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.     

An integrated optimization model for managing the global value chain of a chemical commodities manufacturer

The realization of supply chain management concepts goes along with the introduction of comprehensive software systems for supporting decisions at the strategic, tactical, and operational planning level. Moreover, in industry the focus has shifted from a pure logistics-oriented view towards the integration of pricing and revenue issues into cross-functional value chain planning models. This paper presents a practical decision support tool for global value chain planning in the production of chemical commodities. The proposed linear optimization model consists of various modules that reflect sales, distribution, production, and procurement activities within a company-internal value chain. The objective of the model is to maximize profit by coordinating all activities within the supply chain. The model formulation is related to a real industry case. It is shown how the model can be used to support decision making from sales to procurement by volume and value.     

Single-site strategic capacity planning considering renewal,maintenance, inventory,taxes and cash flow management

This paper deals with strategic capacity planning of a single-site manufacturing system. We propose a MILP model that includes relevant business aspects and possibilities, some of which are only partially or not at all found in the literature. Specifically, we consider decisions on expansion, reduction and renewal of production capacity, and acquisition of storage capacity. In addition, we model aspects such as (a) maintenance costs and unit variable costs depending, respectively, on age and characteristics of facilities, (b) seasonality of the demand and (c) cash flow management, including taxes and, therefore, depreciation of assets. The model maximises the after-tax cash balance at the end of the planning horizon. We also present a computational experiment with 54 instances to show that the model can be solved for a wide range of sizes in a reasonable computing time using comercial software.     

Optimisation of integrated reverse logistics networks with different product recovery routes

The awareness of importance of product recovery has grown swiftly in the past few decades. This paper focuses on a problem of inventory control and production planning optimisation of a generic type of an integrated Reverse Logistics (RL) network which consists of a traditional forward production route, two alternative recovery routes, including repair and remanufacturing and a disposal route. It is assumed that demand and return quantities are uncertain. A quality level is assigned to each of the returned products. Due to uncertainty in the return quantity, quantity of returned products of a certain quality level is uncertain too. The uncertainties are modelled using fuzzy trapezoidal numbers. Quality thresholds are used to segregate the returned products into repair, remanufacturing or disposal routes. A two phase fuzzy mixed integer optimisation algorithm is developed to provide a solution to the inventory control and production planning problem. In Phase 1, uncertainties in quantity of product returns and quality of returns are considered to calculate the quantities to be sent to different recovery routes. These outputs are inputs into Phase 2 which generates decisions on component procurement, production, repair and disassembly. Finally, numerical experiments and sensitivity analysis are carried out to better understand the effects of quality of returns and RL network parameters on the network performance. These parameters include quantity of returned products, unit repair costs, unit production cost, setup costs and unit disposal cost.     

A robust optimization model for multi-product two-stage capacitated production planning under uncertainty

Production planning (PP) is one of the most important issues carried out in manufacturing environments which seeks efficient planning, scheduling and coordination of all production activities that optimizes the company’s objectives. In this paper, we studied a two-stage real world capacitated production system with lead time and setup decisions in which some parameters such as production costs and customer demand are uncertain. A robust optimization model is developed to formulate the problem in which minimization of the total costs including the setup costs, production costs, labor costs, inventory costs, and workforce changing costs is considered as performance measure. The robust approach is used to reduce the effects of fluctuations of the uncertain parameters with regards to all the possible future scenarios. A mixed-integer programming (MIP) model is developed to formulate the related robust production planning problem. In fact the robust proposed model is presented to generate an initial robust schedule. The performance of this schedule could be improved against of any possible occurrences of uncertain parameters. A case from an Iran refrigerator factory is studied and the characteristics of factory and its products are discussed. The computational results display the robustness and effectiveness of the model and highlight the importance of using robust optimization approach in generating more robust production plans in the uncertain environments. The tradeoff between solution robustness and model robustness is also analyzed.     

Speciality oils supply chain optimization: From a decoupled to an integrated planning approach

We study a problem of tactical planning in a divergent supply chain. It involves decisions regarding production, inventory, internal transportation, sales and distribution to customers. The problem is motivated by the context of a company in the speciality oils industry. The overall objective at tactical level is to maximize contribution and, in order to achieve this, the planning has been divided into two separate problems. The first problem concerns sales where the final sales and distribution planning is decentralized to individual sellers. The second problem concerns production, transportation and inventory planning through refineries, hubs and depots and is managed centrally with the aim of minimizing costs. Due to this decoupling, the solution of the two problems needs to be coordinated in order to achieve the overall objective. In the company, this is pursued through an internal price system aiming at giving the sellers the incentives needed to align their decisions with the overall objective. We propose and discuss linear programming models for the decoupled and integrated planning problems. We present numerical examples to illustrate potential effects of integration and coordination and discuss the advantages and disadvantages of the integrated over the decoupled approach. While the total contribution is higher in the integrated approach, it has also been found that the sellers’ contribution can be considerably lower. Therefore, we also suggest contribution sharing rules to achieve a solution where both the company and the sellers attain a better outcome under the integrated planning.     

Coordinating pricing and production decisions in the presence of price competition

In this paper we study the effects of coordinating pricing and production decisions on the improvement of a firm’s position in a price-competitive environment. Assuming duopolistic market conditions, we use game-theoretic concepts and models to analyze two scenarios. A firm’s marketing and production departments may vertically coordinate their pricing and production quantity decisions and the two firms may horizontally compete for price-sensitive random demand. The two scenarios include (i) no coordination and (ii) coordination in both firms. We show that by coordinating their pricing and production decisions, competing firms can increase their profitability—especially when conditions are unfavourable (i.e., with smaller market sizes, higher unit costs and lower unit revenues). While it may be intuitive to expect that coordination will outperform non-coordination, our models provide a means for formalizing and quantifying the differences between the two policies.     

3.1. OR in banking

In this paper, we describe a deterministic multiperiod capacity expansion model in which a single facility serves the demand for many products. Potential applications for the model can be found in the capacity expansion planning of communication systems as well as in the production planning of heavy process industries. The model assumes that each capacity unit simultaneously serves a prespecified (though not necessarily integer) number of demand units of each product. Costs considered include capacity expansion costs, idle capacity holding costs, and capacity shortage costs. All cost functions are assumed to be nondecreasing and concave. Given the demand for each product over the planning horizon, the objective is to find the capacity expansion policy that minimizes the total cost incurred. We develop a dynamic programming algorithm that finds optimal policies. The required computational effort is a polynomial function of the number of products and the number of time periods. When the number of products equals one, the algorithm reduces to the well-known algorithm for the classical dynamic lot size problem.     

Effect of declining selling price: profit analysis for a single period inventory model with stochastic demand and lead time

In this paper, considering the empirical trend for sales and price of fashion apparels as prototype, optimal ordering policy for a single period stochastic inventory model is investigated. The impact of the presence of random lead time and declining selling price on the profitability of the retailer is explored. Existence of unique optimal solutions for net profit functions is proved. Numerical examples are presented to illustrate the method of identifying profitable levels of inventory holding and penalty costs. Percentage profit per unit investment in inventory is obtained in order to assist managers in taking business decisions, specifically to the extent of whether or not to take up a particular business under known constraints. It is demonstrated that the optimal inventory policy in the absence of price decline and lead time differs considerably from that when lead time and price decline are simultaneously considered.     

An Integrated Model for Master Scheduling,Lot Sizing and Capacity Requirements Planning

Although material requirements planning (M.R.P.) allows managers to better plan hierarchical production and inventory systems, much is still left to the planner's intuition and experience in devising realistic master production schedules, selecting appropriate lot sizes for components, and changing capacity levels. Decisions are made sequentially, rather than simultaneously, with no real assurance of satisfactory performance.This research proposes an integrated model for facilitating these decisions. A mixed-integer nonlinear programming model is formulated such that it can be solved by a heuristic procedure. Several versions of this procedure are tested in a research design controlling for nine variables on shop and cost structure. Preliminary research results show that the procedure gives good solutions to the situations represented by the experimental variables. Computational results are also encouraging.     

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.     

Tactical level planning in float glass manufacturing with co-production,random yields and substitutable products

We investigate tactical level planning problems in float glass manufacturing. Float glass manufacturing is a process that has some unique properties such as uninterruptible production, random yields, partially controllable co-production compositions, complex relationships in sequencing of products, and substitutable products. Furthermore, changeover times and costs are very high, and production speed depends significantly on the product mix. These characteristics render measurement and management of the production capacity difficult. The motivation for this study is a real life problem faced at Trakya Cam in Turkey. Trakya Cam has multiple geographically separated production facilities. Since transportation of glass is expensive, logistics costs are high. In this paper, we consider multi-site aggregate planning, and color campaign duration and product mix planning. We develop a decision support system based on several mixed integer linear programming models in which production and transportation decisions are made simultaneously. The system has been fully implemented, and has been in use at Trakya Cam since 2005.     

Maximum-revenue tariff under Bertrand duopoly with unknown costs

This paper considers an international trade under Bertrand model with differentiated products and with unknown production costs. The home government imposes a specific import tariff per unit of imports from the foreign firm. We prove that this tariff is decreasing in the expected production costs of the foreign firm and increasing in the production costs of the home firm. Furthermore, it is increasing in the degree of product substitutability. We also show that an increase in the tariff results in both firms increasing their prices, an increase in both expected sales and expected profits for the home firm, and a decrease in both expected sales and expected profits for the foreign firm.     

A memetic algorithm with dynamic population management for an integrated production–distribution problem

This paper studies an NP-hard multi-period production–distribution problem to minimize the sum of three costs: production setups, inventories and distribution. This problem is solved by a very recent form of metaheuristic called memetic algorithm with population management (MA∣PM). Contrary to classical two-phase methods (production planning, then distribution planning), the algorithm simultaneously tackles production and distribution decisions. Several versions with different population management strategies are evaluated and compared with a two-phase heuristic and a Greedy Randomized Adaptive Search Procedure (GRASP), on 90 randomly generated instances with 20 periods and 50, 100 or 200 customers. The significant savings obtained compared to the two other methods confirm both the interest of integrating production and distribution decisions and of using the MA∣PM template.     

A portfolio approach to managing procurement risk using multi-stage stochastic programming

Procurement is a critical supply chain management function that is susceptible to risk, due mainly to uncertain customer demand and purchase price volatility. A procurement approach in the form of a portfolio that incorporates the common procurement means is proposed. Such means include long-term contracts, spot procurements and option-based supply contracts. The objective is to explore possible synergies among the various procurement means, and so be able to produce optimal or near optimal results in profit while mitigating risk. The implementation of the portfolio approach is based on a multi-stage stochastic programming model in which replenishment decisions are made at various stages along a time horizon, with replenishment quantities being determined by simultaneously considering the stochastic demand and the price volatility of the spot market. The model attempts to minimise the risk exposure of procurement decisions measured as conditional value-at-risk. Numerical experiments to test the effectiveness of the proposed model are performed using demand data from a large air conditioner manufacturer in China and price volatility data from the Shanghai steel market. The results indicate that the proposed model can fairly reliably outperform other approaches, especially when either the demand and/or prices exhibit significant variability.     

Dynamic lot-sizing with price changes and price-dependent holding costs

This paper proposes a new formulation of the dynamic lot-sizing problem with price changes which considers the unit inventory holding costs in a period as a function of the procurement decisions made in previous periods. In Section 1, the problem is defined and some of its fundamental properties are identified. A dynamic programming approach is developed to solve it when solutions are restricted to sequential extreme flows, and results from location theory are used to derive an O(T²) algorithm which provides a provably optimal solution of an integer linear programming formulation of the general problem. In Section 2, a heuristic is developed for the case where the inventory carrying rates and the order costs are constant, and where the item price can change once during the planning horizon. Permanent price increases, permanent price decreases and temporary price reductions are considered. In Section 3, extensive testing of the various optimal and heuristic algorithms is reported. Our results show that, in this context, the two following intuitive actions usually lead to near optimal solutions: accumulate stock at the lower price just prior to price increase and cut short on orders when a price decrease is imminent.     

A tactical model for planning the production and distribution of fresh produce

We present an integrated tactical planning model for the production and distribution of fresh produce. The main objective of the model is to maximize the revenues of a producer that has some control over the logistics decisions associated with the distribution of the crop. The model is used for making planning decisions for a large fresh produce grower in Northwestern Mexico. The decisions obtained are based on traditional factors such as price estimation and resource availability, but also on factors that are usually neglected in traditional planning models such as price dynamics, product decay, transportation and inventory costs. The model considers the perishability of the crops in two different ways, as a loss function in its objective function, and as a constraint for the storage of products. The paper presents a mixed integer programming model used to implement the problem as wells as the computational results obtained from it.     

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.     

A new decision support framework for managing foot-and-mouth disease epidemics

Animal disease epidemics such as the foot-and-mouth disease (FMD) pose recurrent threat to countries with intensive livestock production. Efficient FMD control is crucial in limiting the damage of FMD epidemics and securing food production. Decision making in FMD control involves a hierarchy of decisions made at strategic, tactical, and operational levels. These decisions are interdependent and have to be made under uncertainty about future development of the epidemic. Addressing this decision problem, this paper presents a new decision-support framework based on multi-level hierarchic Markov processes (MLHMP). The MLHMP model simultaneously optimizes decisions at strategic, tactical, and operational levels, using Bayesian forecasting methods to model uncertainty and learning about the epidemic. As illustrated by the example, the framework is especially useful in contingency planning for future FMD epidemics.     

On a production-inventory system of deteriorating items subject to random machine breakdowns with a fixed repair time

This paper considers the impact of random machine breakdowns on the classical Economic Production Quantity (EPQ) model for a product subject to exponential decay and under a no-resumption (NR) inventory control policy. A product is manufactured in batches on a machine that is subject to random breakdowns in order to meet a constant demand over an infinite planning horizon. The product is assumed to have a significant rate of deterioration and time to deterioration is described by an exponential distribution. Also, the time-to-breakdown is a random variable following an exponential distribution. Under the NR policy, when a breakdown occurs during a production run, the run is immediately aborted. A new run will not be started until all available inventories are depleted. Corrective maintenance of the production system is carried out immediately after a breakdown and it takes a fixed period of time to complete such an activity. The objective is to determine the optimal production uptime that minimizes the expected total cost per unit time consisting of setup, corrective maintenance, inventory carrying, deterioration, and lost sales costs. A near optimal production uptime is derived under conditions of continuous review, deterministic demand, and no shortages.