Coordination mechanisms with mathematical programming models for decentralized decision-making, a literature review

[EN] The increase in the complexity of supply chains requires greater efforts to align the activities of all its members in order to improve the creation of value of their products or services offered to customers. In general, the information is asymmetric; each member has its own objective and limitations that may be in conflict with other members. Operations managements face the challenge of coordinating activities in such a way that the supply chain as a whole remains competitive, while each member improves by cooperating. This document aims to offer a systematic review of the collaborative planning in the last decade on the mechanisms of coordination in mathematical programming models that allow us to position existing concepts and identify areas where more research is needed.Rius-Sorolla, G.; Maheut, J.; Estelles Miguel, S.; García Sabater, JP. (2020). Coordination mechanisms with mathematical programming models for decentralized decision-making, a literature review. 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Optimal production planning for a multi-product closed loop system with uncertain demand and return

We study the production planning problem for a multi-product closed loop system, in which the manufacturer has two channels for supplying products: producing brand-new products and remanufacturing returns into as-new ones. In the remanufacturing process, used products are bought back and remanufactured into as-new products which are sold together with the brand-new ones. The demands for all the products are uncertain, and their returns are uncertain and price-sensitive. The problem is to maximize the manufacturer\u27s expected profit by jointly determining the production quantities of brand-new products, the quantities of remanufactured products and the acquisition prices of the used products, subject to a capacity constraint. A mathematical model is presented to formulate the problem and a Lagrangian relaxation based approach is developed to solve the problem. Numerical examples are presented to illustrate the model and test the solution approach. Computational results show that the proposed approach is highly promising for solving the problems. The sensitivity analysis is also conducted to generate managerial insights

An Integrated Strategy for a Production Planning and Warehouse Layout Problem: Modeling and Solution Approaches

We study a real-world production warehousing case, where the company always faces the challenge to find available space for their products and to manage the items in the warehouse. To resolve the problem, an integrated strategy that combines warehouse layout with the capacitated lot-sizing problem is presented, which have been traditionally treated separately in the existing literature. We develop a mixed integer linear programming model to formulate the integrated optimization problem with the objective of minimizing the total cost of production and warehouse operations. The problem with real data is a large-scale instance that is beyond the capability of optimization solvers. A novel Lagrangian relax-and-fix heuristic approach and its variants are proposed to solve the large-scale problem. The preliminary numerical results from the heuristic approaches are reported

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In this paper, the joint production and recycling problem is investigated for a hybrid manufacturing and remanufacturing system where brand-new products are produced in the manufacturing plant and recycled products are remanufactured into as-new products in the remanufacturing facility. Both the brand-new products and remanufactured products are used to satisfy customer demands. Returns of used products that are recycled from customers are assumed to be stochastic and nonlinearly price-dependent. A mathematical model is proposed to maximize the overall profit of the system through simultaneously optimizing the production and recycling decisions, subject to two capacity constraints — the manufacturing capacity and the remanufacturing capacity. Based on Lagrangian relaxation method, subgradient algorithm and heuristic algorithm, a solution approach is developed to solve the problem. A representative example is presented to illustrate the system, and managerial analysis indicates that the uncertainties in demand and return have much influence on the production and recycling policy. In addition, twenty randomly produced examples are solved, and computational results show that the solution approach can obtain very good solutions for all examples in reasonable time

Modeling Industrial Lot Sizing Problems: A Review

In this paper we give an overview of recent developments in the field of modeling single-level dynamic lot sizing problems. The focus of this paper is on the modeling various industrial extensions and not on the solution approaches. The timeliness of such a review stems from the growing industry need to solve more realistic and comprehensive production planning problems. First, several different basic lot sizing problems are defined. Many extensions of these problems have been proposed and the research basically expands in two opposite directions. The first line of research focuses on modeling the operational aspects in more detail. The discussion is organized around five aspects: the set ups, the characteristics of the production process, the inventory, demand side and rolling horizon. The second direction is towards more tactical and strategic models in which the lot sizing problem is a core substructure, such as integrated production-distribution planning or supplier selection. Recent advances in both directions are discussed. Finally, we give some concluding remarks and point out interesting areas for future research

Open source solution approaches to a class of stochastic supply chain problems

This research proposes a variety of solution approaches to a class of stochastic supply chain problems, with normally distributed demand in a certain period of time in the future. These problems aim to provide the decisions regarding the production levels; supplier selection for raw materials; and optimal order quantity. The typical problem could be formulated as a mixed integer nonlinear program model, and the objective function for maximizing the expected profit is expressed in an integral format. In order to solve the problem, an open source solution package BONMIN is first employed to get the exact optimum result for small scale instances; then according to the specific feature of the problem a tailored nonlinear branch and bound framework is developed for larger scale problems through the introduction of triangular approximation approach and an iterative algorithm. Both open source solvers and commercial solvers are employed to solve the inner problem, and the results to larger scale problems demonstrate the competency of introduced approaches. In addition, two small heuristics are also introduced and the selected results are reported

Design of a Distribution Network Using Primal-Dual Decomposition

Amethodtosolvethedesignofadistributionnetworkforbottleddrinkscompanyisintroduced.Thedistributionnetworkproposed includes three stages: manufacturing centers, consolidation centers using cross-docking, and distribution centers. The problem is formulated using a mixed-integer programming model in the deterministic and single period contexts. Because the problem considersseveralelementsineachstage,adirectsolutionisverycomplicated.Formedium-to-largeinstancestheproblemfallsinto large scale. Based on that, a primal-dual decomposition known as cross decomposition is proposed in this paper. This approach allows exploring simultaneously the primal and dual subproblems of the original problem. A comparison of the direct solution withamixed-integerlinealprogrammingsolverversusthecrossdecompositionisshownforseveralrandomlygeneratedinstances. Resultsshowthegoodperformanceofthemethodproposed

Integrated optimisation for production capacity, raw material ordering and production planning under time and quantity uncertainties based on two case studies

Abstract This paper develops a supply chain (SC) model by integrating raw material ordering and production planning, and production capacity decisions based upon two case studies in manufacturing firms. Multiple types of uncertainties are considered; including: time-related uncertainty (that exists in lead-time and delay) and quantity-related uncertainty (that exists in information and material flows). The SC model consists of several sub-models, which are first formulated mathematically. Simulation (simulation-based stochastic approximation) and genetic algorithm tools are then developed to evaluate several non-parameterised strategies and optimise two parameterised strategies. Experiments are conducted to contrast these strategies, quantify their relative performance, and illustrate the value of information and the impact of uncertainties. These case studies provide useful insights into understanding to what degree the integrated planning model including production capacity decisions could benefit economically in different scenarios, which types of data should be shared, and how these data could be utilised to achieve a better SC system. This study provides insights for small and middle-sized firm management to make better decisions regarding production capacity issues with respect to external uncertainty and/or disruptions; e.g. trade wars and pandemics.</jats:p

Assessment of Lagrangean decomposition for short-term planning of integrated refinery-petrochemical operations

We present an integrated methodology for optimal short-term planning of integrated refinery-petrochemical complexes (IRPCs) and demonstrate it on a full-scale industrial case study under four realistic planning scenarios. The large-scale mixed-integer quadratically constrained optimization models are amenable to a spatial Lagrangean decomposition through dividing the IRPC into multiple subsections, which comprise crude management, refinery, fuel blending, and petrochemical production. The decomposition algorithm creates virtual markets for trading crude blends and intermediate petrochemical streams within the IRPC and seeks an optimal tradeoff in such markets, with the Lagrange multipliers acting as transfer prices. The best results are obtained for decompositions with two or three subsections, achieving optimality gaps below 4% in all four planning scenarios. The Lagrangean decomposition provides tighter primal and dual bounds than the global solvers BARON and ANTIGONE, and it also improves the dual bounds computed using piecewise linear relaxation strategies