Optimal models for a multi-stage supply chain system controlled by kanban under just-in-time philosophy

This research studies a multi-stage supply chain system that operates under a JIT (just-in-time) delivery policy. Kanbans play an important role in the information and material flows in a supply chain system. Thus, a kanban mechanism is employed to assist in linking different production processes in a supply chain system to implement the scope of JIT philosophy. For a multi-stage supply chain system, a mixed-integer nonlinear programming (MINLP) problem is formulated from the perspective of JIT delivery policy where a kanban may reflect to a transporter such as a truck or a fork-lifter. The number of kanbans, the batch size, the number of batches and the total quantity over one period are determined optimally. It is solved optimally by branch and bound method. A greedy heuristic to avoid the large computational time in branch-and-bound algorithm is developed for solving a large MINLP. Coupled with plant-wide efforts for cost control and management commitment, a logistic system for controlling the production as well as the supply chain is built, which results in minimizing the total cost of the supply chain system. The results show that the improvements in reduction of inventory, wasted labor and customer service in a supply chain are significantly accomplished through the kanban mechanism.     

A single-stage supply chain system controlled by kanban under just-in-time philosophy

The production system using kanban was pioneered by Toyota Motor Company in Japan and subsequently it was adopted by numerous other Japanese and US companies for applying the just-in-time manufacturing principles. This research studies a single-stage supply chain system that is controlled by kanban mechanism. The supply chain system is modelled as a mixed-integer nonlinear programming (MINLP) problem. It is solved optimally by branch-and-bound method to determine the number of kanbans, batch size, number of batches, and the total quantity over one period. Meanwhile, the kanban operation between two adjacent plants is worked out considering the factors of loading and unloading time, and transport time. Coupled with plant-wide efforts for cost control and management commitment to enhance other measures of performance, a logistics system for controlling the production as well as the supply chain system is developed, which results in minimizing the total cost of the supply chain system. The results show that the improvements in reduction of inventory, wasted labour, and customer service in a supply chain are accomplished through the kanban mechanism.     

Optimizing Multi-stage Production for an Assembly-Type Supply Chain with Unequal Sized Batch Shipments

This paper studies the multi-stage logistics and inventory problem in an?assembly-type supply chain where a uniform lot size is produced uninterruptedly with a single setup at each stage. Partial lots, or sub-batches, can be transported to next stage upon completion. Unequal sub-batch sizes at each stage follow geometric series and the numbers of sub-batches across stages are allowed to be different. Since the mainline and each branch line of an assembly-type supply chain are series-type supply chains, a model of the series-type supply chain is first established and a model of the assembly-type supply chain is subsequently developed. Optimization algorithms that determine the economic lot sizes, the optimal sub-batch sizes and the number of sub-batches for each stage are developed. The polynomial-time algorithms incorporate the optimality properties derived in the paper to find the lower and upper bounds of the solutions by constructing the solution ranges and then the optimal solutions accordingly.     

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.     

Global Solution Approach for a Nonconvex MINLP Problem in Product Portfolio Optimization

The rigorous and efficient determination of the global solution of a nonconvex MINLP problem arising from product portfolio optimization introduced by Kallrath (2003) is addressed. The objective of the optimization problem is to determine the optimal number and capacity of reactors satisfying the demand and leading to a minimal total cost. Based on the model developed by Kallrath (2003), an improved formulation is proposed, which consists of a concave objective function and linear constraints with binary and continuous variables. A variety of techniques are developed to tighten the model and accelerate the convergence to the optimal solution. A customized branch and bound approach that exploits the special mathematical structure is proposed to solve the model to global optimality. Computational results for two case studies are presented. In both case studies, the global solutions are obtained and proved optimal very efficiently in contrast to available commercial MINLP solvers.     

Scheduling under a common due-data on parallel unrelated machines

Due-data determination problems have gained significant attention in recent years due to the industrial focus in the just-in-time philosophy. In this paper the problem of scheduling a set of independent jobs on parallel unrelated processors under a common due-date is examined. The common due-date is a decision variable. The objective is to allocate and sequence the jobs on the machines and to determine the optimal due-data, so that the total cost be minimised. This cost is composed of the due-date assignment, the total earliness and the total tardiness cost. As the problem is NP-hard, a polynomial time heuristic procedure, which provides efficient solutions, is developed. The procedure is illustrated by means of an example and is tested via two small size experiments.     

Optimal model for warehouse location and retailer allocation

Warehouse location and retailer allocation is a high‐level strategic decision problem that is commonly encountered by logisticians and supply chain managers, especially during the supply chain design phase. Considering the product distribution cost and warehouse capital cost trade‐offs, this paper models the warehouse location and retailer allocation problem as a 0–1 integer programming problem and provides an efficient two‐stage set covering heuristic algorithm to solve large‐sized problems. Finally, concluding remarks and some recommendations for further research are also presented. Copyright © 2007 John Wiley & Sons, Ltd.     

Optimal number and location of storage hubs and biogas production reactors in farmlands with allocation of multiple feedstocks

This paper focuses on the problem for designing a logistics system for bio-methane gas (BMG) production. In practice, farm residues such as crop residue, wood residue, and livestock manure are used in reactors as reactants to generate BMG. A multi-residue, multi-hub, multi-reactor location-allocation model is developed to design the logistics of BMG production system. Both the hubs’ and reactors’ locations, and the residue's distribution plan are investigated to minimize the total construction and logistical cost. The costs of construction, transportation, feedstocks and labor are taken into consideration to reflect the lifecycle cost of the entire undertaking. In this paper, a mixed-integer nonlinear problem is proposed to simulate a BMG production supply chain. In addition to the optimal solution methods, a search-based heuristic was also proposed to determine the locations of hubs and reactors for large instances and along with a proper allocation of residues that are transported from the farms to the hubs to the reactors. Several numerical examples are tested to evaluate the performance of the heuristic as well.     

A heuristic solution technique to attain the minimal total cost bounds of transporting a homogeneous product with varying demands and supplies

Transportation of a product from multi-source to multi-destination with minimal total transportation cost plays an important role in logistics and supply chain management. Researchers have given considerable attention in minimizing this cost with fixed supply and demand quantities. However, these quantities may vary within a certain range in a period due to the variation of the global economy. So, the concerned parties might be more interested in finding the lower and the upper bounds of the minimal total costs with varying supplies and demands within their respective ranges for proper decision making. This type of transportation problem has received attention of only one researcher, who formulated the problem and solved it by LINGO. We demonstrate that this method fails to obtain the correct upper bound solution always. Then we extend this model to include the inventory costs during transportation and at destinations, as they are interrelated factors. The number of choices of supplies and demands within their respective ranges increases enormously as the number of suppliers and buyers increases. In such a situation, although the lower bound solution can be obtained methodologically, determination of the upper bound solution becomes an NP hard problem. Here we carry out theoretical analyses on developing the lower and the upper bound heuristic solution techniques to the extended model. A comparative study on solutions of small size numerical problems shows promising performance of the current upper bound technique. Another comparative study on results of numerical problems demonstrates the effect of inclusion of the inventory costs.     

Achieving sharp deliveries in supply chains through variance pool allocation

Variability reduction and business process synchronization are acknowledged as key to achieving sharp and timely deliveries in supply chain networks. In this paper, we develop an approach that facilitates variability reduction and business process synchronization for supply chains in a cost effective way. The approach developed is founded on an analogy between mechanical design tolerancing and supply chain lead time compression. We first present a motivating example to describe this analogy. Next, we define, using process capability indices, a new index of delivery performance called delivery sharpness which, when used with the classical performance index delivery probability, measures the accuracy as well as the precision with which products are delivered to the customers. Following this, we solve the following specific problem: how do we compute the allowable variability in lead time for individual stages of the supply chain so that specified levels of delivery sharpness and delivery probability are achieved in a cost-effective way? We call this the variance pool allocation (VPA) problem. We suggest an efficient heuristic approach for solving the VPA problem and also show that a variety of important supply chain design problems can be posed as instances of the VPA problem. One such problem, which is addressed in this paper, is the supply chain partner selection problem. We formulate and solve the VPA problem for a plastics industry supply chain and demonstrate how the solution can be used to choose the best mix of supply chain partners.     

An Improved Branch & Bound Method for the Uncapacitated Competitive Location Problem

In this paper, the problem of locating new facilities in a competitive environment is considered. The problem is formulated as the firm expected profit maximization and a set of nodes is selected in a graph representing the geographical zone. Profit depends on fixed and deterministic location costs and, since customers are independent decision-makers, on the expected market share. The problem is an instance of nonlinear integer programming, because the objective function is concave and submodular. Due to this complexity a branch & bound method is developed for solving small size problems (that is, when the number of nodes is less than 50), while a heuristic is necessary for larger problems. The branch & bound is called data-correcting method, while the approximate solutions are obtained using the heuristic-concentration method.     

Scheduling just-in-time part supply for mixed-model assembly lines

With increasing cost competition and product variety, providing an efficient just-in-time (JIT) supply has become one of the greatest challenges in the use of mixed-model assembly line production systems. In the present paper, therefore, we propose a new approach for scheduling JIT part supply from a central storage center. Usually, materials are stored in boxes that are allotted to the consumptive stations of the line by a forklift. For such a real-world problem, a new model, a complexity proof as well as different exact and heuristic solution procedures are provided. Furthermore, a direct comparison with a simple two-bin kanban system is provided. Such a system is currently applied in the real-world industrial process that motivates our research. It becomes obvious that this policy is considerably outperformed according to the resulting inventory- and α-service levels. Moreover, at the interface between logistics and assembly operations, strategic management implications are obtained. Specifically, based on the new approach, it is the first time a statistical analysis is being made as to whether widespread Level Scheduling policies, which are well-known from the Toyota Production System, indeed facilitate material supply. Note that in the literature it is frequently claimed that this causality exists.     

Nonconvex piecewise linear knapsack problems

This paper considers the minimization version of a class of nonconvex knapsack problems with piecewise linear cost structure. The items to be included in the knapsack have a divisible quantity and a cost function. An item can be included partially in the given quantity range and the cost is a nonconvex piecewise linear function of quantity. Given a demand, the optimization problem is to choose an optimal quantity for each item such that the demand is satisfied and the total cost is minimized. This problem and its close variants are encountered in manufacturing planning, supply chain design, volume discount procurement auctions, and many other contemporary applications. Two separate mixed integer linear programming formulations of this problem are proposed and are compared with existing formulations. Motivated by different scenarios in which the problem is useful, the following algorithms are developed: (1) a fast polynomial time, near-optimal heuristic using convex envelopes; (2) exact pseudo-polynomial time dynamic programming algorithms; (3) a 2-approximation algorithm; and (4) a fully polynomial time approximation scheme. A comprehensive test suite is developed to generate representative problem instances with different characteristics. Extensive computational experiments show that the proposed formulations and algorithms are faster than the existing techniques.     

The warehouse-inventory-transportation problem for supply chains

Warehouses play a vital role in mitigating variations in supply and demand, and in providing value-added services in a supply chain. However, our observation of supply chain practice reveals that warehousing decisions are not included when developing a distribution plan for the supply chain. This lack of integration has resulted in a substantial variation in workload (42–220%) at our industry partner’s warehouse costing them millions of dollars. To address this real-world challenge, we introduce the warehouse-inventory-transportation problem (WITP) of determining an optimal distribution plan from vendors to customers via one or more warehouses in order to minimize the total distribution cost. We present a nonlinear integer programming model for the WITP considering supply chains with multiple vendors, stores, products, and time-periods, and one warehouse. The model also considers worker congestion at the warehouse that could affect worker productivity. A heuristic based on iterative local search is developed to solve industry-sized problems with up to 500 stores and 1000 products. Our experiments indicate that the distribution plans obtained via the WITP, as compared to a sequential approach, result in a substantial reduction in workload variance at the warehouse, while considerably reducing the total distribution cost. These plans, however, are sensitive to aisle configuration and technology at the warehouse, and the level and productivity of temporary workers.     

Branch and bound based solution algorithms for the budget constrained discrete time/cost trade-off problem

The time/cost trade-off models in project management aim to reduce the project completion time by putting extra resources on activity durations. The budget problem in discrete time/cost trade-off scheduling selects a time/cost mode for each activity so as to minimize the project completion time without exceeding the available budget. There may be alternative modes that solve the budget problem optimally and each solution may have a different total cost value. In this study we consider the budget problem and aim to find the minimum cost solution among the minimum project completion time solutions. We analyse the structure of the problem together with its linear programming relaxation and derive some mechanisms for reducing the problem size. We solve the reduced problem by branch and bound based optimization and heuristic algorithms. We find that our branch and bound algorithm finds optimal solutions for medium-sized problem instances in reasonable times and the heuristic algorithms produce high quality solutions very quickly.     

A Dynamic Domain Contraction Algorithm for Nonconvex Piecewise Linear Network Flow Problems*

We consider the Nonconvex Piecewise Linear Network Flow Problem (NPLNFP) which is known to be -hard. Although exact methods such as branch and bound have been developed to solve the NPLNFP, their computational requirements increase exponentially with the size of the problem. Hence, an efficient heuristic approach is in need to solve large scale problems appearing in many practical applications including transportation, production-inventory management, supply chain, facility expansion and location decision, and logistics. In this paper, we present a new approach for solving the general NPLNFP in a continuous formulation by adapting a dynamic domain contraction. A Dynamic Domain Contraction (DDC) algorithm is presented and preliminary computational results on a wide range of test problems are reported. The results show that the proposed algorithm generates solutions within 0 to 0.94 % of optimality in all instances that the exact solutions are available from a branch and bound method.     

基于多目标进化算法的供水系统优化运行研究

将多目标进化算法与启发式算法相接合,对供水管网微观模型进行优化调度研究.目标函数为供水系统的运行费用和维护费用最小化,以及水压服务水平的最大化(保证安全供水),以各泵站各型号水泵的开启和调速泵的转数比为决策变量,进行二进制-实数混合编码,并采用新型的交叉算子.运用NSGA-Ⅱ、epsilon-MOEA、SPEA2三种多目标进化方法求解优化运行模型,并通过工程算例进行比较.应用表明,多目标进化算法能为供水系统的优化决策提供支持.     

Genetic Algorithm for Network Cost Minimization Using Threshold Based Discounting

We present a genetic algorithm for heuristically solving a cost minimization problem applied to communication networks with threshold based discounting. The network model assumes that every two nodes can communicate and offers incentives to combine of from different sources. Namely, there is a prescribed threshold on every link, and if the total of on a link is greater than the threshold, the cost of this of is discounted by a factor. A heuristic algorithm based on genetic strategy is developed and applied to a benchmark set of problems. The results are compared with former branch and bound results using the CPLEX(r)solver. For larger data instances we were able to obtain improved solutions using less CPU time, confirming the effectiveness of our heuristic approach.     

Order splitting with multiple capacitated suppliers

This paper studies an integrated decision making model for a supply chain system where a manufacturer faces a price-sensitive demand and multiple capacitated suppliers, two issues that are often considered separately in the literature. The goal is to maximize total profit by determining an optimal selling price and at the same time acquiring enough supplying capacity. The problem is proved to be NP-hard in the ordinary sense, a heuristic algorithm and an optimal dynamic programming algorithm are developed. Computational experiments are conducted to study the efficiency and effectiveness of the algorithms. Some managerial insights are observed.     

Fixed Charge Transportation Problems: a new heuristic approach based on Lagrangean relaxation and?the?solving of core problems

In this paper the Fixed Charge Transportation Problem is considered. A new heuristic approach is proposed, based on the intensive use of Lagrangean relaxation techniques. The more novel aspects of this approach are new Lagrangean relaxation and decomposition methods, the consideration of several core problems, defined from the previously computed Lagrangean reduced costs, the heuristic selection of the most promising core problem and the final resort to enumeration by applying a branch and cut algorithm to the selected core problem. For problems with a small ratio of the average fixed cost to the average variable cost (lower than or equal to 25), the proposed method can obtain similar or better solutions than the state-of-art algorithms, such as the tabu search procedure and the parametric ghost image processes. For larger ratios (between 50 and 180), the quality of the obtained solutions could be considered to be halfway between both methods.