Planning and coordination of production and distribution facilities for multiple commodities

We study an integrated logistics model for locating production and distribution facilities in a multi-echelon environment. Designing such logistics systems requires two essential decisions, one strategic (e.g., where to locate plants and warehouses) and the other operational (distribution strategy from plants to customer outlets through warehouses). The distribution strategy is influenced by the product mix at each plant, the shipments of raw material from vendors to manufacturing plants and the distribution of finished products from the plants to the different customer zones through a set of warehouses. First we provide a mixed integer programming formulation to the integrated model. Then, we present an efficient heuristic solution procedure that utilizes the solution generated from a Lagrangian relaxation of the problem. We use this heuristic procedure to evaluate the performance of the model with respect to solution quality and algorithm performance. Results of extensive tests on the solution procedure indicate that the solution method is both efficient and effective. Finally a `real-world' example is solved to explore the implications of the model.     

A decision support system for order acceptance/rejection in hybrid MTS/MTO production systems

In this paper, we present a novel decision support system for order acceptance/rejection in a hybrid Make-to-Stock/Make-to-Order production environment. The proposed decision support system is comprised of five steps. At the first step, the customers are prioritized based on a fuzzy TOPSIS method. Rough-cut capacity and rough-cut inventory are calculated in the second step and in case of unavailability in capacity and materials, some undesirable orders are rejected. Also, proper decisions are made about non-rejected orders. At the next step, prices and delivery dates of the non-rejected orders are determined by running a mixed-integer mathematical programming model. At the fourth step, a set of guidelines are proposed to help the organization negotiate over price and due date with the customers. In the next step, if the customer accepts the offered price and delivery date, the order is accepted and later considered in the production schedule of the shop floor, otherwise the order is rejected. Finally, numerical experiments are conducted to show the tractability of the applied mathematical programming model.     

Integrated production planning and order acceptance under uncertainty: A robust optimization approach

The aim of this paper is to formulate a model that integrates production planning and order acceptance decisions while taking into account demand uncertainty and capturing the effects of congestion. Orders/customers are classified into classes based on their marginal revenue and their level of variability in order quantity (demand variance). The proposed integrated model provides the flexibility to decide on the fraction of demand to be satisfied from each customer class, giving the planner the choice of selecting among the highly profitable yet risky orders or less profitable but possibly more stable orders. Furthermore, when the production stage exceeds a critical utilization level, it suffers the consequences of congestion via elongated lead-times which results in backorders and erodes the firm’s revenue. Through order acceptance decisions, the planner can maintain a reasonable level of utilization and hence avoid increasing delays in production lead times. A robust optimization (RO) approach is adapted to model demand uncertainty and non-linear clearing functions characterize the relationship between throughput and workload to reflect the effects of congestion on production lead times. Illustrative simulation and numerical experiments show characteristics of the integrated model, the effects of congestion and variability, and the value of integrating production planning and order acceptance decisions.     

Price and lead time decisions in dual-channel supply chains

Manufacturers today are increasingly adopting a dual channel to sell their products, i.e., the traditional retail channel and an online direct channel. Empirical studies have shown that service quality (we focus on the delivery lead time of the direct channel) even goes beyond product price as one of the major factors influencing consumer acceptance of the direct channel. Delivery lead time has significant effects on demand, profit, and pricing strategy. However, there is scant literature addressing the decision on the promised delivery lead time of a direct channel and its impact on the manufacturer’s and retailer’s pricing decisions. To fill this gap, we examine the optimal decisions of delivery lead time and prices in a centralized and a decentralized dual-channel supply chain using the two-stage optimization technique and Stackelberg game, and analyze the impacts of delivery lead time and customer acceptance of a direct channel on the manufacturer’s and retailer’s pricing behaviours. We analytically show that delivery lead time strongly influences the manufacturer’s and the retailer’s pricing strategies and profits. Our numerical studies reveal that the difference between the demand transfer ratios in the two channels with respect to delivery lead time and direct sale price, customer acceptance of the direct channel, and product type have great effects on the lead time and pricing decisions.     

Supply chain scheduling with receiving deadlines and non-linear penalty

We study the operations scheduling problem with delivery deadlines in a three-stage supply chain process consisting of (1) heterogeneous suppliers, (2) capacitated processing centres (PCs), and (3) a network of business customers. The suppliers make and ship semi-finished products to the PCs where products are finalized and packaged before they are shipped to customers. Each business customer has an order quantity to fulfil and a specified delivery date, and the customer network has a required service level so that if the total quantity delivered to the network falls below a given targeted fill rate, a non-linear penalty will apply. Since the PCs are capacitated and both shipping and production operations are non-instantaneous, not all the customer orders may be fulfilled on time. The optimization problem is therefore to select a subset of customers whose orders can be fulfilled on time and a subset of suppliers to ensure the supplies to minimize the total cost, which includes processing cost, shipping cost, cost of unfilled orders (if any), and a non-linear penalty if the target service level is not met. The general version of this problem is difficult because of its combinatorial nature. In this paper, we solve a special case of this problem when the number of PCs equals one, and develop a dynamic programming-based algorithm that identifies the optimal subset of customer orders to be fulfilled under each given utilization level of the PC capacity. We then construct a cost function of a recursive form, and prove that the resulting search algorithm always converges to the optimal solution within pseudo-polynomial time. Two numerical examples are presented to test the computational performance of the proposed algorithm.     

Optimization-Based Available-To-Promise with Multi-Stage Resource Availability

Increasingly, customer service, rapid response to customer requirements, and flexibility to handle uncertainties in both demand and supply are becoming strategic differentiators in the marketplace. Organizations that want to achieve these benchmarks require sophisticated approaches to conduct order promising and fulfillment, especially in today’s high-mix low-volume production environment. Motivated by these challenges, the Available-to-Promise (ATP) function has migrated from a set of availability records in a Master Production Schedule (MPS) toward an advanced real-time decision support system to enhance decision responsiveness and quality in Assembly To Order (ATO) or Configuration To Order (CTO) environments. Advanced ATP models and systems must directly link customer orders with various forms of available resources, including both material and production capacity. In this paper, we describe a set of enhancements carried out to adapt previously published mixed-integer-programming (MIP) models to the specific requirements posed by an electronic product supply chain within Toshiba Corporation. This model can provide individual order delivery quantities and due dates, together with production schedules, for a batch of customer orders that arrive within a predefined batching interval. The model considers multi-resource availability including manufacturing orders, production capability and production capacity. In addition, the model also takes into account a variety of realistic order promising issues such as order splitting, model decomposition and resource expediting and de-expediting. We conclude this paper with comparison of our model execution results vs. actual historical performance of systems currently in place.     

Impacts of inventory shortage policies on transportation requirements in two-stage distribution systems

This paper investigates the impacts inventory shortage policies have on transportation costs in base-stock distribution systems under uncertain demand. The model proposed demonstrates how backlogging arrangements can serve to decrease the variability of transportation capacity requirements, and hence the magnitude of transportation costs, when compared with policies that expedite demand shortages. The model shows how inventory policy decisions directly impact expected transportation costs and provides a new method for setting stock levels that jointly minimizes inventory and transportation costs. The model and solution method provide insights into the relationship between inventory decisions and transportation costs and can serve to support delivery policy negotiations between a supplier and customer that must choose between expediting and backlogging demand shortages.     

The effect of product variety on supply-chain performance

We present a stylized model for analyzing the effect of product variety on supply-chain performance for a supply chain with a single manufacturer and multiple retailers. The manufacturer produces multiple products on a shared resource with limited capacity and the effect of changeovers on supply-chain cost is due primarily to setup time rather than setup cost. We show that the expected replenishment lead time and the retailers' costs are concave increasing in product variety and that the increase is asymptotically linear. Thus, if setup times are significant, the effect of product variety on cost is substantially greater than that suggested by the risk-pooling literature for perfectly flexible manufacturing processes, where the cost increases proportionally to the square root of product variety. We demonstrate that disregarding the effect of product variety on lead time can lead to poor decisions and can lead companies to offer product variety that is greater than optimal. The results of our analysis enable decision-makers to quantify the effect of product variety on supply-chain performance and thus to determine the optimal product variety to offer. The results can also be used to evaluate how changes in the manufacturing process, the supply-chain structure, and the customer demand rate can improve the performance of supply chains with high product variety.     

Coordination of a Supply Chain with One-Manufacturer and Two-Retailers Under Demand Promotion and Disruption Management Decisions

Increasingly, customer service, rapid response to customer requirements, and flexibility to handle uncertainties in both demand and supply are becoming strategic differentiators in the marketplace. Organizations that want to achieve these benchmarks require sophisticated approaches to conduct order promising and fulfillment, especially in today’s high-mix low-volume production environment. Motivated by these challenges, the Available-to-Promise (ATP) function has migrated from a set of availability records in a Master Production Schedule (MPS) toward an advanced real-time decision support system to enhance decision responsiveness and quality in Assembly To Order (ATO) or Configuration To Order (CTO) environments. Advanced ATP models and systems must directly link customer orders with various forms of available resources, including both material and production capacity. In this paper, we describe a set of enhancements carried out to adapt previously published mixed-integer-programming (MIP) models to the specific requirements posed by an electronic product supply chain within Toshiba Corporation. This model can provide individual order delivery quantities and due dates, together with production schedules, for a batch of customer orders that arrive within a predefined batching interval. The model considers multi-resource availability including manufacturing orders, production capability and production capacity. In addition, the model also takes into account a variety of realistic order promising issues such as order splitting, model decomposition and resource expediting and de-expediting. We conclude this paper with comparison of our model execution results vs. actual historical performance of systems currently in place.     

Setting Job-Shop Due-Dates with Service-Level Constraints

The job-shop due-date assignment problem arises when a manager needs to ‘promise’ a delivery date to a customer. Previous methods yield due-dates which are either optimistic (unlikely to be achieved) or conservative (the promise will be met, but too easily, because the date given was very pessimistic). This paper investigates the due-date assignment problem with a customer ‘service-level’ constraint, the percentage of time that promised delivery dates are honoured. We formulate a rule to attain this service level, yet maintain as short a due-date lead time as possible. Unlike previous attempts, this due-date rule considers not only the job content and instantaneous shop congestion information, but also implicitly incorporates information on how the jobs will be scheduled (or ‘loaded’) once they are in the shop. We simulate a single-machine shop for various measures of performance under several dispatching priorities, comparing our due-date rule with one reported to yield satisfactory performance. Our rule meets all requirements and is found to be superior for most measures of performance.     

Inventory competition in a dual-channel supply chain with delivery lead time consideration

Aimed at the inventory competition of perishable products in a dual-channel supply chain with consideration of the delivery lead time in the online direct channel, we extend the Newsvendor model considering stock-out-based consumer switching behavior to include the delivery lead time. We examine the retailer's optimal order quantity decision in the retail channel and the manufacturer's optimal inventory level decision in the online direct channel, explore the manufacturer's optimal delivery lead time decision in the online direct channel, discuss the impact of the product price and consumer switching behavior on the optimal decisions of supply chain members, and compare the optimal decisions between decentralized and centralized scenarios. The results show that, compared with the centralized scenario, at least one of the supply chain members will overstock in the decentralized scenario and that consumers in the online direct channel enjoy a shorter delivery lead time and hence better service in the decentralized scenario. Finally, we present numerical examples to analyze the impact of relevant parameters on the supply chain members’ profits and the supply chain efficiency.     

Managerial and economic impacts of reducing delivery variance in the supply chain

This paper addresses the managerial and economic impacts of improving delivery performance in a serial supply chain when delivery performance is evaluated with respect to a delivery window. Building on contemporary management theories that advocate variance reduction as the critical step in improving the overall performance of a system, we model the variance of delivery time to the final customer as a function of the investment to reduce delivery variance and the costs associated with untimely delivery (expected earliness and lateness). A logarithmic investment function is used and the model solution involves the minimization of a convex–concave total cost function. A numerical example is provided to illustrate the model and the solution procedure. The model presented provides guidelines for determining the optimal level of financial investment for reducing delivery variance. The managerial implications as well as the economic aspects of delivery variance reduction in supply chain management are discussed.     

Strategic capacity planning for light emitting diode (LED) supply chains across Taiwan and China

This paper describes a mixed-integer programming (MIP) model formulated for strategic capacity planning for light emitting diode (LED) makers of Taiwan, major companies in the global LED market. These firms have complex supply chains across Taiwan and China, and the region’s unique political and economic environment has created not only competitive advantages but also challenges in supply chain management: government regulations require that customer orders be accepted from Taiwan or China according to customer attributes; when conducting manufacturing, Taiwanese firms may need to transfer orders across national borders for reasons such as manufacturing technology (the required technology is available only at certain manufacturing facilities) or more efficient capacity utilization; and there are operations to be performed with specific processing requirements to follow, posing substantial challenges for planners. Motivated by the significance of these firms in the global market, we develop a MIP model with novel features to support their strategic capacity planning, covering demand and manufacturing-related decisions, including order acceptance and transfer, manufacturing starts, capacity expansion, and logistics. We illustrate the model’s performance using modified industry data in a numerical example; we also describe the potential impacts the model may create in industry applications.     

Customer Enquiry Management: Part of a Hierarchical System to Control Lead Times in Make-to-Order Companies

The authors are currently developing a hierarchical production planning system specifically designed for the ‘make-to-order’ sector of industry. Its aim is to control the delivery and manufacturing lead times of all orders processed by a firm. Two major decision levels are identified - the customer enquiry stage and the order release stage. Input/output control is exercised at both stages. This paper is concerned with the control mechanisms used at the customer enquiry stage. Two important backlogs of work, along with their associated backlog lengths, are identified. The system aims to maintain these backlogs between predetermined minimum and maximum lengths in order to process all orders within an acceptable length of time. It is shown that the two backlogs are linked in a manner that enables them to be controlled simultaneously. Hence, a procedure for dealing with incoming customer orders is presented.     

The capacity planning problem in make-to-order enterprises

This paper addresses the short-term capacity planning problem in a make-to-order (MTO) operation environment. A mathematical model is presented to aid an operations manager in an MTO environment to select a set of potential customer orders to maximize the operational profit such that all the selected orders are fulfilled by their deadline. With a given capacity limit on each source for each resource type, solving this model leads to an optimal capacity plan as required for the selected orders over a given (finite) planning horizon. The proposed model considers regular time, overtime, and outsourcing as the sources for each resource type. By applying this model to a small MTO operation, this paper demonstrates a contrast between maximal capacity utilization and optimal operational profit.     

A Solution Method for a Two-dispatch Delivery Problem with Stochastic Customers

We study a vehicle routing problem in which vehicles are dispatched multiple times a day for product delivery. In this problem, some customer orders are known in advance while others are uncertain but are progressively realized during the day. The key decisions include determining which known orders should be delivered in the first dispatch and which should be delivered in a later dispatch, and finding the routes and schedules for customer orders. This problem is formulated as a two-stage stochastic programming problem with the objective of minimizing the expected total cost. A worst-case analysis is performed to evaluate the potential benefit of the stochastic approach against a deterministic approach. Furthermore, a sample-based heuristic is proposed. Computational experiments are conducted to assess the effectiveness of the model and the heuristic.      

Quality and pricing decisions in production/inventory systems

In this article, we consider the impact of finite production capacity on the optimal quality and pricing decisions of a make-to-stock manufacturer. Products are differentiated along a quality index; depending on the price and quality levels of the products offered, customers decide to either buy a given product, or not to buy at all. We show that, assuming fixed exogenous lead times and normally distributed product demands, the optimal solution has a simple structure (this is referred to as the load-independent system). Using numerical experiments, we show that with limited production capacity (which implies load-dependent lead times) the manufacturer may have an incentive to limit the quality offered to customers, and to decrease market coverage, especially in settings where higher product quality leads to higher congestion in production. Our findings reveal that the simple solution assuming load-independent lead times is suboptimal, resulting in a profit loss; yet, this profit loss can be mitigated by constraining the system utilization when deciding on quality and price levels. Our results highlight the importance of the relationship between marketing decisions and load-dependent production lead times.     

A zero-inventory production and distribution problem with a fixed customer sequence

In this paper, we study the zero-inventory production and distribution problem with a single transporter and a fixed sequence of customers. The production facility has a limited production rate, and the delivery truck has non-negligible traveling times between locations. The order in which customers may receive deliveries is fixed. Each customer requests a delivery quantity and a time window for receiving the delivery. The lifespan of the product starts as soon as the production for a customer’s order is finished, which makes the product expire in a constant time. Since the production facility and the shipping truck are limited resources, not all the customers may receive the delivery within their specified time windows and/or within product lifespan. The problem is then to choose a subset of customers from the given sequence to receive the deliveries to maximize the total demand satisfied, without violating the product lifespan, the production/distribution capacity, and the delivery time window constraints. We analyze several fundamental properties of the problem and show that these properties can lead to a fast branch and bound search procedure for practical problems. A heuristic lower bound on the optimal solution is developed to accelerate the search. Empirical studies on the computational effort required by the proposed search procedure comparing to that required by CPLEX on randomly generated test cases are reported.     

Efficient techniques for the multi-period vehicle routing problem with time windows within a branch and price framework

In many appointment-based logistics systems customer orders may be served within a set of consecutive periods/days (i.e. a period window). In this case, the Multi-Period Vehicle Routing Problem (MPVRP) is relevant, and its efficient solution may lead to significant operational improvements. In this paper we investigate the MPVRP with Time Windows (MPVRPTW). The latter are time intervals within each period of the period window, during which service may be provided to the customer. A general model and an exact method to solve the MPVRPTW are presented. The solution method is based on column generation. Furthermore, two novel, efficient techniques to accelerate the solution procedure of the MPVRPTW are proposed. These techniques exploit the structure of the multi-period setting in order to identify similarities within the different subproblems and, thus, avoid solving every subproblem at each iteration. The experimental study analyzed the performance of the proposed methods systematically for various problem parameters, such as geographical distribution of customers and period window patterns. In most cases, the new methods improve significantly the efficiency of convergence to the optimal solution as compared to the classical method.     

A branch and price solution approach for order acceptance and capacity planning in make-to-order operations

Make-to-order (MTO) operations have to effectively manage their capacity to make long-term sustainable profits. This objective can be met by selectively accepting available customer orders and simultaneously planning for capacity. We model a MTO operation of a job-shop with multiple resources having regular and non-regular capacity. The MTO firm has a set of customer orders at time zero with fixed due-dates. The process route, processing times, and sales price for each order are given. Since orders compete for limited resources, the firm can only accept some orders. In this paper a Mixed-Integer Linear Program (MILP) is proposed to aid an operational manager to decide which orders to accept and how to allocate resources such that the overall profit is maximized. A branch-and-price (B&P) algorithm is devised to solve the MILP effectively. The MILP is first decomposed into a master problem and several sub-problems using Dantzig-Wolfe decomposition. Each sub-problem is represented as a network flow problem and an exact procedure is proposed to solve the sub-problems efficiently. We also propose an approximate B&P scheme, Lagrangian bounds, and approximations to fathom nodes in the branch-and-bound tree. Computational analysis shows that the proposed B&P algorithm can solve large problem instances with relatively short time.