Strategic facility location: A review

Facility location decisions are a critical element in strategic planning for a wide range of private and public firms. The ramifications of siting facilities are broadly based and long-lasting, impacting numerous operational and logistical decisions. High costs associated with property acquisition and facility construction make facility location or relocation projects long-term investments. To make such undertakings profitable, firms plan for new facilities to remain in place and in operation for an extended time period. Thus, decision makers must select sites that will not simply perform well according to the current system state, but that will continue to be profitable for the facility's lifetime, even as environmental factors change, populations shift, and market trends evolve. Finding robust facility locations is thus a difficult task, demanding that decision makers account for uncertain future events. The complexity of this problem has limited much of the facility location literature to simplified static and deterministic models. Although a few researchers initiated the study of stochastic and dynamic aspects of facility location many years ago, most of the research dedicated to these issues has been published in recent years. In this review, we report on literature which explicitly addresses the strategic nature of facility location problems by considering either stochastic or dynamic problem characteristics. Dynamic formulations focus on the difficult timing issues involved in locating a facility (or facilities) over an extended horizon. Stochastic formulations attempt to capture the uncertainty in problem input parameters such as forecast demand or distance values. The stochastic literature is divided into two classes: that which explicitly considers the probability distribution of uncertain parameters, and that which captures uncertainty through scenario planning. A wide range of model formulations and solution approaches are discussed, with applications ranging across numerous industries.     

Hybrid heuristics for the capacitated lot sizing and loading problem with setup times and overtime decisions

The capacitated lot sizing and loading problem (CLSLP) deals with the issue of determining the lot sizes of product families/end items and loading them on parallel facilities to satisfy dynamic demand over a given planning horizon. The capacity restrictions in the CLSLP are imposed by constraints specific to the production environment considered. When a lot size is positive in a specific period, it is loaded on a facility without exceeding the sum of the regular and overtime capacity limits. Each family may have a different process time on each facility and furthermore, it may be technologically feasible to load a family only on a subset of existing facilities. So, in the most general case, the loading problem may involve unrelated parallel facilities of different classes. Once loaded on a facility, a family may consume capacity during setup time. Inventory holding and overtime costs are minimized in the objective function. Setup costs can be included if setups incur costs other than lost production capacity. The CLSLP is relevant in many industrial applications and may be generalized to multi-stage production planning and loading models. The CLSLP is a synthesis of three different planning and loading problems, i.e., the capacitated lot sizing problem (CLSP) with overtime decisions and setup times, minimizing total tardiness on unrelated parallel processors, and, the class scheduling problem, each of which is NP in the feasibility and optimality problems. Consequently, we develop hybrid heuristics involving powerful search techniques such as simulated annealing (SA), tabu search (TS) and genetic algorithms (GA) to deal with the CLSLP. Results are compared with optimal solutions for 108 randomly generated small test problems. The procedures developed here are also compared against each other in 36 larger size problems.     

An upper bound for the competitive location and capacity choice problem with multiple demand scenarios

A new mathematical model is considered related to competitive location problems where two competing parties, the Leader and the Follower, successively open their facilities and try to win customers. In the model, we consider a situation of several alternative demand scenarios which differ by the composition of customers and their preferences.We assume that the costs of opening a facility depend on its capacity; therefore, the Leader, making decisions on the placement of facilities, must determine their capacities taking into account all possible demand scenarios and the response of the Follower. For the bilevel model suggested, a problem of finding an optimistic optimal solution is formulated. We show that this problem can be represented as a problem of maximizing a pseudo- Boolean function with the number of variables equal to the number of possible locations of the Leader’s facilities.We propose a novel systemof estimating the subsets that allows us to supplement the estimating problems, used to calculate the upper bounds for the constructed pseudo-Boolean function, with additional constraints which improve the upper bounds.     

Lagrangian heuristics for the two-echelon,single-source,capacitated facility location problem

Facility location problems form an important class of integer programming problems, with application in the distribution and transportation industries. In this paper we are concerned with a particular type of facility location problem in which there exist two echelons of facilities. Each facility in the second echelon has limited capacity and can be supplied by only one facility (or depot) in the first echelon. Each customer is serviced by only one facility in the second echelon. The number and location of facilities in both echelons together with the allocation of customers to the second-echelon facilities are to be determined simultaneously. We propose a mathematical model for this problem and consider six heuristics based on Lagrangian relaxation for its solution. To solve the dual problem we make use of a subgradient optimization procedure. We present numerical results for a large suite of test problems. These indicate that the lower-bounds obtained from some relaxations have a duality gap which frequently is one third of the one obtained from traditional linear programming relaxation. Furthermore, the overall solution time for the heuristics are less than the time to solve the LP relaxation.     

Siting and Sizing of Facilities under Probabilistic Demands

In this paper a discrete location model for non-essential service facilities planning is described, which seeks the number, location, and size of facilities, that maximizes the total expected demand attracted by the facilities. It is assumed that the demand for service is sensitive to the distance from facilities and to their size. It is also assumed that facilities must satisfy a threshold level of demand (facilities are not economically viable below that level). A Mixed-Integer Nonlinear Programming (MINLP) model is proposed for this problem. A branch-and-bound algorithm is designed for solving this MINLP and its convergence to a global minimum is established. A finite procedure is also introduced to find a feasible solution for the MINLP that reduces the overall search in the binary tree generated by the branch-and-bound algorithm. Some numerical results using a GAMS/MINOS implementation of the algorithm are reported to illustrate its efficacy and efficiency in practice.     

Siting and Sizing of Facilities under Probabilistic Demands

In this paper a discrete location model for non-essential service facilities planning is described, which seeks the number, location, and size of facilities, that maximizes the total expected demand attracted by the facilities. It is assumed that the demand for service is sensitive to the distance from facilities and to their size. It is also assumed that facilities must satisfy a threshold level of demand (facilities are not economically viable below that level). A Mixed-Integer Nonlinear Programming (MINLP) model is proposed for this problem. A branch-and-bound algorithm is designed for solving this MINLP and its convergence to a global minimum is established. A finite procedure is also introduced to find a feasible solution for the MINLP that reduces the overall search in the binary tree generated by the branch-and-bound algorithm. Some numerical results using a GAMS/MINOS implementation of the algorithm are reported to illustrate its efficacy and efficiency in practice.     

A two-phase tabu search approach to the location routing problem

In many distribution systems, the location of the distribution facilities and the routing of the vehicles from these facilities are interdependent. Although this interdependence has been recognized by academics and practitioners alike, attempts to integrate these two decisions have been limited. The location routing problem (LRP), which combines the facility location and the vehicle routing decisions, is NP-hard. Due to the problem complexity, simultaneous solution methods are limited to heuristics. This paper presents a two-phase tabu search architecture for the solution of the LRP. First introduced in this paper, the two-phase approach offers a computationally efficient strategy that integrates facility location and routing decisions. This two-phase architecture makes it possible to search the solution space efficiently, thus producing good solutions without excessive computation. An extensive computational study shows that the TS algorithm achieves significant improvement over a recent effective LRP heuristic.     

Plant location and procurement planning in knockdown production systems

We consider an integrated problem of plant location and capacity planning for components procurement in knockdown production systems. The problem is that of determining the schedule of opening components manufacturing plants, plans for acquisition of capacities in opened components manufacturing plants, and plans for components procurement in final assembly plants with the objective of minimizing the sum of fixed costs for opening plants, acquisition and operation costs of facilities, and delivery and subcontracting costs of components. The problem is formulated as a mixed integer linear program and solved by a two-stage solution procedure. In the solution procedure, the problem is decomposed into two tractable subproblems and these subproblems are solved sequentially. In the first stage, a dynamic plant location problem is solved using a cut and branch algorithm based on Gomory cuts, while a multiperiod capacity planning problem is solved in the second stage by a heuristic algorithm that uses a cut and branch algorithm and a variable reduction scheme. The solution procedure is tested on problems of a practical size and results show that the procedure gives reasonably good solutions.     

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.     

Integrated supply chain planning under uncertainty using an improved stochastic approach

This paper proposes an integrated model and a modified solution method for solving supply chain network design problems under uncertainty. The stochastic supply chain network design model is provided as a two-stage stochastic program where the two stages in the decision-making process correspond to the strategic and tactical decisions. The uncertainties are mostly found in the tactical stage because most tactical parameters are not fully known when the strategic decisions have to be made. The main uncertain parameters are the operational costs, the customer demand and capacity of the facilities. In the improved solution method, the sample average approximation technique is integrated with the accelerated Benders’ decomposition approach to improvement of the mixed integer linear programming solution phase. The surrogate constraints method will be utilized to acceleration of the decomposition algorithm. A computational study on randomly generated data sets is presented to highlight the efficiency of the proposed solution method. The computational results show that the modified sample average approximation method effectively expedites the computational procedure in comparison with the original approach.     

Dynamic dairy facility location and supply chain planning under traffic congestion and demand uncertainty: A case study of Tehran

In this paper, dynamic dairy facility location and supply chain planning are studied through minimizing the costs of facility location, traffic congestion and transportation of raw/processed milk and dairy products under demand uncertainty. The proposed model dynamically incorporates possible changes in transportation network, facility investment costs, monetary value of time and changes in production process. In addition, the time variation and the demand uncertainty for dairy products in each period of the planning horizon is taken into account to determine the optimal facility location and the optimal production volumes. Computational results are presented for the model on a number of test problems. Also, an empirical case study is conducted in order to investigate the dynamic effects of traffic congestion and demand uncertainty on facility location design and total system costs.     

Location and allocation for distribution systems with transshipments and transportion economies of scale

Locating transshipment facilities and allocating origins and destinations to transshipment facilities are important decisions for many distribution and logistic systems. Models that treat demand as a continuous density over the service region often assume certain facility locations or a certain allocation of demand. It may be assumed that facility locations lie on a rectangular grid or that demand is allocated to the nearest facility or allocated such that each facility serves an equal amount of demand. These assumptions result in suboptimal distribution systems. This paper compares the transportation cost for suboptimal location and allocation schemes to the optimal cost to determine if suboptimal location and allocation schemes can produce nearly optimal transportation costs. Analytical results for distribution to a continuous demand show that nearly optimal costs can be achieved with suboptimal locations. An example of distribution to discrete demand points indicates the difficulties in applying these results to discrete demand problems.     

Simple dynamic location problem with uncertainty: a primal-dual heuristic approach

Abstract

In this paper, the simple dynamic facility location problem is extended to uncertain realizations of the potential locations for facilities and the existence of customers as well as fixed and variable costs. With limited knowledge about the future, a finite and discrete set of scenarios is considered. The decisions to be made are where and when to locate the facilities, and how to assign the existing customers over the whole planning horizon and under each scenario, in order to minimize the expected total costs. Whilst assignment decisions can be scenario dependent, location decisions have to take into account all possible scenarios and cannot be changed according to each scenario in particular. We first propose a mixed linear programming formulation for this problem and then we present a primal-dual heuristic approach to solve it. The heuristic was tested over a set of randomly generated test problems. The computational results are provided.     

A framework for evaluating remote diagnostics investment decisions for semiconductor equipment suppliers

With advances in information technology, service activities for expensive equipment used in semiconductor manufacturing can be performed from a remote location. This capability is called remote diagnostics (RD). Currently, there are intense development efforts in the semiconductor industry for implementing RD in wafer fabrication facilities to reduce maintenance and capital costs and improve productivity. In this paper, we develop a queueing-location model to analyze the capacity and location problem of after sales service providers, considering the effects of RD technology. Our model optimizes the location, capacity and the type of service centers while taking congestion effects into consideration. We solve this model using a simulation optimization approach in which we use a genetic algorithm to search the solution space. We demonstrate how our methodology can be used in strategic investment planning regarding the adoption of RD technology and service center siting through a realistic case study.     

The capacitated maximal covering location problem with backup service

The maximal covering location problem has been shown to be a useful tool in siting emergency services. In this paper we expand the model along two dimensions — workload capacities on facilities and the allocation of multiple levels of backup or prioritized service for all demand points. In emergency service facility location decisions such as ambulance sitting, when all of a facility's resources are needed to meet each call for service and the demand cannot be queued, the need for a backup unit may be required. This need is especially significant in areas of high demand. These areas also will often result in excessive workload for some facilities. Effective siting decisions, therefore, must address both the need for a backup response facility for each demand point and a reasonable limit on each facility's workload. In this paper, we develop a model which captures these concerns as well as present an efficient solution procedure using Lagrangian relaxation. Results of extensive computational experiments are presented to demonstrate the viability of the approach.     

A hierarchical location model for public facility planning

In this article, we present a discrete hierarchical location model for public facility planning. The main features of the model are: an accessibility maximization objective; several levels of demand and of facilities; a nested hierarchy of facilities (i.e. a facility of a given level can serve demand of equal and lower levels); maximum and minimum capacity constraints; and user-to-facility assignment constraints. The latter include single-assignment and closest-assignment constraints, as well as a new type of constraints called path-assignment constraints. Their purpose is to enforce some desirable properties for the spatial pattern of assignments. If they are not included, model solutions are difficult to interpret and to explain in a public facility planning context, therefore being less likely to be accepted by the users. The usefulness of the model is illustrated through a real-world application to school network planning.     

Tools of the mind: Techniques and methods for intellectual work: V. STIBIC North-Holland,Amsterdam, 1982, xiii + 297 pages,Dfl.85.00

Many location problems may be separated into a series of interrelated macro, meso and micro decision-making states. The macro scale decision determines the type, capacity and number of facilities, the meso scale decision determines the location and allocation of facilities and the micro scale decision determines such considerations as routing and scheduling of service vehicles. This paper concerns the first two levels of decision-making.The present paper demonstrates the use of two models: (i) an analytical model that uses continuum approximations and methods of calculus to determine the number of facilities, the capacity and the approximate location of each that minimizes the sum of the transportation and facility costs for a slowly varying demand rate, and (ii) a traditional location-allocation model that determines more exactly the resulting locations and allocations. These two approaches have specific requirements in terms of data input, cost of data collection and cost of solution and, consequently, yield unique insights and benefits for practising planners. The strengths and weaknesses of the two models are complementary. This thesis is developed with an analysis of the Calgary, Alberta refuse collection and disposal system.     

An Inventory-Location Model: Formulation, Solution Algorithm and Computational Results

We introduce a distribution center (DC) location model that incorporates working inventory and safety stock inventory costs at the distribution centers. In addition, the model incorporates transport costs from the suppliers to the DCs that explicitly reflect economies of scale through the use of a fixed cost term. The model is formulated as a non-linear integer-programming problem. Model properties are outlined. A Lagrangian relaxation solution algorithm is proposed. By exploiting the structure of the problem we can find a low-order polynomial algorithm for the non-linear integer programming problem that must be solved in solving the Lagrangian relaxation subproblems. A number of heuristics are outlined for finding good feasible solutions. In addition, we describe two variable forcing rules that prove to be very effective at forcing candidate sites into and out of the solution. The algorithms are tested on problems with 88 and 150 retailers. Computation times are consistently below one minute and compare favorably with those of an earlier proposed set partitioning approach for this model (Shen, 2000; Shen, Coullard and Daskin, 2000). Finally, we discuss the sensitivity of the results to changes in key parameters including the fixed cost of placing orders. Significant reductions in these costs might be expected from e-commerce technologies. The model suggests that as these costs decrease it is optimal to locate additional facilities.     

An analysis of p-median location problem: Effects of backup service level and demand assignment policy

Any solution to facility location problems will consider determining the best suitable locations with respect to certain criteria. Among different types of location problems, involving emergency service system (ESSs) are one of the most widely studied in the literature, and solutions to these problems will mostly aim to minimize the mean response time to demands. In practice, however, a demand may not be served from its nearest facility if that facility is engaged in serving other demands. This makes it a requirement to assign backup services so as to improve response time and service quality. The level of backup service is a key, strategic-level planning factor, and must be taken into consideration carefully. Moreover, in emergency service operations conducted in congested demand regions, demand assignment policy is another important factor that affects the system performance. Models failing to adopt sufficient levels of backup service and realistic demand assignment policies may significantly deteriorate the system performance.Considering the classic p-median problem (pMP) location model, this paper investigates the effects of backup service level, demand assignment policy, demand density, and number of facilities and their locations on the solution performance in terms of multiple metrics. For this purpose, we adopt a combined optimization and simulation approach. We will first modify the classic pMP to account for distances to backup services. Next, we employ a discrete event simulation to evaluate the performance of location schemes obtained from the deterministic mathematical model. Our results provide insights for decision-makers while planning ESS operations.     

General network design: A unified view of combined location and network design problems

This paper presents a unified framework for the general network design problem which encompasses several classical problems involving combined location and network design decisions. In some of these problems the service demand relates users and facilities, whereas in other cases the service demand relates pairs of users between them, and facilities are used to consolidate and re-route flows between users. Problems of this type arise in the design of transportation and telecommunication systems and include well-known problems such as location-network design problems, hub location problems, extensive facility location problems, tree-star location problems and cycle-star location problems, among others. Relevant modeling aspects, alternative formulations and possible algorithmic strategies are presented and analyzed.