Supply chain management in forestry––case studies at Södra Cell AB

The use of supply chain management and optimisation is of increasing importance in the forest industry. The overall wood-flow starts with standing trees in forests and continues with harvesting, bucking, sorting, transportation to terminals, sawmills, pulp mills, paper mills and heating plants, conversion into products such as pulp, paper, lumber, and ends at different customers. Many planning problems arise along the chain and these cover different time horizons. Co-ordinating the wood-flow is a vital concern for many companies. We study Södra, one of the larger Swedish forest companies, which is involved in all stages of the wood-flow. We focus in particular on Södra Cell AB, a company within Södra, which is responsible for pulp production. We describe the operations at Södra Cell and the decision support tools used for supply chain planning. We describe five major projects or cases which focus on improving their supply chain management and optimisation. These cases include the introduction of new technologies for sales and orders, new distribution structures using terminals, and the development of integrated optimisation models and methods.     

Optimising a value-based performance indicator in mid-term sales and operations planning

Economic Value Added (EVA^®) and corresponding value driver trees are prevalent frameworks of value-based management to measure and analyse shareholder value creation. However, they are explanatory models from an operations research perspective and do not provide decision support for performance optimisation. In this paper, we develop a comprehensive value-based decision framework for mid-term sales and operations planning (S&OP) in the supply chain implementing EVA as the objective function. The pivotal element of our framework is a decision-oriented extension of EVA-based value driver trees bridging the gap to the decision variables of S&OP as the operational performance levers. We utilise a numerical example to highlight the significant improvement potential due to the value-based optimisation approach. Working capital management emerges as the major mid- to short-term value driver in the supply chain.     

Scheduling coordination problems in supply chain planning

Scheduling algorithms and their role in supply chain planning are topics that have been discussed in scheduling literature for many years. Based on examples and experience with commercial supply chain planning software, this paper presents background information about production planning and scheduling functionality in commercial supply chain planning software and interesting scheduling coordination problems in supply chain planning for researchers. We first provide an overview of different planning activities in supply chain planning, while taking into consideration existing functionalities that are available in commercial supply chain planning software. As a second step, we show three scheduling coordination problems in supply chain planning, namely the integration of production planning and production scheduling, the integration of sales order confirmation and production scheduling and the integration of VMI planning and production scheduling. We conclude this paper with a detailed discussion of an implementation of a supply chain planning solution at the tissue producer SCA Hygiene in Sweden. This paper expresses the authors opinion and does not represent an official statement from SAP.     

A multiperiod model for production planning and design in a multiproduct batch environment

A general multiperiod model to optimize simultaneously production planning and design decisions applied to multiproduct batch plants is proposed. This model includes deterministic seasonal variations of costs, prices, demands and supplies. The overall problem is formulated as a mixed-integer linear programming model by applying appropriate linearizations of non-linear terms. The performance criterion is to maximize the net present value of the profit, which comprises sales, investment, inventories, waste disposal and resources costs, and a penalty term accounting for late deliveries. A noteworthy feature of this approach is the selection of unit dimensions from the available discrete sizes, following the usual procurement policy in this area. The model simultaneously calculates the plant structure (parallel units in every stage, and allocation of intermediate storage tanks), and unit sizes, as well as the production planning decisions in each period (stocks of both product and raw materials, production plans, policies of sales and procurement, etc.).     

Integrated multi-site aggregate production-pricing planning in a two-echelon supply chain with multiple demand classes

This paper proposes a production and differential pricing decision model in a two-echelon supply chain that involves a demand from two or more market segments. In this framework, the retailer is allowed to set different prices during the planning horizon. While integrated production-marketing management has been a key research issue in supply chain management for a long time, little attention has been given to set prices and marketing expenditures in integrated multi-site (parallel) manufacturing systems and multiple demand classes. Generally, the presence of multiple demand classes induced by different market segments may impose demand leakage and then change production plan and ordering policies throughout the supply chain system. To tackle this problem, this paper develops a novel approach in order to provide an optimal aggregate production and marketing plan by interconnecting the sales channels of the retailer and demand. A non-linear model is established to determine optimal price differentiation, marketing expenditures and production plans of manufacturing sites in a multi-period, multi-product and multi-sale channels production planning problem by maximizing total profit of the supply chain. To handle the model and obtain solutions, we propose an efficient analytical model based upon convex hulls. Finally, we apply the proposed procedure to a clothing company in order to show usefulness and significance of the model and solution method.     

A robust optimization model for agile and build-to-order supply chain planning under uncertainties

Supply chain planning as one of the most important processes within the supply chain management concept, has a great impact on firms’ success or failure. This paper considers a supply chain planning problem of an agile manufacturing company operating in a build-to-order environment under various kinds of uncertainty. An integrated optimization approach of procurement, production and distribution costs associated with the supply chain members has been taken into account. A robust optimization scenario-based approach is used to absorb the influence of uncertain parameters and variables. The formulation is a robust optimization model with the objective of minimizing the expected total supply chain cost while maintaining customer service level. The developed multi-product, multi-period, multi-echelon robust mixed-integer linear programming model is then solved using the CPLEX optimization studio and guidance related to future areas of research is given.     

考虑残值变化和消费者低碳偏好的生产定价与销售激励机制

在消费者低碳偏好和产品残值变化下,研究制造商的碳减排、生产及定价联合决策、以及对销售商的销售激励契约设计问题。不同于以往的研究假设残值不变,本文考虑残值依赖于清仓期库存以及碳减排问题。提出委托代理模型,求解模型并从理论上分析残值的变化和碳减排成本对双方决策和收益的影响。研究表明,残值变化率的增加只导致制造商的收益和生产量下降,不影响制造商的碳减排、定价、销售契约及零售商的决策和收益,但碳减排成本将导致制造商的收益和双方决策变量的下降。最后通过算例分析验证了结论,对供应链的运营实践有指导意义。     

Supply chain dynamic configuration as a result of new product development

This study considers supply chain network configuration in an innovative environment while the new product development (NPD) will affect the supply chain configuration (SCC). The time of new product introduction has a significant effect on the market performance while it has an effect on the supply chain configuration. Supplier integration into the new product introduction is the key parameter for successfully new product introduction, which may contribute to supply chain reconfiguration. Consequently By considering the new product development concept, we may face with dynamic supply chain configuration during a planning horizontal time. In this study, a new model is presented to consider the dynamic configuration of a supply chain by developing new products. In the proposed model, the dynamic configuration of a supply chain and the new product launching time is optimized simultaneously. The proposed model considers production, sales and transportation planning for the entire supply chain in order to achieve an integrative and efficient supply as well. Then some numerical analyses have been done to show the applicability of the proposed model. The results show that the new product development has a significant effect on the configuration of supply chain.     

A mathematical programming model for integrating production and procurement transport decisions

In this paper, we propose a new mathematical programming model for integrating production and procurement transport planning decisions in manufacturing systems in a unique optimization model. This problem was introduced conceptually and dubbed as MRP IV by Díaz-Madroñero et al. (2012) to extend the current MRP (material requirement planning) systems. This proposal simultaneously considers material, production resources capacities and procurement transport planning decisions with different shipping modes (such as full-truckload, less-than-truckload and milk-run) in the supply chain to avoid suboptimal results, which are usually generated due to sequential and independent plans. We considered an industrial automobile company to validate the proposed model using real world data. The results obtained by the MRP IV proposed model, in terms of total planning costs and transport efficiency indicators, are better than those obtained in the current heuristic procedures followed in the company under study.     

Supply-chain coordination model with insufficient production capacity and option for outsourcing

In this paper, a mathematical model is developed to analyze the situation of lost sales from the supply-chain coordination perspective. In a two-stage supply chain, the supplier’s production capacity is less than the annual demand of the retailer. The supplier may recover the deficit by procuring the same from an external source at a certain price and then supplying it back to the retailer. Here, the conditions have been derived when the practice of external procurement may be a viable solution to enhance the profits of both the supplier and retailer in a coordinated approach. A numerical example is carried out to illustrate the efficacy of the developed model and the procedure developed for solving the problem.     

Furniture supply chain tactical planning optimization using a time decomposition approach

We study the supply chain tactical planning problem of an integrated furniture company located in the Province of Québec, Canada. The paper presents a mathematical model for tactical planning of a subset of the supply chain. The decisions concern procurement, inventory, outsourcing and demand allocation policies. The goal is to define manufacturing and logistics policies that will allow the furniture company to have a competitive level of service at minimum cost. We consider planning horizon of 1 year and the time periods are based on weeks. We assume that customer’s demand is known and dynamic over the planning horizon. Supply chain planning is formulated as a large mixed integer programming model. We developed a heuristic using a time decomposition approach in order to obtain good solutions within reasonable time limit for large size problems. Computational results of the heuristic are reported. We also present the quantitative and qualitative results of the application of the mathematical model to a real industrial case.     

A multi-objective approach to supply chain visibility and risk

This paper investigates the twin effects of supply chain visibility (SCV) and supply chain risk (SCR) on supply chain performance. Operationally, SCV has been linked to the capability of sharing timely and accurate information on exogenous demand, quantity and location of inventory, transport related cost, and other logistics activities throughout an entire supply chain. Similarly, SCR can be viewed as the likelihood that an adverse event has occurred during a certain epoch within a supply chain and the associated consequences of that event which affects supply chain performance. Given the multi-faceted attributes of the decision making process which involves many stages, objectives, and stakeholders, it beckons research into this aspect of the supply chain to utilize a fuzzy multi-objective decision making approach to model SCV and SCR from an operational perspective. Hence, our model incorporates the objectives of SCV maximization, SCR minimization, and cost minimization under the constraints of budget, customer demand, production capacity, and supply availability. A numerical example is used to demonstrate the applicability of the model. Our results suggest that decision makers tend to mitigate SCR first then enhance SCV.     

A practical expected-value-approach model to assess the relevant procurement costs

As an improvement to a series of expected value approach models, this study presents a supplier portfolio decision model, rather than a number of suppliers decision model. The model assesses risks as costs, considers types of heterogeneity in a procurement process and links the assessed terms in the programming model with accounting concepts. The model is then confirmed by using a procurement decision case with real data. The analysis has several implications for modelling, application and practice. In the light of the counterexamples shown, some thoughts pertaining to procurement decisions in supply management are reconsidered.     

Coordinated supply chain management

Historically, the three fundamental stages of the supply chain, procurement, production and distribution, have been managed independently, buffered by large inventories. Increasing competitive pressures, and market globalization are forcing firms to develop supply chains that can quickly respond to customer needs. To remain competitive, these firms must reduce operating costs while continuously improving customer service. With recent advances in communications and information technology, as well as a rapidly growing array of logistics options, firms have an opportunity to reduce operating costs by coordinating the planning of these stages. In this paper, we review the literature addressing coordinated planning between two or more stages of the supply chain, placing particular emphasis on models that would lend themselves to a total supply chain model. Finally, we suggest directions for future research.     

Integrated planning of transportation and recycling for multiple plants based on process simulation

By-products accrue in all stages of industrial production networks. Legal requirements, shortening of primary resources and their increasing prices make their recycling more and more important. For the re-integration into the economic cycle the scope of common supply chain management is enlarged and so-called closed-loop supply chains with adapted and new planning tasks are developed. In process industries this requires a detailed modelling of the recycling processes. This is of special relevance for operational planning tasks in which an optimal usage of a given production system is envisaged. This contribution presents an integrated planning approach for a real-world case study from the zinc industry to achieve such an adequate process modelling. We consider the planning problem of a company that operates four metallurgical recycling plants and has to allocate residues from different sources to these recycling sites. The allocation determines the raw material mix used in the plants. This blending has an effect on the transportation costs and the costs and revenues of the individual technical processes in the recycling plants. Therefore in this problem transportation and recycling planning for multiple sites have to be regarded in an integrated way. The necessary detailed process modelling is achieved by the use of a flowsheet process simulation system to model each recycling plant individually. The models are used to derive linear input–output functions by multiple linear regression analyses. These are used in an integrated planning model to calculate the decision-relevant input and output flows that are dependent upon the allocation of the residues to the recycling sites. The model is embedded in a decision support system for the operational use. An example application and sensitivity analyses demonstrate and validate the approach and its potentials. The approach is transferable to other recycling processes as well as to other processes in process industries.     

Sales and operations planning in systems with order configuration uncertainty

This paper addresses the problem of aligning demand and supply in configure-to-order systems. Using stochastic programming methods, this study demonstrates the value of accounting for the uncertainty associated with how orders are configured. We also demonstrate the value of component supply flexibility in the presence of order configuration uncertainty. We present two stochastic models: an explosion problem model and an implosion problem model. These models are positioned sequentially within a popular business process called sales and operations planning. Both models are formulated as two-stage stochastic programs with recourse and are solved using the sample average approximation method. Computational analyses were performed using data obtained from IBM System and Technology Group. The problem sets used in our analysis are created from actual industry data and our results show that significant improvements in revenue and serviceability can be achieved by appropriately accounting for the uncertainty associated with order configurations.     

基于改进EAHP的装备采购供应链质量绩效评价

针对装备采购供应链质量绩效评价指标体系不能真实反映供应链质量状况和评价方法不够合理的问题,基于平衡计分卡模型框架建立了装备采购供应链质量绩效评价指标体系,提出了一种新的改进可拓层次分析法(EAHP),用于评价供应链质量绩效。该方法通过个体指标权重向量与群体指标权重向量之间的贴近度确定初始专家权重,并通过引入修正参数的序关系分析法(G1)来多轮修正专家权重分配,克服了传统EAHP在群决策中集结专家判断信息后一致性检验难以通过的问题。计算实例表明该方法能有效集结群决策信息,并减少偏差较大的决策信息带来的不良影响。     

Concurrent optimization in designing for logistics support

Concurrent Engineering has always been an important field within military industry and is gaining recognition within commercial industry as well. Studies have suggested that long-range research efforts need to be directed to the area of integrated logistics. In order to satisfy the overall logistics objectives, product designs must incorporate consideration of the impact that design decisions have on operations, maintenance, transportation and supply. This paper presents a model that carries out a concurrent optimization of a product design and its associated manufacturing and logistics support systems. We offer this model as a framework for decision support of concurrent engineering activities.     

An automated planning engine for biopharmaceutical production

We introduce an optimization-based production planning tool for the biotechnology industry. The industry’s planning problem is unusually challenging because the entire production process is regulated by multiple external agencies – such as the US Food and Drug Administration – representing countries where the biopharmaceutical is to be sold. The model is structured to precisely capture the constraints imposed by current and projected regulatory approvals of processes and facilities, as well as capturing the outcomes of quality testing and processing options, facility capacities and initial status of work-in-process. The result is a supply chain “Planning Engine” that generates capacity-feasible batch processing schedules for each production facility within the biomanufacturing supply chain and an availability schedule for finished product against a known set of demands and regulations. Developing the formulation based on distinct time grids tailored for each facility, planning problems with more than 27,000 boolean variables, more than 130,000 linear variables and more than 80,000 constraints are automatically formulated and solved within a few hours. The Planning Engine’s development and implementation at Bayer Healthcare’s Berkeley, CA manufacturing site is described.     

The Application of Preprocessing and Cutting Plane Techniques for a Class of Production Planning Problems

This paper investigates properties of integer programming models for a class of production planning problems. The models are developed within a decision support system to advise a sales team of the products on which to focus their efforts in gaining new orders in the short term. The products generally require processing on several manufacturing cells and involve precedence relationships. The cells are already (partially) committed with products for stock and to satisfy existing orders and therefore only the residual capacities of each cell in each time period of the planning horizon are considered. The determination of production recommendations to the sales team that make use of residual capacities is a nontrivial optimization problem. Solving such models is computationally demanding and techniques for speeding up solution times are highly desirable. An integer programming model is developed and various preprocessing techniques are investigated and evaluated. In addition, a number of cutting plane approaches have been applied. The performance of these approaches which are both general and application specific is examined.