Synchronizing inventory and transport within supply chain management

The problem considers synchronized optimization of inventory and transport, and focuses on producer-distributor relations. Particular attention is paid to developing a mathematical model and an optimization problem that can be used to minimize the overall distribution cost by an appropriate placement of warehouses and cross-docking points. Solutions to this problem are explored using genetic algorithms and ideas from graph/network theory. Note: there are three separate reports contained within the uploaded .pdf file

An Efficient Genetic Algorithm for Solving the Multi-Level Uncapacitated Facility Location Problem

In this paper a new evolutionary approach for solving the multi-level uncapacitated facility location problem (MLUFLP) is presented. Binary encoding scheme is used with appropriate objective function containing dynamic programming approach for finding sequence of located facilities on each level to satisfy clients' demands. The experiments were carried out on the modified standard single level facility location problem instances. Genetic algorithm (GA) reaches all known optimal solutions for smaller dimension instances, obtained by total enumeration and CPLEX solver. Moreover, all optimal/best known solutions were reached by genetic algorithm for a single-level variant of the problem

DYNAMIC LOT-SIZING PROBLEMS: A Review on Model and Efficient Algorithm

Due to their importance in industry, dynamic demand lot-sizing problems are frequently studied.This study consider dynamic lot-sizing problems with recent advances in problem and modelformulation, and algorithms that enable large-scale problems to be effectively solved.Comprehensive review is given on model formulation of dynamic lot-sizing problems, especiallyon capacitated lot-sizing (CLS) problem and the coordinated lot-sizing problem. Bothapproaches have their intercorrelated, where CLS can be employed for single or multilevel/stage, item, and some restrictions. When a need for joint setup replenishment exists, thenthe coordinated lot-sizing is the choice. Furthermore, both algorithmics and heuristics solutionin the research of dynamic lot sizing are considered, followed by an illustration to provide anefficient algorithm

Fine-grained Tournament Selection Operator in Genetic Algorithms

Tournament selection is one of the most popular selection operators in Genetic Algorithms. Recently, its popularity is increasing because this operator is well suited for Parallel Genetic Algorithms applications. In this paper, new selection operator is proposed. The new operator, which should be an improvement of the tournament selection, is named ``Fine-grained Tournament Selection'' (FGTS). It is shown that classical tournament selection is a special case of the FGTS and that new operator preserves its good features. Furthermore, theoretical estimations for the FGTS are made. Estimations for the FGTS are similar to those for the classical tournament selection. Finally, classical tournament selection, rank-based selection and FGTS are experimentally compared on a real world NP-hard problem and the obtained results are discussed

A hybrid multi-objective approach to capacitated facility location with flexible store allocation for green logistics modeling

We propose an efficient evolutionary multi-objective optimization approach to the capacitated facility location–allocation problem (CFLP) for solving large instances that considers flexibility at the allocation level, where financial costs and CO2 emissions are considered simultaneously. Our approach utilizes suitably adapted Lagrangian Relaxation models for dealing with costs and CO2 emissions at the allocation level, within a multi-objective evolutionary framework at the location level. Thus our method assesses the robustness of each location solution with respect to our two objectives for customer allocation. We extend our exploration of selected solutions by considering a range of trade-offs for customer allocation

On the use of biased-randomized algorithms for solving non-smooth optimization problems

Soft constraints are quite common in real-life applications. For example, in freight transportation, the fleet size can be enlarged by outsourcing part of the distribution service and some deliveries to customers can be postponed as well; in inventory management, it is possible to consider stock-outs generated by unexpected demands; and in manufacturing processes and project management, it is frequent that some deadlines cannot be met due to delays in critical steps of the supply chain. However, capacity-, size-, and time-related limitations are included in many optimization problems as hard constraints, while it would be usually more realistic to consider them as soft ones, i.e., they can be violated to some extent by incurring a penalty cost. Most of the times, this penalty cost will be nonlinear and even noncontinuous, which might transform the objective function into a non-smooth one. Despite its many practical applications, non-smooth optimization problems are quite challenging, especially when the underlying optimization problem is NP-hard in nature. In this paper, we propose the use of biased-randomized algorithms as an effective methodology to cope with NP-hard and non-smooth optimization problems in many practical applications. Biased-randomized algorithms extend constructive heuristics by introducing a nonuniform randomization pattern into them. Hence, they can be used to explore promising areas of the solution space without the limitations of gradient-based approaches, which assume the existence of smooth objective functions. Moreover, biased-randomized algorithms can be easily parallelized, thus employing short computing times while exploring a large number of promising regions. This paper discusses these concepts in detail, reviews existing work in different application areas, and highlights current trends and open research lines

Forklift Routing Optimization in a Warehouse using a Clustering-based Approach

Order picking in a warehouse is considered to be a time-consuming and costly process that results in loss of profit for the management. Hence a warehouse management team is always looking to improve their picking process and increase their efficiency. In this research, a warehouse with narrow aisles is studied. The aisles are so narrow that a forklift is only allowed to traverse them in one direction thus making them unidirectional. The picking process is modeled first as an uncapacitated vehicle routing problem and then as a capacitated vehicle routing problem. The objective is to minimize the total travel distance. Since the Mixed Integer Programming model takes a long time to solve large instances, we develop a heuristic algorithm both for the uncapacitated and capacitated problems by combining two methodologies of heuristics and machine learning. The algorithm is able to solve the instances to near optimality quickly, finding practical solutions that could potentially be implemented into actual warehouses to reduce order picking time and hence, overall warehouse costs

Optimal Global Supply Chain and Warehouse Planning under Uncertainty

A manufacturing company\u27s inbound supply chain consists of various processes such as procurement, consolidation, and warehousing. Each of these processes is the focus of a different chapter in this dissertation. The manufacturer depends on its suppliers to provide the raw materials and parts required to manufacture a finished product. These suppliers can be located locally or overseas with respect to the manufacturer\u27s geographic location. The ordering and transportation lead times are shorter if the supplier is located locally. Just In Time (JIT) or Just In Sequence (JIS) inventory management methods could be practiced by the manufacturer to procure the raw materials and parts from the local supplier and control the inventory levels in the warehouse. In contrast, the lead time for the orders placed with an overseas supplier is usually long because sea-freight is often used as a primary mode of transportation. Therefore, the orders for the raw materials and parts (henceforth, we collectively refer to raw material and part by part) procured from overseas suppliers are usually placed using forecasted order quantities. In Chapter 2, we study the procurement process to reduce the overall expected cost and determine the optimal order quantities as well as the mode of transportation for procurement under forecast and inventory uncertainty. We formulate a two-stage stochastic integer programming model and solve it using the progressive hedging algorithm, a scenario-based decomposition method. Generally, the orders are placed with overseas suppliers using weekly or monthly forecasted demands, and the ordered part is delivered using sea-containers since sea-freight is the primary mode of transportation. However, the end manufacturing warehouse is usually designed to hold around one to two days of parts. To replenish the inventory levels, the manufacturer considered in this research unloads the sea-container that contains the part that needs to be restocked entirely. This may cause over-utilization of the manufacturer\u27s warehouse if an entire week\u27s supply of part is consolidated into a single sea-container. This problem is further aggravated if the manufacturer procures hundreds of different parts from overseas suppliers and stores them in its warehouse. In Chapter 3, we study the time-series forecasting models that help predict the manufacturing company\u27s daily demand quantities for parts with different characteristics. The manufacturer can use these forecasted daily demand quantities to consolidate the sea-containers instead of the weekly forecasted demand. In most cases, there is some discrepancy between the predicted and actual demands for parts, due to which the manufacturer can either have excess inventory or shortages. While excess inventory leads to higher inventory holding costs and warehouse utilization, shortages can result in substantially undesirable consequences, such as the total shutdown of production lines. Therefore, to avoid shortages, the manufacturer maintains predetermined safety stock levels of parts with the suppliers to fulfill the demands arising from shortages. We formulate a chance-constraint optimization model and solve it using the sample approximation approach to determine the daily safety stock levels at the supplier warehouse under forecast error uncertainty. Once the orders are placed with the local and overseas suppliers, they are consolidated into trailers (for local suppliers) and sea-containers (for overseas suppliers). The consolidated trailers and sea-containers are then delivered to the manufacturing plant, where they are stored in the yard until they are called upon for unloading. A detention penalty is incurred on a daily basis for holding a trailer or sea-container. Consolidating orders from different suppliers helps maximize trailer and sea-container space utilization and reduce transportation costs. Therefore, every sea-container and trailer potentially holds a mixture of parts. When a manufacturer needs to replenish the stocks of a given part, the entire sea-container or trailer that contains the required part is unloaded. Thus, some parts that are not imminently needed for production are also unloaded and stored inside the manufacturing warehouse along with the required parts. In Chapter 4, we study a multi-objective optimization model to determine the sea-containers and trailers to be unloaded on a given day to replenish stock levels such that the detention penalties and the manufacturing warehouse utilization are minimized. Once a sea-container or trailer is selected to replenish the warehouse inventory levels, its contents (i.e., pallets of parts) must be unloaded by the forklift operator and then processed by workers to update the stock levels and break down the pallets if needed. Finally, the unloaded and processed part is stored in the warehouse bins or shelves. In Chapter 5, we study the problem of determining the optimal team formation such that the total expected time required to unload, process, and store all the parts contained in the sea-containers and trailers selected for unloading on a given day is minimized