The boomerang returns? Accounting for the impact of uncertainties on the dynamics of remanufacturing systems

Recent years have witnessed companies abandon traditional open-loop supply chain structures in favour of closed-loop variants, in a bid to mitigate environmental impacts and exploit economic opportunities. Central to the closed-loop paradigm is remanufacturing: the restoration of used products to useful life. While this operational model has huge potential to extend product life-cycles, the collection and recovery processes diminish the effectiveness of existing control mechanisms for open-loop systems. We systematically review the literature in the field of closed-loop supply chain dynamics, which explores the time-varying interactions of material and information flows in the different elements of remanufacturing supply chains. We supplement this with further reviews of what we call the three ‘pillars’ of such systems, i.e. forecasting, collection, and inventory and production control. This provides us with an interdisciplinary lens to investigate how a ‘boomerang’ effect (i.e. sale, consumption, and return processes) impacts on the behaviour of the closed-loop system and to understand how it can be controlled. To facilitate this, we contrast closed-loop supply chain dynamics research to the well-developed research in each pillar; explore how different disciplines have accommodated the supply, process, demand, and control uncertainties; and provide insights for future research on the dynamics of remanufacturing systems

Disposition Choices Based on Energy Footprints instead of Recovery Quota

This paper addresses the impact of disposition choices on the energy use of closed-loop supply chains. In a life cycle perspective, energy used in the forward chain which is locked up in the product is recaptured in recovery. High quality recovery replaces virgin production and thereby saves energy. This so called substitution effect is often ignored. Governments worldwide implement Extended Producer Responsibility (EPR). Policies are based on recovery quota and not effective from an energy point of view. This in turn leads to unnecessary emissions of amongst others CO2. This research evaluates current EPR policies and presents six policy alternatives from an energy standpoint. The Pareto-frontier model used is generic and can be applied to other closed loops supply chains under EPR, exploiting the substitution effect. The measures modeled are applied to five WEEE cases. We discuss results, pros an cons of various alternatives and complementary measures that might be taken.extended producer responsibility;disposition;energy perspective;substitution effect;government policies;Pareto efficiency

Applying Revenue Management to the Reverse Supply Chain

We study the disposition decision for product returns in a closed-loop supply chain. Motivated by the asset recovery process at IBM, we consider two disposition alternatives. Returns may be either refurbished for reselling or dismantled for spare parts. Reselling a refurbished unit typically yields higher unit margins. However, demand is uncertain. A common policy in many firms is to rank disposition alternatives by unit margins. We show that a revenue management approach to the disposition decision which explicitly incorporates demand uncertainty can increase profits significantly. We discuss analogies between the disposition problem and the classical airline revenue management problem. We then develop single period and multi-period stochastic optimization models for the disposition problem. Analyzing these models, we show that the optimal allocation balances expected marginal profits across the disposition alternatives. A detailed numerical study reveals that a revenue management approach to the disposition problem significantly outperforms the current practice of focusing exclusively on high-margin options, and we identify conditions under which this improvement is the highest. We also show that the value recovered from the returned products critically depends on the coordination between forward and reverse supply chain decisions.remanufacturing;revenue management;onderdelen;revenues;spare parts inventory

Selection of return channels and recovery options for used products

Due to legal, economic and socio-environmental factors, reverse logistics practices and extended producer responsibility have developed into a necessity in many countries. The end results and expectations may differ, but the motivation remains the same. Two significant components in a reverse logistics system -product recovery options and return channels - are the focus of this thesis. The two main issues examined are allocation of the returned products to recovery options, and selection of the collection methods for product returns. The initial segment of this thesis involves the formulation of a linear programming model to determine the optimal allocation of returned products differing in quality to specific recovery options. This model paves the way for a study on the effects of flexibility on product recovery allocation. A computational example utilising experimental data was presented to demonstrate the viability of the proposed model. The results revealed that in comparison to a fixed match between product qualities and recovery options, the product recovery operation appeared to be more profitable with a flexible allocation. The second segment of this thesis addresses the methods employed for the initial collection of returned products. A mixed integer nonlinear programming model was developed to facilitate the selection of optimal collection methods for these products. This integrated model takes three different initial collection methods into consideration. The model is used to solve an illustrative example optimally. However, as the complexity of the issue renders this process ineffective in the face of larger problems, the Lagrangian relaxation method was proposed to generate feasible solutions within reasonable computational times. This method was put to the test and the results were found to be encouraging

Production planning and control of closed-loop supply chains

More and more supply chains emerge that include a return flow of materials. Many original equipment manufacturers are nowadays engaged in the remanufacturing business. In many process industries, production defectives and by-products are reworked. These closed-loop supply chains deserve special attention. Production planning and control in such hybrid systems is a real challenge, especially due to increased uncertainties. Even companies that are engaged in remanufacturing operations only, face more complicated planning situations than traditional manufacturing companies.We point out the main complicating characteristics in closed-loop systems with both remanufacturing and rework, and indicated the need for new or modified/extended production planning and control approaches. An overview of the existing scientific contributions is given. It appears that we only stand at the beginning of this line of research, and that many more contributions are needed and expected in the future.closed-loop supply chains;Production planning and control

Coordination in closed-loop supply chain with price-dependent returns

This paper proposes two Closed-loop Supply Chain (CLSC) games in which a manufacturer sets some green activity programs efforts and a retailer sets the selling price. Both strategies influence the return rate, which is a state variable. The pricing strategy plays a key role in the identification of the best contract to achieve coordination as well as in achieving environmental objectives. The pricing strategy influences the return rate negatively, as consumers delay the return of their goods when the purchasing (and repurchasing) price is high. We then compare a wholesale price contract (WPC) and a revenue sharing contract (RSC) mechanism as both have interesting pricing policy implications. Our result shows that firms coordinate the CLSC through a (WPC) when the sharing parameter is too low while the negative effect of pricing on returns is too severe. In that case, the low sharing parameter deters the manufacturer to accept any sharing agreements. Further, firms coordinate the CLSC when the sharing parameter is medium independent of the negative impact of pricing on returns. When the sharing parameter is too high the retailer never opts for an RSC. We find that the magnitude of pricing effect on returns determines the contract to be adopted: For certain sharing parameter, firms prefer an RSC when the price effect on return is low and a WPC when this effect is high. In all other cases, firms do not have a consensus on the contract to be adopted and coordination is then not achieved

E-Fulfillment and Multi-Channel Distribution – A Review

This review addresses the specific supply chain management issues of Internet fulfillment in a multi-channel environment. It provides a systematic overview of managerial planning tasks and reviews corresponding quantitative models. In this way, we aim to enhance the understanding of multi-channel e-fulfillment and to identify gaps between relevant managerial issues and academic literature, thereby indicating directions for future research. One of the recurrent patterns in today’s e-commerce operations is the combination of ‘bricks-and-clicks’, the integration of e-fulfillment into a portfolio of multiple alternative distribution channels. From a supply chain management perspective, multi-channel distribution provides opportunities for serving different customer segments, creating synergies, and exploiting economies of scale. However, in order to successfully exploit these opportunities companies need to master novel challenges. In particular, the design of a multi-channel distribution system requires a constant trade-off between process integration and separation across multiple channels. In addition, sales and operations decisions are ever more tightly intertwined as delivery and after-sales services are becoming key components of the product offering.Distribution;E-fulfillment;Literature Review;Online Retailing

Remanufacturing Process Planning Considering Quality Uncertainties, Environmental Taxes and Incentives

As environmental issues are gradually being valued by governments and societies, companies have begun to engage in economic sustainable practices such as remanufacturing, reuse and recycling, among other socially responsible practices. The broader impact of these practices enables companies to archive the goal of circular economies. Under normal circumstances, consumers’ used products have often been released into landfills, resulting in environmental pollution. This is especially so for electronic products since most materials used in their production are non-biodegradable. This research addresses the practice of remanufacturing. The remanufacturing value of the products gradually declines with the usage--also referred to as the product resident time. So the remanufacturer must decide when to acquire these end of life products from customers, to carry out remanufacturing at maximum benefits. Companies face logistical challenges in the remanufacturing process, including uncertainties in the quality and quantity of returned products, and uncertainties in the process variables including process times and resource availability. In order to maximize expected profits, we provide a decision model for finding the optimal quality threshold to accept into the system and also show the variability in the profit percentages when products are returned at various stages in their life cycle. The model also considers a system that not only remanufactures products but also salvages components and uses them in the remanufacturing process. The model also allows for purchases of new components from suppliers as needed. The model also includes environmental factors such as emissions taxes and remanufacturing government incentives. The model is applied to a case study of a real control drive remanufacturing process, with two types of products that have interchangeable key components. The results confirm that the quality threshold is indeed of significance in the process. The demand forecast for remanufactured products in the secondary market is even more significant, driving the acceptable threshold quality to as low as 0.25 on a scale of 0 (worst quality) to 1 (best quality). Lastly, the results show that the resident time (time of return after the product was first sold in the first market) also significantly impacts the profit