Integrated Supply Chain Network Design: Location, Transportation, Routing and Inventory Decisions

abstract: In this dissertation, an innovative framework for designing a multi-product integrated supply chain network is proposed. Multiple products are shipped from production facilities to retailers through a network of Distribution Centers (DCs). Each retailer has an independent, random demand for multiple products. The particular problem considered in this study also involves mixed-product transshipments between DCs with multiple truck size selection and routing delivery to retailers. Optimally solving such an integrated problem is in general not easy due to its combinatorial nature, especially when transshipments and routing are involved. In order to find out a good solution effectively, a two-phase solution methodology is derived: Phase I solves an integer programming model which includes all the constraints in the original model except that the routings are simplified to direct shipments by using estimated routing cost parameters. Then Phase II model solves the lower level inventory routing problem for each opened DC and its assigned retailers. The accuracy of the estimated routing cost and the effectiveness of the two-phase solution methodology are evaluated, the computational performance is found to be promising. The problem is able to be heuristically solved within a reasonable time frame for a broad range of problem sizes (one hour for the instance of 200 retailers). In addition, a model is generated for a similar network design problem considering direct shipment and consolidation within the same product set opportunities. A genetic algorithm and a specific problem heuristic are designed, tested and compared on several realistic scenarios.Dissertation/ThesisPh.D. Industrial Engineering 201

An integrated shipment planning and storage capacity decision under uncertainty: a simulation study

Purpose – In transportation and distribution systems, the shipment decisions, fleet capacity, and storage capacity are interrelated in a complex way, especially when the authors take into account uncertainty of the demand rate and shipment lead time. While shipment planning is tactical or operational in nature, increasing storage capacity often requires top management’s authority. The purpose of this paper is to present a new method to integrate both operational and strategic decision parameters, namely shipment planning and storage capacity decision under uncertainty. The ultimate goal is to provide a near optimal solution that leads to a striking balance between the total logistics costs and product availability, critical in maritime logistics of bulk shipment of commodity items. Design/methodology/approach – The authors use simulation as research method. The authors develop a simulation model to investigate the effects of various factors on costs and service levels of a distribution system. The model mimics the transportation and distribution problems of bulk cement in a major cement company in Indonesia consisting of a silo at the port of origin, two silos at two ports of destination, and a number of ships that transport the bulk cement. The authors develop a number of “what-if” scenarios by varying the storage capacity at the port of origin as well as at the ports of destinations, number of ships operated, operating hours of ports, and dispatching rules for the ships. Each scenario is evaluated in terms of costs and service level. A full factorial experiment has been conducted and analysis of variance has been used to analyze the results. Findings – The results suggest that the number of ships deployed, silo capacity, working hours of ports, and the dispatching rules of ships significantly affect both total costs and service level. Interestingly, operating fewer ships enables the company to achieve almost the same service level and gaining substantial cost savings if constraints in other part of the system are alleviated, i.e., storage capacities and working hours of ports are extended. Practical implications – Cost is a competitive factor for bulk items like cement, and thus the proposed scenarios could be implemented by the company to substantially reduce the transportation and distribution costs. Alleviating storage capacity constraint is obviously an idea that needs to be considered when optimizing shipment planning alone could not give significant improvements. Originality/value – Existing research has so far focussed on the optimization of shipment planning/scheduling, and considers shipment planning/scheduling as the objective function while treating the storage capacity as constraints. The simulation model enables “what-if” analyses to be performed and has overcome the difficulties and impracticalities of analytical methods especially when the system incorporates stochastic variables exhibited in the case example. The use of efficient frontier analysis for analyzing the simulation results is a novel idea which has been proven to be effective in screening non-dominated solutions. This has provided the authors with near optimal solutions to trade-off logistics costs and service levels (availability), with minimal experimentation times

Factory Gate Pricing: An Analysis of the Dutch Retail Distribution

Factory Gate Pricing (FGP) is a relatively new phenomenon in retail distribution. Under FGP, products are no longer delivered at the retailer distribution center, but collected by the retailer at the factory gates of the suppliers. Owing to both the asymmetry in the distribution networks (the supplier sites greatly outnumber the retailer distribution centers) and the better inventory and transport coordination mechanisms, this is likely to result in high savings. A mathematical model was used to analyze the benefits of FGP for a case study in the Dutch retail sector. Extensive numerical results are presented to show the effect of the orchestration shift from supplier to retailer, the improved coordination mechanisms, and sector-wide cooperation.supply chain management;factory gate pricing;retail distribution

Supply chain management: An opportunity for metaheuristics

In today’s highly competitive and global marketplace the pressure on organizations to find new ways to create and deliver value to customers grows ever stronger. In the last two decades, logistics and supply chain has moved to the center stage. There has been a growing recognition that it is through an effective management of the logistics function and the supply chain that the goal of cost reduction and service enhancement can be achieved. The key to success in Supply Chain Management (SCM) require heavy emphasis on integration of activities, cooperation, coordination and information sharing throughout the entire supply chain, from suppliers to customers. To be able to respond to the challenge of integration there is the need of sophisticated decision support systems based on powerful mathematical models and solution techniques, together with the advances in information and communication technologies. The industry and the academia have become increasingly interested in SCM to be able to respond to the problems and issues posed by the changes in the logistics and supply chain. We present a brief discussion on the important issues in SCM. We then argue that metaheuristics can play an important role in solving complex supply chain related problems derived by the importance of designing and managing the entire supply chain as a single entity. We will focus specially on the Iterated Local Search, Tabu Search and Scatter Search as the ones, but not limited to, with great potential to be used on solving the SCM related problems. We will present briefly some successful applications.Supply chain management, metaheuristics, iterated local search, tabu search and scatter search

Class-based storage location assignment : an overview of the literature

Storage, per se, is not only an important process in a warehouse, also it has the greatest influence on the most expensive one, i.e., order picking. This study aims to give a literature overview on class-based storage location assignment (CBSLAP). In this paper, we discuss storage policies and present a classification of storage location assignment problem. Next, different configuration of classes are presented. We identify the research gaps in the literature and conclude with promising future research directions

Modeling and solving the multi-period inventory routing problem with constant demand rates

The inventory routing problem (IRP) is one of the challenging optimization problems in supply chain logistics. It combines inventory control and vehicle routing optimization. The main purpose of the IRP is to determine optimal delivery times and quantities to be delivered to customers, as well as optimal vehicle routes to distribute these quantities. The IRP is an underlying logistical optimization problem for supply chains implementing vendor-managed inventory (VMI) policies, in which the supplier takes responsibility for the management of the customers' inventory. In this paper, we consider a multi-period inventory routing problem assuming constant demand rates (MP-CIRP). The proposed model is formulated as a linear mixed-integer program and solved with a Lagrangian relaxation method. The solution obtained by the Lagrangian relaxation method is then used to generate a close to optimal feasible solution of the MP-CIRP by solving a series of assignment problems. The numerical experiments carried out so far show that the proposed Lagrangian relaxation approach nds quite good solutions for the MP-CIRP and in reasonable computation times

Factory Gate Pricing: An Analysis of the Dutch Retail Distribution

Factory Gate Pricing (FGP) is a relatively new phenomenon in retail distribution.Under FGP, products are no longer delivered at the retailer distribution center, but collected by the retailer at the factory gates of the suppliers.Owing to both the asymmetry in the distribution networks (the supplier sites greatly outnumber the retailer distribution centers) and the better inventory and transport coordination mechanisms, this is likely to result in high savings.A mathematical model was used to analyze the benefits of FGP for a case study in the Dutch retail sector.Extensive numerical results are presented to show the effect of the orchestration shift from supplier to retailer, the improved coordination mechanisms, and sector-wide cooperation.pricing;retailing;distribution;supply chain management;Netherlands

Inventory routing problem with non-stationary stochastic demands

In this paper we solve Stochastic Periodic Inventory Routing Problem (SPIRP) when the accuracy of expected demand is changing among the periods. The variability of demands increases from period to period. This variability follows a certain rate of uncertainty. The uncertainty rate shows the change in accuracy level of demands during the planning horizon. To deal with the growing uncertainty, we apply a safety stock based SPIRP model with different levels of safety stock. To satisfy the service level in the whole planning horizon, the level of safety stock needs to be adjusted according to the demand's variability. In addition, the behavior of the solution model in long term planning horizons for retailers with different demand accuracy is taken into account. We develop the SPIRP model for one retailer with an average level of demand, and standard deviation for each period. The objective is to find an optimum level of safety stock to be allocated to the retailer, in order to achieve the expected level of service, and minimize the costs. We propose a model to deal with the uncertainty in demands, and evaluate the performance of the model based on the defined indicators and experimentally designed cases

Designing Enterprise Resources Planning Application for Integrating Main Activities in a Simulator Model of SCM Network Distribution

Collaborative supply chain is a specific topic in supply chain management and studied by industrial engineering students in supply chain management course. Unfortunately, conventional learning media cannot explain the phenomenon of collaborative supply chain to the students. This study aimed to design a dynamic learning media so that inter-company collaboration and information sharing on the activities of Supply Chain entities can be explained effectively to the students. The problem was solved using 3 (three) steps. First, the distribution network was described using mock up. It consists of miniature trucks, miniature network and miniature of the manufacturer-distributor-retailer embedded with tag and reader of RFID. Second, the Enterprise Resources Planning application was developed for supporting business activities. Third, we developed the integrator consists of monitor’s user interface and practice modules. The result of the research - an SCM-Simulator – will be able to improve learning skills of industrial engineering graduates, especially abilities to identify, formulate, and solve the activities of tactical plan & operational routines of Supply Chain entities. However, distribution module designed is for limited scale laboratory study of simple objects. Keywords: Distribution Network, Enterprise Resource Planning, Industrial Engineering Education, SCM Simulator,and Learning Media