Stochastic multi-period multi-product multi-objective Aggregate Production Planning model in multi-echelon supply chain

In this paper a multi-period multi-product multi-objective aggregate production planning (APP) model is proposed for an uncertain multi-echelon supply chain considering financial risk, customer satisfaction, and human resource training. Three conflictive objective functions and several sets of real constraints are considered concurrently in the proposed APP model. Some parameters of the proposed model are assumed to be uncertain and handled through a two-stage stochastic programming (TSSP) approach. The proposed TSSP is solved using three multi-objective solution procedures, i.e., the goal attainment technique, the modified ε-constraint method, and STEM method. The whole procedure is applied in an automotive resin and oil supply chain as a real case study wherein the efficacy and applicability of the proposed approaches are illustrated in comparison with existing experimental production planning method

The impact of freight transport capacity limitations on supply chain dynamics

We investigate how capacity limitations in the transportation system affect the dynamic behaviour of supply chains. We are interested in the more recently defined, 'backlash' effect. Using a system dynamics simulation approach, we replicate the well-known Beer Game supply chain for different transport capacity management scenarios. The results indicate that transport capacity limitations negatively impact on inventory and backlog costs, although there is a positive impact on the 'backlash' effect. We show that it is possible for both backlog and inventory to simultaneous occur, a situation which does not arise with the uncapacitated scenario. A vertical collaborative approach to transport provision is able to overcome such a trade-off. © 2013 Taylor & Francis

Distribution Network Configuration Considering Inventory Cost

Inter-city distribution network structure is considered as one of which determine the quantity of economic activities in each city. In the field of operations research, several types of optimal facility location problem and algorithms for them have been proposed. Such problems typically minimize the logistic cost with given inter-city transportation cost and facility location cost. But, when we take inventory to coop with fluctuating demands into account, facility size becomes different for each location reflecting the level of uncertainty of demand there. As observed in many developed countries, customers require more variety of commercial goods, and we must prepare more number of commercial goods. Moreover, life length of each product becomes shorter. Without highly organized management, large inventory for many products yield large risk of depreciation of commercial value as well as large cost for floor space for stocking. Considering those, inventory cost should be explicitly considered in distribution network configuration problem. There is an essential trade off between inventory cost and transportation cost: when you set smaller number of distribution center having thicker demands there, relative stock size to coop with fluctuations become small and then, we need less inventory cost. But such concentrated location pattern results longer transportation to the customers and larger transportation cost. Nozick and Turnquist(2001) formulated a two-echelon distribution network formation problem considering inventory cost at plant and distribution centers. They used optimal inventory assignment considering the expected penalty of distribution center stock-out and plant stock-out. Stock-out was considered as the situation when Poisson distributed demand exceeded stock size, and the mean demand there was given by optimal facility location model. Inventory size of distribution center alters the location cost of distribution center, therefore optimal facility location problem was refreshed and solved again. The paper proposed iterative algorithm to get optimal inventory locations. Our paper expands their model in two ways; first we admit the difference of unit location cost for distribution centers by geographical locations, and secondly, we consider different uncertainties for customer orders by departing from simple Poisson distribution. The first alternation gives new explanation for the following situations: highly dense metropolitan regions have relatively larger number of centers and smaller coverage of each center. But such propensity usually contradicts with the land price; then center location should be limited considering higher land price in metropolitan areas. Then the optimal locations cannot be prospected in straight forwardly. The second model expansion allows our model to analyze how regularity of demands affects on the network structure. Our paper applies the model to the realistic Japanese transportation network, and show which cities may possess distribution center function in the nationwide distribution network. Without the back-stock in plant level, each distribution center must prepare inventory for their demand, but such inventory sometime requires unrealistic large location cost in metropolitan area such as Tokyo. On the other hand, if distribution center can rely on the back stock in plant, the centers in metropolitan regions stand without their own inventory.

Practical extensions to the level of repair analysis

The level of repair analysis (lora) gives answers to three questions that are posed when deciding on how to maintain capital goods: 1) which components to repair upon failure and which to discard, 2) at which locations in the repair network to perform each type of repairs, and 3) at which locations in the network to deploy resources, such as test equipment. The goal is to achieve the lowest possible life cycle costs. Various models exist for the lora problem. However, these models tend to be restrictive in that specic business situations cannot be incorporated, for example, having repair equipment with a capacity restriction or the occurrence of unsuccessful repairs.We discuss and model various practically relevant extensions to an existing minimum cost \ud ow formulation for the lora problem. We show the added value of these model renements in an extensive numerical experiment

An approximate approach for the joint problem of level of repair analysis and spare parts stocking

For the spare parts stocking problem, generally METRIC type methods are used in the context of capital goods. A decision is assumed on which components to discard and which to repair upon failure, and where to perform repairs. In the military world, this decision is taken explicitly using the level of repair analysis (LORA). Since the LORA does not consider the availability of the capital goods, solving the LORA and spare parts stocking problems sequentially may lead to suboptimal solutions. Therefore, we propose an iterative algorithm. We compare its performance with that of the sequential approach and a recently proposed, so-called integrated algorithm that finds optimal solutions for twoechelon, single-indenture problems. On a set of such problems, the iterative algorithm turns out to be close to optimal. On a set of multi-echelon, multi-indenture problems, the iterative approach achieves a cost reduction of 3%on average (35%at maximum) as compared to the sequential approach. Its costs are only 0.6 % more than those of the integrated algorithm on average (5 % at maximum). Considering that the integrated algorithm may take a long time without guaranteeing optimality, we believe that the iterative algorithm is a good approach. This result is further strengthened in a case study, which has convinced Thales Nederland to start using the principles behind our algorithm

Level of Repair Analysis: A Generic Model

Given a product design and a repair network, a level of repair analysis (lora) determines for each component in the product (1) whether it should be discarded or repaired upon failure and (2) at which echelon in the repair network to do this. The objective of the lora is to minimize the total (variable and fixed) costs. We propose an ip model that generalizes the existing models, based on cases that we have seen in practice. Analysis of our model reveals that the integrality constraints on a large number of binary variables can be relaxed without yielding a fractional solution. As a result, we are able to solve problem instances of a realistic size in a couple of seconds on average. Furthermore, we suggest some improvements to the lora analysis in the current literature

An efficient model formulation for level of repair analysis \ud

Given a product design and a repair network, a level of repair analysis (LORA)\ud determines for each component in the product (1) whether it should be discarded or repaired\ud upon failure and (2) at which echelon in the repair network to do this. The objective of\ud the LORA is to minimize the total (variable and fixed) costs. We propose an IP model that\ud generalizes the existing models, based on cases that we have seen in practice. Analysis of\ud our model reveals that the integrality constraints on a large number of binary variables can\ud be relaxed without yielding a fractional solution. As a result, we are able to solve problem\ud instances of a realistic size in a couple of seconds on average. Furthermore, we suggest some\ud improvements to the LORA analysis in the current literatur