ion Heu is ic
In he con ex o MRP pa ame e se ing, simheu is ic algo i hms [
25
] a e a meaning ul
app oach o e alua e a b oad ange o pa ame e combina ions wi h a de ined objec i e
(e.g., minimizing o e all cos ). A i s simple simheu is ic wi h wo ex ensions o minimize
o e all cos s was p esen ed in [
26
]. Howe e , hei app oach is limi ed in he sense ha i
excludes lo sizing. Thei simheu is ic is signi ican ly ex ended in his pape and applied
also o he lo sizing decision which has a majo impac on he o e all cos . In addi ion,
he new simheu is ic algo i hm is u he in eg a ed in o a disc e e-e en simula ion model,
which implemen s a p oduc ion sys em elying on MRP. Du ing a simula ion expe imen ,
he simheu is ic is applied o compu e new planning pa ame e s o each planned ma e ial.
The nex simula ion i e a ion is hen pe o med wi h he changed planning pa ame e s.
In Sec ion 3.1, h ee e sions o he p oposed simheu is ic a e desc ibed. They all ely on
Algo i hm 1.
3.1. Ini ial Simheu is ic Algo i hm
The ini ial simheu is ic depic ed in Algo i hm 1allows us o de elop di e en a ian s,
named: s a ic ange (STR), exponen ial ange educ ion (ERR), and bes solu ion-se base
ange (BSBR). The ini ial simheu is ic p o ides a desc ip ion o he algo i hmic low, and
his gene ic s uc u e acili a es o subsequen ly in eg a e he a o emen ioned a ian s. The
algo i hm s a s by selec ing he bes solu ion o all p e iously inished i e a ions. The bes
solu ion ep esen s he minimum o e all cos o all inished i e a ions and p o ides a lis
wi h he used mode, lowe bound (LB), and uppe bound (UB).
Fo he STR e sion, a iangula dis ibu ion is used o compu e new alues using
he LB, he UB, and he mode gi en by he midpoin o he ange. Fo all h ee a ian s,
he possible alues o he MRP pa ame e s (planned lead ime and sa e y s ock) lie wi hin
he LB and he UB. While in [
26
] he lo size is no included, in his pape , we conside i s
pa ame e sampling o op imiza ion in he same way as o he pa ame e s planned lead
ime and sa e y s ock.
The second simheu is ic e sion, named ERR, upda es LB and UB using he bes
solu ion. This makes i possible o each a sea ch space ou side he o iginal bounds. The
solu ion ange is de ined as
0=
mode
−
UB o bo h MRP pa ame e s. The new bounds
o he MRP pa ame e s and o each i em a e compu ed as
i= (
1
−α)∗ i−1
, whe e, iis
he simula ion i e a ion numbe and
α
is he ange educ ion le el. The goal o he ERR
a ian is o educe he LB and UB when he numbe o i e a ions inc ease, so he possible
solu ion ange is i e a i ely sh inking.
In he hi d e sion, named BSBR, he LB and he UB a e compu ed using he minimum
and maximum o he bes nsolu ions.

Algo i hms 2022,15, 40 6 o 18
Algo i hm 1 Base Simheu is ic Algo i hm.
1: i Ini ializa ion hen
2: α←e.g., 0.025
3: opN ←e.g., 7
4: ini I e a ions ←e.g., 50
5: ini Pa ame e Range(lb,ub,mode)
6: n←0
7: endIni Phase ← alse
8: cu en Solu ion ←T iangula Dis ibu ion(pa ame e Range)
9: baseSolu ion ←cu en Solu ion
10: end i
11: while n≤maxReplica ions do
12: cos (cu en Solu ion)←Simula eMRP(cu en Solu ion)
13: i n>ini I e a ions hen
14: endIni Phase ← ue
15: end i
16: i cos (baseSolu ion)<cos (cu en Solu ion) hen
17: baseSolu ion ←cu en Solu ion
18: end i
19: baseSolu ion ←Ge Bes Solu ion()
20: i simheu is ic =STR ∨endIni Phase = alse hen
21: pa ame e Range.mode ←baseSolu ion
22: end i
23: i simheu is ic =ERR ∧endIni Phase = ue hen
24: oldRange ←(pa ame e Range.ub −pa ame e Range.lb)/2
25: newRange ←(1−α)∗oldRange
26: pa ame e Range.mode ←baseSolu ion
27: pa ame e Range.lb ←pa ame e Range.mode −newRange
28: pa ame e Range.ub ←pa ame e Range.mode +newRange
29: end i
30: i simheu is ic =BSBR ∧endIni Phase = ue hen
31: bes NSolu ions ←Ge Bes NSolu ions( opN)
32: pa ame e Range.mode ←baseSolu ion
33: pa ame e Range.lb ←min(bes NSolu ions)
34: pa ame e Range.ub ←max(bes NSolu ions)
35: end i
36: baseSolu ion ←T iangula Dis ibu ion(pa ame e Range)
37: n←n+ eplica ionsPe I e a ion
38: end while
The cons an
α
is se o he ERR ange educ ion and opN is equi ed only o he BSBR
e sion. An ini ializa ion phase can be applied o bo h he ERR and BSBR e sions. The
numbe o i e a ions is ep esen ed by he cons an ini I e a ions. The a iable endIni Phase
is used o con ol he end o he ini ializa ion phase. No ice ha , by design, ERR and BSBR
a e ex ensions o STR. The e o e, STR is applied du ing he ini I e a ions. Thus, o example,
50 i e a ions ou o a maximum o 300 i e a ions can be used o ind s a ing alues o
ange educ ion and he bes
n
solu ions. A key componen in he algo i hmic low is
he a ay pa ame e Range, as i ep esen s he s a ing LB and UB alues, as well as he
mode o each MRP pa ame e and planned i em. In addi ion, his a ay is con inuously
upda ed du ing he simula ion. The inal s ep o each i e a ion in each e sion is o pass
he adap ed pa ame e Range o he iangula dis ibu ion. This allows us o gene a e new
MRP pa ame e alues and apply hem du ing he MRP simula ion. A he beginning o
each i e a ion, he base solu ion is upda ed o he cu en Solu ion in case his is he new
bes - ound solu ion. The bes solu ion is ep esen ed by he minimum o e all cos o he
p e ious i e a ions, compu ed using he a e age o e all cos o he simula ion uns. The
objec i e is o minimize o e all cos s. A limi a ion is ha logis ic objec i es such as se ice
Algo i hms 2022,15, 40 7 o 18
le el and lead ime a e no conside ed. E en hough he o e all cos c i e ia a e common
in a lo o s udies (see Sec ion 2, e.g., [
5
,
13
,
15
]), his limi a ion implies ha he e ec o
he op imized planning pa ame e s on o he impo an key pe o mance indica o s is no
analyzed which es ic s he discussion o one dimension.
The algo i hm is epea ed un il a maximum numbe o uns (maxReplica ions) is
eached. Hence, o ins ance, o 100 i e a ions wi h 20 uns, he alue o maxReplica-
ions is 2000. The s a emen Simula eMRP is hen pe o med 20 imes pe i e a ion.
As shown in [
26
], e en basic e sions o hese concep s can be use ul o iden i y
pa ame e se ings ha minimize he o e all cos . In his pape , we ex end he ini ial
concep s o de elop a holis ic app oach o MRP pa ame e op imiza ion. Thus, he
ollowing no el aspec s ha e been conside ed in ou s udy: (i) he MRP pa ame e lo size
has been added; (ii) he o iginal heu is ic has been ex ended in o a ull simheu is ic; and
(iii) an in elligen simula ion budge managemen is included. The a ge o he simula ion
budge managemen is o es solu ion quali y a e each un wi hin an i e a ion. In o he
wo ds, o each pa ame e se , he o e all cos is compa ed o he pas esul s, and only i
he solu ion is su icien ly good, u he uns o he cu en i e a ion a e conduc ed. The
a ge is o pe o m mo e i e a ions wi h he same o e all numbe o uns—i.e., he same
simula ion budge —by a oiding unnecessa y uns.
3.2. Simula ed Annealing
Escaping a local minimum and explo ing a new solu ion ange equi es a conc e e
s a egy. A biased- andomiza ion algo i hm [
27
] o iangula dis ibu ion mode is de-
sc ibed in Algo i hm 2. This algo i hm applies aspec s o he SA amewo k [
28
]. In
addi ion, he eedom aspec o a demon algo i hm is used. Such a demon-based beha io
is explained in [
29
]. A e each i e a ion, he cos s o he base solu ion a e compa ed o he
cos s o he bes solu ion. Each ime he cos s o he base solu ion a e g ea e o equal o
he bes solu ion, a ese coun e is dec eased by one. When he ese coun e eaches 0,
he base solu ion is ese o he bes solu ion. The ese o he bes solu ion a oids was ing
simula ion budge in a no p omising solu ion space.
Algo i hm 2 Reac i e biased- andomiza ion o iangula dis ibu ion mode.
1: i Ini ializa ion hen
2: ese Coun e ←ini ialValue e.g., 5
3: bes Solu ion ←baseSolu ion
4: end i
5: δ=cos (baseSolu ion)−cos (cu en Solu ion)
6: i δ>0 hen
7: c edi ←δ
8: baseSolu ion ←cu en Solu ion
9: i cos (baseSolu ion)<cos (bes Solu ion) hen
10: bes Solu ion ←baseSolu ion
11: end i
12: else i −δ≤c edi hen
13: baseSolu ion ←cu en Solu ion
14: c edi ←0
15: end i
16: i cos (cu en Solu ion)≥cos (bes Solu ion) hen
17: ese Coun e
−−
18: end i
19: i ese Coun e =0 hen
20: baseSolu ion ←bes Solu ion
21: ese Coun e ←ini alValue
22: end i
Algo i hms 2022,15, 40 8 o 18
3.3. Simula ion Budge Managemen (Sbm)
Limi ing he simula ion expe imen by a maximum numbe o i e a ions and uns pe
i e a ion inc eases he p obabili y o exclude po en ial good solu ions, as hey a e excluded
due o he un ou o simula ion i e a ions. Always pe o ming a cons an numbe o
uns pe i e a ion will no necessa ily inc ease he po en ial o ind a new bes solu ion.
Consequen ly, i would be mo e meaning ul o in oduce a cons ain o skipping he
ac ual i e a ion and in es he emaining simula ion budge o explo e new solu ions wi h
addi ional i e a ions and a changed se o pa ame e alues. A simple simula ion budge
managemen pseudocode, which acili a es o un he simula ion expe imen , is desc ibed in
Algo i hm 3. This algo i hm allows as many i e a ions as budge is a ailable, and will s op
he las i e a ion when he maximum numbe o uns is eached. The bes solu ion always
has he maximum numbe o he gi en eplica ions due o he s opping c i e ia. The a e age
cos o he p e ious i e a ions (a gI e a ionO e allCos s) is equal o
1
n∑n
io e allCos si
, wi h
n=
maximum uns pe i e a ion (maxReplica ionsPe I e a ion). The a gI e a ionO e allCos s
is compa ed o he pe cen ile alue o all pas i e a ions, which depends on he eplica ion
numbe . The pe cen ile alue is compu ed using Ge Pe cen ilValue(se O AllSolu ions,
β)
,
which equi es he p e ious o e all cos o be equal o se O AllSolu ions, and a alue
educed a e each un om a UB, e u ning he alue associa ed wi h he posi ion in
he passed solu ions. These alues a e ep esen ed by
β
and pe cen ileS ep. A e each
eplica ion, he o e all cos is added o he alues o he cu en i e a ion and he new
pe cen ile alue is compu ed. Compa ed o he ini ial Algo i hm 1, we do no always
pe o m a ixed numbe o uns. The SBM s ops a e he simula ionBudge is exhaus ed.
Algo i hm 3 Simula ion budge managemen .
1: i Ini ializa ion hen
2: o alReplica ionCoun ←0
3: simula ionBudge ←maxI e a ions ∗maxReplica ionsPe I e a ion
4: s opCu en I e a ion ← alse
5: cu en Replica ionCoun ←1
6: pe cen ileS ep ←0.0175
7: end i
8: β←0.4
9: while cu en Replica ionCoun ≤maxReplica ionsPe I e a ion ∧
10: s opCu en I e a ion = alse do
11: o alReplica ionCoun
++
12: cu en Replica ionCoun
++
13: i a gI e a ionO e allCos s >Ge Pe cen ilValue(se O AllSolu ions,β)∧
cu en Replica ionCoun >3 hen
14: s opCu en I e a ion ← ue
15: end i
16: β=β−pe cen ilS ep
17: end while
18: s opCu en I e a ion ← alse
19: eplica ionsPe I e a ion ←cu en Replica ionCoun
4. Modeling a S ochas ic M p-Based P oduc ion Sys em
To model a s ochas ic MRP sys em, disc e e e en simula ion can be used [
30
]. F om
a echnical pe spec i e, his equi es agen s o simula e he cus ome s’ o de s beha io
and a simula ion amewo k capable o eading he gi en expe imen planning pa ame e s
and change hem a e each i e a ion. The expe imen planning pa ame e s include s a
alues and bounda ies o he MRP- ela ed planning pa ame e s o lo size, planned lead
ime, and sa e y s ock. In addi ion, MRP ela ed se ings, such as planning ho izon and
addi ionally echnical pa ame e s a e equi ed o he simula ion expe imen s, such as
he numbe o simula ion uns and algo i hm i e a ions [
31
]. Cus ome ’s o de agen s
Algo i hms 2022,15, 40 9 o 18
a e passed o a queue. Whene e a cus ome ’s o de canno be comple ed be o e he
deadline, i is classi ied as ‘delayed’. The same logic is applied o he p oduc ion o de s.
The p oduc ion o de s a e gene a ed based on cus ome ’s o de s, which a e he g oss
equi emen s o he applied MRP un. The ou pu o each MRP un is he p oduc ion
o de s, which p o ide he in o ma ion on quan i y, i em, s a and end da e. A e each
i e a ion he solu ion quali y is e alua ed, i.e., he a e age o all eplica ions’ o e all cos s is
calcula ed, and he simheu is ic is applied o se he new MRP planning pa ame e alues
o he nex i e a ion. The simula ion esul s o each i e a ion (MRP pa ame e s, backo de
cos s, in en o y cos s, i e a ion coun , eplica ion coun ,
. . .
) a e s o ed a e each i e a ion
in he linked in-memo y da abase. These alues a e hen a ailable o he subsequen
i e a ions. The esul s o he cu en i e a ion including each eplica ion a e hold in he
wo king memo y o he simula ion compu e , un il he las eplica ion is pe o med. The
esul s o he in-memo y da abase a e s o ed as da abase ile and a e he basis o he
pe o mance analysis o he unde aken simula ion s udy.
4.1. S ochas ic M p Se ing
Ou MRP simula ion model can handle s ochas ic demands as well as andom p o-
cessing imes, and p o ides he desc ibed s anda d MRP logic o ea cus ome s’ o de s.
S ochas ic beha io is in oduced and con olled using log-no mal p obabili y dis ibu ions
wi h expec ed alues (
µi
) and a iances (
σ2
i
) o machine se up ime, cus ome equi ed
lead ime and cus ome ’s expec ed o de amoun . The andom a iables can be ound in
Table 2, which also includes he espec i e coe icien s o a ia ion (CVi).
Table 2. Random a iables wi h log-no mal beha io .
Pa ame e I em µiσ2
iCVi
o de amoun 10 10 2 0.1414
o de amoun 11 15 6 0.1633
cus ome equi ed lead ime
10 6 9 0.5000
cus ome equi ed lead ime
11 6 10 0.5270
machine se up ime all 12 36 0.5000
The simula ed p oduc ion sys em is illus a ed in Figu e 1. The ole o he de eloped
simheu is ic is o se lo size, planned lead ime and sa e y s ock pa ame e s in o de o
minimize he o e all cos , which is he sum o in en o y and a diness cos s. Despi e being
a simple BOM ha conside s only h ee le els, he example allows o demons a e how
simheu is ics can be meaning ully in eg a ed in o an MRP sys em o op imize o e all cos s
o all h ee planning pa ame e s. Two inal p oduc s, p oduc s 10 and 11, a low-le el-code
(LLC) 0 a e p oduced on machine
M
2. The wo semi- inished p oduc s, ma e ials 20 and
21, a e p oduced on machine
M
1. Fo one uni o inal p oduc 10, 1 semi- inished p oduc
20 is needed. One piece o semi- inished p oduc 21 is needed o inal p oduc 11. The aw
ma e ial 100, which is a pu chased p oduc , is needed o he semi- inished p oduc s 20
and 21. This aw ma e ial is assumed o be always a ailable. Fo his simple p oduc ion
sys em, 12 di e en pa ame e s ha e o be op imized because du ing simula ion o each
o he ma e ials (10, 11, 20 and 21), all h ee MRP planning pa ame e s ha e o be es ed
o op imali y. Table 3shows he s a -up alues and espec i e anges o op imiza ion
pa ame e s. Please no e ha he MRP planning pa ame e alues a e ea ed and e alua ed
as in ege uni s. This means ha in he simula ion esul s, he inc ease o dec ease o
o e all cos s ela ed o each indi idual MRP pa ame e can be acked. Fu he mo e, he
in e ela ion be ween he single planning pa ame e s is in eg a ed in he simula ion model,
e.g., bo h a highe planned lead ime and a highe sa e y s ock lead o highe in en o y cos s
and lowe a diness cos s, also compa e o Buzaco and Shan hikuma
[8]
. A dec ease in
lo size, o example, leads o highe se up e o s and, he e o e, also a ec s he p oduc ion
Algo i hms 2022,15, 40 16 o 18
mo e MRP planning pa ame e s, i.e., mo e decision a iables. This equi es o upscale
he sys em o pa ame e handling and in e media e esul compu a ion. Fu he mo e, an
e icien MRP pa ame e upda e s a egy has o be de eloped. Resul s o such an implemen-
a ion wi h eal da a can p o ide aluable esul s abou op imal pa ame e combina ions
and he pe o mance issues o he espec i e p oduc ion sys em. The au oma ic compu-
a ion o op imal MRP planning pa ame e based on op imized in en o y and backo de
cos s p o ides use ul in o ma ion o p oduc ion planning ela ed decision making. F om
a scien i ic poin o iew, especially he gene al app oach o SBM is eusable o o he
simula ion s udies and can help consume he a ailable simula ion budge o es la ge
solu ion spaces.
Figu e 3. Compa ison be ween he bes esul ob ained in each simheu is ic.
The p esen ed simheu is ic does no explici ly conside he in e ela ion be ween
op imized planning pa ame e s. Igno ing he pa ame e dependency can ha e nega i e
e ec s on he op imized pa ame e s and he inal esul . Howe e , pa ame e in e ela ion
is also igno ed by o he heu is ics, compa e wi h [
16
]. In es iga ing MRP pa ame e
in e ela ion may p o ide addi ional insigh in o op imiza ion-based p oduc ion sys em
simula ions, bu is ou o con ex o his a icle.
7. Conclusions and Fu u e Wo k
This a icle p o ides insigh s in o he applica ion o simheu is ics in iden i ying op i-
mal MRP planning pa ame e alues o lo size, planned lead ime and sa e y s ock. The
aim is o ind he minimal o e all cos (in en o y cos s plus backo de cos s) compu ed
du ing he applica ion o he MRP planning algo i hm in a simula ion en i onmen . This
a icle is a u he de elopmen o he esul s based on h ee di e en simheu is ic e sions
o iden i y he minimal o e all cos only o he MRP planning pa ame e sa e y s ock and
planned lead ime. The i s ex ension is ha op imal alues o all h ee MRP planning
pa ame e s a e sea ched. A second ex ension is he de elopmen o a SA-based simheu is ic
ex ension. The hi d ex ension ocuses on inding op imal pa ame e s wi hou was ing
simula ion budge o non-p omising i e a ions. Hence, an in elligen simula ion budge
managemen (SBM) is in oduced o consume he a ailable eplica ions only o po en ial
bes solu ions, hus skipping solu ions ou side he de ined pe cen ile ange. SBM was
combined wi h he SA ex ension o addi ionally explo e new a eas o he solu ion space
and o escape local minima. The applica ion o he de eloped SBM and SA ex ensions,
combined wi h all h ee planning pa ame e s, allows o a sys ema ic iden i ica ion o
op imal planning pa ame e s wi h a clea op imiza ion a ge . The nume ical esul s show
ha he bes pe o ming e sion o his applica ion is ERR. F om a p oduc ion planning

Algo i hms 2022,15, 40 17 o 18
pe spec i e, he de eloped simheu is ic e sions, speci ically ERR, p o ides a as and well
pe o ming simula ion-based op imiza ion app oach which is simple o apply in p ac ical
en i onmen s. The pe o med simula ion s udy shows he imp o emen o he exis ing
simheu is ic e sions ega ding he iden i ica ion o he minimal o e all cos wi h he join
applica ion o SBM and SA. This inding is suppo ed by he lowes o e all cos ob ained
wi h he highes simula ion budge and he join applica ion o SBM and SA o all h ee
simheu is ic e sions. Limi a ions o his s udy a e ela ed o he applica ion ield and he
p oduc ion sys em wi hin which he simheu is ics a e es ed, i.e., only one applica ion ield
is e alua ed in his s udy and he espec i e p oduc ion sys em is s ill a he simple. How-
e e , his a icle p o ides he ounda ion o u u e in es iga ions, o sys ema ically apply
he simheu is ics concep o mo e complex p oduc ion sys em s uc u es and o o he ap-
plica ion ields. The de eloped simheu is ics ocus on a single objec i e unc ion, howe e ,
o eal p oduc ion sys ems, i is no always possible o ans o m all objec i e dimensions
in o cos s. The e o e, u u e wo k could in es iga e how o ex end he simheu is ic o a
mul i-objec i e app oach. A b oad sensi i i y analysis o p o e he p omising esul s o
SBM is also planned in u u e wo k.
Au ho Con ibu ions:
Concep ualiza ion, K.A. and A.A.J.; me hodology, K.A. and J.P.; so wa e,
W.S.; alida ion, K.A., W.S.; o mal analysis, K.A., W.S. and J.C.; in es iga ion, W.S. and J.C.; esou ces,
W.S.; da a cu a ion, W.S.; w i ing—o iginal d a p epa a ion, W.S. and J.C.; w i ing— e iew and
edi ing, K.A., W.S., J.C. and A.A.J.; isualiza ion, W.S. and J.C.; supe ision, K.A. and J.P.; p ojec
adminis a ion, K.A. and J.P. All au ho s ha e ead and ag eed o he published e sion o he
manusc ip .
Funding:
This wo k has been pa ially unded by he Spanish Minis y o Science (PID2019-111100RB-
C21/AEI/10.13039/501100011033 and RED2018-102642-T), he E asmus+ P og am (2019-I-ES01-
KA103-062602), and unded by he Aus ian Science Fund (FWF): P32954-G.
Ins i u ional Re iew Boa d S a emen : No applicable.
In o med Consen S a emen : No applicable.
Da a A ailabili y S a emen : No applicable.
Con lic s o In e es :
The au ho s decla e no con lic o in e es . The unde s had no ole in he design
o he s udy; in he collec ion, analyses, o in e p e a ion o da a; in he w i ing o he manusc ip , o
in he decision o publish he esul s.
Abb e ia ions
The ollowing abb e ia ions a e used in his manusc ip :
BOM Bill o Ma e ial
CU Cos Uni
CV Coe icien o a ia ion
ERP En e p ise Resou ce Planning
FOP Fixed O de Pe iod
FOQ Fixed O de Quan i y
LB Lowe Bound
MRP Ma e ial Requi emen s Planning
UB Uppe Bound
SA Simula ed Annealing
SBM Simula ion Budge Managemen
Re e ences
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