A fuzzy linear programming based approach for tactical supply chain planning in an uncertainty environment

This paper models supply chain (SC) uncertainties by fuzzy sets and develops a fuzzy linear programming model for tactical supply chain planning in a multi-echelon, multi-product, multi-level, multi-period supply chain network. In this approach, the demand, process and supply uncertainties are jointly considered. The aim is to centralize multi-node decisions simultaneously to achieve the best use of the available resources along the time horizon so that customer demands are met at a minimum cost. This proposal is tested by using data from a real automobile SC. The fuzzy model provides the decision maker (DM) with alternative decision plans with different degrees of satisfaction.     

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 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.     

Column generation based heuristic for tactical planning in multi-period vehicle routing

The periodic vehicle routing problem (PVRP) consists in establishing a planning of visits to clients over a given time horizon so as to satisfy some service level while optimizing the routes used in each time period. The tactical planning model considered here restricts its attention to scheduling visits and assigning them to vehicles while leaving sequencing decisions for an underlying operational model. The objective is twofold: to optimize regional compactness of the routes in a desire to specialize routes to restricted geographical area and to balance the workload evenly between vehicles. Approximate solutions are constructed using a truncated column generation procedure followed by a rounding heuristic. This mathematical programming based procedure can deal with problems with 50–80 customers over five working days which is the range of size of most PVRP instances treated in the literature with meta-heuristics. The paper highlights the importance of alternative optimization criteria not accounted for in standard operational models and provides insights on the implementation of a column generation based rounding heuristic.     

Formulations for a problem of petroleum transportation

Oil tankers play a fundamental role in every offshore petroleum supply chain and due to its high price, it is essential to optimize its use. Since this optimization requires handling detailed operational aspects, complete optimization models are typically intractable. Thus, a usual approach is to solve a tactical level model prior to optimize the operational details. In this case, it is desirable that tactical models are as precise as possible to avoid too severe adjustments in the next optimization level. In this paper, we study tactical models for a crude oil transportation problem by tankers. We did our work on the top of a previous paper found in the literature. The previous model considers inventory capacities and discrete lot sizes to be transported, aiming to meet given demands over a finite time horizon. We compare several formulations for this model using 50 instances from the literature and proposing 25 new harder ones. A column generation-based heuristic is also proposed to find good feasible solutions with less computational burden than the heuristics of the commercial solver used.     

Production strategies for a stochastic lot-sizing problem with constant capacity

This paper presents a single item capacitated stochastic lot-sizing problem motibated by a Dutch company operating in a Make-To-Order environment. Due to a highly fluctuating and unpredictable demand, it is not possible to keep any finished goods inventory. In response to a customer's order, a fixed delivery date is quoted by the company. The objective is to determine in each period of the planning horizon the optimal size of production lots so that delivery dates are met as closely as possible at the expense of minimal average costs. These include set-up costs, holding costs for orders that are finished before their promised delivery date and penalty costs for orders that are not satisfied on time and are therefore backordered. Given that the optimal production policy is likely to be too complex in this situation, attention is focused on the development of heuristic procedures. In this paper two heuristics are proposed. The first one is an extension of a simple production strategy derived by Dellaert [5] for the uncapacitated version of the problem. The second heuristic is based on the well-known Silver-Meal algorithm for the case of deterministic time-varying demand. Experimental results suggest that the first heuristic gives low average costs especially when the demand variability is low and there are large differences in the cost parameters. The Silver-Meal approach is usually outperformed by the first heuristic in situations where the available production capacity is tight and the demand variability is low.     

基于收益共享的多周期易变质产品供应链协调模型

研究了单个供应商与单个零售商组成的易变质产品供应链系统在有限计划期内的协调问题。考虑到市场需求会同时受到多种因素的影响,构建了市场需求率依赖于销售价格与当前库存水平且随时间呈现一般连续变化的需求函数。将零售商的订购次数、销售价格以及供应商的批发价格作为决策变量,分别求解了集中式与分散式供应链系统下的最优策略。通过与分散式决策的利润值进行比较,得出集中式决策能够使得供应链系统的利润值至少增加1/3。利用收益共享契约机制协调此系统,求解了供应链实现完美协调时收益共享因子的取值区间。最后通过算例验证了理论结果并分析了相关参数变化对系统协调的影响。     

Asymptotic Analysis of a Greedy Heuristic for the Multi-Period Single-Sourcing Problem: The Acyclic Case

The multi-period single-sourcing problem that we address in this paper can be used as a tactical tool for evaluating logistics network designs in a dynamic environment. In particular, our objective is to find an assignment of customers to facilities, as well as the location, timing and size of production and inventory levels, that minimizes total assignment, production, and inventory costs. We propose a greedy heuristic, and prove that this greedy heuristic is asymptotically optimal in a probabilistic sense for the subclass of problems where the assignment of customers to facilities is allowed to vary over time. In addition, we prove a similar result for the subclass of problems where each customer needs to be assigned to the same facility over the planning horizon, and where the demand for each customer exhibits the same seasonality pattern. We illustrate the behavior of the greedy heuristic, as well as some improvements where the greedy heuristic is used as the starting point of a local interchange procedure, on a set of randomly generated test problems. These results suggest that the greedy heuristic may be asymptotically optimal even for the cases that we were unable to analyze theoretically.     

Hybrid heuristics for a short sea inventory routing problem

We consider a short sea fuel oil distribution problem where an oil company is responsible for the routing and scheduling of ships between ports such that the demand for various fuel oil products is satisfied during the planning horizon. The inventory management has to be considered at the demand side only, and the consumption rates are given and assumed to be constant within the planning horizon. The objective is to determine distribution policies that minimize the routing and operating costs, while the inventory levels are maintained within their limits. We propose an arc-load flow formulation for the problem which is tightened with valid inequalities. In order to obtain good feasible solutions for planning horizons of several months, we compare different hybridization strategies. Computational results are reported for real small-size instances.     

A three-phase matheuristic for the Packaging and Shipping Problem

E-commerce has been continuously growing in the last years to a primary retail market. Recently in France, the threshold of 1 billion of online transactions was overcome. Due to a high demand fluctuation of e-commerce, the workforce sizing for the logistic chain is a challenging problem. Companies have to develop good strategies to have a sustainable workforce size while guaranteeing a high-level service.In this paper, we consider the management of the workforce for a warehouse of an e-commerce company. Specifically, we address issues as i) How the workforce at the warehouse can be determined; ii) What is the daily operational production planning; iii) How the demand peaks can be smoothed, and the production maintained ideally constant over the time horizon.To provide answers to these issues, we introduce the Packaging and Shipping Problem (PSP). The PSP looks for a solution approach that jointly determines the workforce over a multi-period horizon and daily operational plans while minimizing the total logistics cost. We consider two strategies that aim to enhance the flexibility of the process and the efficiency of resources use: reassignment and postponement. To tackle the Packaging and Shipping Problem we propose a model, and a three-phase matheuristic. This heuristic is proved to be competitive with respect to the direct solution of the model with a commercial solver on real-life based instances.     

On sourcing and stocking policies in a two-echelon,multiple location,repairable parts supply chain

This research develops policies to minimize spare part purchases and repair costs for maintaining a fleet of mission-critical systems that operate from multiple forward (base) locations within a two-echelon repairable supply chain with a central depot. We take a tactical planning perspective to support periodic decisions for spare part purchases and repair sourcing, where the repair capabilities of the various locations are overlapping. We consider three policy classes: a central policy, where all repairs are sourced to a central depot; a local policy, whereby failures are repaired at forward locations; and a mixed policy, where a fraction of the parts is repaired at the bases and the remainder is repaired at the depot. Parts are classified based on their repair cost and lead time. For each part class, we suggest a solution that is based on threshold policies or on the use of a heuristic solution algorithm that extends the industry standard of marginal analysis to determine spare parts positioning by including repair fraction sourcing. A validation study shows that the suggested heuristic performs well compared to an exhaustive search (an average 0.2% difference in cost). An extensive numerical study demonstrates that the algorithm achieves costs which are lower by about 7–12% on average, compared to common, rule-based sourcing policies.     

Cost allocation in collaborative forest transportation

Transportation planning is an important part of the supply chain or wood flow chain in forestry. There are often several forest companies operating in the same region and collaboration between two or more companies is rare. However, there is an increasing interest in collaborative planning as the potential savings are large, often in the range 5–15%. There are several issues to agree on before such collaborative planning can be used in practice. A key question is how the total cost or savings should be distributed among the participants. In this paper, we study a large application in southern Sweden with eight forest companies involved in a collaboration. We investigate a number of sharing mechanisms based on economic models including Shapley value, the nucleolus, separable and non-separable costs, shadow prices and volume weights. We also propose a new allocation method, with the aim that the participants relative profits are as equal as possible. We use two planning models, the first is based on direct flows between supply and demand points and the second includes backhauling. We also study how several time periods and geographical distribution of the supply and demand nodes affect the solutions. Better planning within each company can save about 5% and collaboration can increase this about another 9% to a total of 14%. The proposed allocation method is shown to be a practical approach to share the overall cost/savings.     

A new lot sizing and scheduling heuristic for multi-site biopharmaceutical production

Biopharmaceutical manufacturing requires high investments and long-term production planning. For large biopharmaceutical companies, planning typically involves multiple products and several production facilities. Production is usually done in batches with a substantial set-up cost and time for switching between products. The goal is to satisfy demand while minimising manufacturing, set-up and inventory costs. The resulting production planning problem is thus a variant of the capacitated lot-sizing and scheduling problem, and a complex combinatorial optimisation problem. Inspired by genetic algorithm approaches to job shop scheduling, this paper proposes a tailored construction heuristic that schedules demands of multiple products sequentially across several facilities to build a multi-year production plan (solution). The sequence in which the construction heuristic schedules the different demands is optimised by a genetic algorithm. We demonstrate the effectiveness of the approach on a biopharmaceutical lot sizing problem and compare it with a mathematical programming model from the literature. We show that the genetic algorithm can outperform the mathematical programming model for certain scenarios because the discretisation of time in mathematical programming artificially restricts the solution space.     

Planning Activities in a Network of Logistic Platforms with Shared Resources

This paper has been motivated by the study of a real application, the transshipment container terminal of Gioia Tauro in Italy. The activities in a container terminal concern with the movement of containers from/to mother vessels and feeders and with the handling and storage of containers in the yard. For such type of applications both operational (e.g., scheduling) and tactical (e.g., planning) models, currently available in the literature, are not useful in terms of operations management and resources optimization. Indeed, the former models are too detailed for the complexity of the systems, while the latter are not able to capture the operational constraints in representing those activities which limit the nominal capacity. Herein, the container terminal, or more in general a service or production system, is represented as a network of complex substructures or platforms. The idea is to formalize the concept of platform capacity, which is used to represent the operational aspects of the container terminal in a mathematical model for the tactical planning. The problem, which consists in finding an allocation of resources in each platform in order to minimize the total delay on the overall network and on the time horizon, is modelled by a mathematical programming formulation for which we carry out a computational analysis using CPLEX-MIP solver. Moreover, we present a dynamic programming based heuristic to solve larger instances in short computational time. On all but one of the smaller instances, the heuristic solutions are also optimal. On the larger instances, the maximum gap, i.e. the percentage deviation, between the heuristic solutions and the best solutions computed by CPLEX-MIP within the time limit of 3600 s, has been 6.3%.     

A solution approach for optimizing long- and short-term production scheduling at LKAB’s Kiruna mine

We present a mixed-integer program to schedule long- and short-term production at LKAB’s Kiruna mine, an underground sublevel caving mine located in northern Sweden. The model minimizes deviations from monthly preplanned production quantities while adhering to operational constraints. Because of the mathematical structure of the model and its moderately large size, instances spanning a time horizon of more than a year or two tend to be intractable. We develop an optimization-based decomposition heuristic that, on average, obtains better solutions faster than solving the model directly. We show that for realistic data sets, we can generate solutions with deviations that comprise about 3-6% of total demand in about a third of an hour.     

A stochastic aggregate production planning model in a green supply chain: Considering flexible lead times,nonlinear purchase and shortage cost functions

In this paper we develop a stochastic programming approach to solve a multi-period multi-product multi-site aggregate production planning problem in a green supply chain for a medium-term planning horizon under the assumption of demand uncertainty. The proposed model has the following features: (i) the majority of supply chain cost parameters are considered; (ii) quantity discounts to encourage the producer to order more from the suppliers in one period, instead of splitting the order into periodical small quantities, are considered; (iii) the interrelationship between lead time and transportation cost is considered, as well as that between lead time and greenhouse gas emission level; (iv) demand uncertainty is assumed to follow a pre-specified distribution function; (v) shortages are penalized by a general multiple breakpoint function, to persuade producers to reduce backorders as much as possible; (vi) some indicators of a green supply chain, such as greenhouse gas emissions and waste management are also incorporated into the model. The proposed model is first a nonlinear mixed integer programming which is converted into a linear one by applying some theoretical and numerical techniques. Due to the convexity of the model, the local solution obtained from linear programming solvers is also the global solution. Finally, a numerical example is presented to demonstrate the validity of the proposed model.     

Integrated Production and Distribution Planning for Södra Cell AB

In this paper we consider integrated planning of transportation of raw material, production and distribution of products of the supply chain at Södra Cell AB, a major European pulp mill company. The strategic planning period is one year. Decisions included in the planning are transportation of raw materials from harvest areas to pulp mills, production mix and contents at pulp mills, distribution of pulp products from mills to customer via terminals or directly and selection of potential orders and their levels at customers. Distribution is carried out by three different transportation modes; vessels, trains and trucks. We propose a mathematical model for the entire supply chain which includes a large number of continuous variables and a set of binary variables to reflect decisions about product mix and order selection at customers. Five different alternatives regarding production mix in a case study carried out at Södra Cell are analyzed and evaluated. Each alternative describes which products will be produced at which pulp mills.     

Harvest planning in the Brazilian sugar cane industry via mixed integer programming

This work addresses harvest planning problems that arise in the production of sugar and alcohol from sugar cane in Brazil. The planning is performed for two planning horizons, tactical and operational planning, such that the total sugar content in the harvested cane is maximized. The tactical planning comprises the entire harvest season that averages seven months. The operational planning considers a horizon from seven to thirty days. Both problems are solved by mixed integer programming. The tactical planning is well handled. The model for the operational planning extends the one for the tactical planning and is presented in detail. Valid inequalities are introduced and three techniques are proposed to speed up finding quality solutions. These include pre-processing by grouping and filtering the distance matrix between fields, hot starting with construction heuristic solutions, and dividing and sequentially solving the resulting MIP program. Experiments are run over a set of real world and artificial instances. A case study illustrates the benefits of the proposed planning.     

Consolidating Product Sizes to Minimize Inventory Levels for a Multi-Stage Production and Distribution System

The optimal design of a supply chain was approached in two phases by using: (1) a mathematical programming formulation and heuristic solution approach to minimize the distinct number of product types held at various points in the supply chain; and (2) a spreadsheet inventory model to estimate the safety stock needed to absorb random fluctuations in both demand and lead time throughout the system. This two-phased approach allowed management to quantify the effects of inventory required for locating parts of the supply chain in different geographic areas. The quantification of projected inventory requirements was a critical input used by senior management to clarify their final decision-making process.     

Probabilistic modeling of multiperiod service levels

This study investigates multiperiod service level (MSL) policies in supply chains facing a stochastic customer demand. The objective of the supply chains is to construct integrated replenishment plans that satisfy strict stockout-oriented performance measures which apply across a multiperiod planning horizon. We formulate the stochastic service level constraints for the fill rate, ready rate, and conditional expected stockout MSL policies. The modeling approach is based on the concept of service level trajectory and provides reformulations of the stochastic planning problems associated with each MSL policy that can be efficiently solved with off-the-shelf optimization solvers. The approach enables the handling of correlated and non-stationary random variables, and is flexible enough to accommodate the implementation of fair service level policies, the assignment of differentiated priority levels per products, or the introduction of response time requirements. We use an earthquake disaster management case study to show the applicability of the approach and derive practical implications about service level policies.