An exact algorithm for a cross-docking supply chain network design problem

This paper proposes a branch-and-price algorithm as an exact algorithm for the cross-docking supply chain network design problem introduced by one of the authors of this paper. The objective is to optimally locate cross-docking (CD) centres and allocate vehicles for direct transportation services from the associated origin node to the associated CD centre or from the associated CD centre to the associated destination node so as to satisfy a given set of freight demands at minimum cost subject to the associated service (delivery) time restriction. A set-partitioning-based formulation is derived for the problem for which some solution properties are characterized. Based on the properties, a branch-and-price algorithm is derived. The properties can also be used in deriving any efficient local search heuristics with the move operation (neighbourhood search operation) of modifying assignment of some freight demands from current CD centres to other CD centres. Computational experiments show that the branch-and-price algorithm is effective and efficient and also that the solution properties contribute to improve the efficiency of the local search heuristics.     

Multi-criteria robust design of a JIT-based cross-docking distribution center for an auto parts supply chain

We present a solution framework based on discrete-event simulation and enhanced robust design technique to address a multi-response optimization problem inherent in logistics management. The objective is to design a robust configuration for a cross-docking distribution center so that the system is insensitive to the disturbances of supply uncertainty, and provides steady parts supply to downstream assembly plants. In the proposed approach, we first construct a simulation model using factorial design and central composite design (CCD), and then identify the models that best describe the relationship between the simulation responses and system factors. We employ the response surface methodology (RSM) to identify factor levels that would maximize system potential.     

Development of a new approach for deterministic supply chain network design

This paper proposes a mixed integer linear programming model and solution algorithm for solving supply chain network design problems in deterministic, multi-commodity, single-period contexts. The strategic level of supply chain planning and tactical level planning of supply chain are aggregated to propose an integrated model. The model integrates location and capacity choices for suppliers, plants and warehouses selection, product range assignment and production flows. The open-or-close decisions for the facilities are binary decision variables and the production and transportation flow decisions are continuous decision variables. Consequently, this problem is a binary mixed integer linear programming problem. In this paper, a modified version of Benders’ decomposition is proposed to solve the model. The most difficulty associated with the Benders’ decomposition is the solution of master problem, as in many real-life problems the model will be NP-hard and very time consuming. In the proposed procedure, the master problem will be developed using the surrogate constraints. We show that the main constraints of the master problem can be replaced by the strongest surrogate constraint. The generated problem with the strongest surrogate constraint is a valid relaxation of the main problem. Furthermore, a near-optimal initial solution is generated for a reduction in the number of iterations.     

A stochastic programming approach for supply chain network design under uncertainty

This paper proposes a stochastic programming model and solution algorithm for solving supply chain network design problems of a realistic scale. Existing approaches for these problems are either restricted to deterministic environments or can only address a modest number of scenarios for the uncertain problem parameters. Our solution methodology integrates a recently proposed sampling strategy, the sample average approximation (SAA) scheme, with an accelerated Benders decomposition algorithm to quickly compute high quality solutions to large-scale stochastic supply chain design problems with a huge (potentially infinite) number of scenarios. A computational study involving two real supply chain networks are presented to highlight the significance of the stochastic model as well as the efficiency of the proposed solution strategy.     

A facility location model for global closed-loop supply chain network design

Forward and reverse supply chains form a closed-loop supply chain. In this paper, a mathematical model is proposed for a closed-loop supply chain network by considering global factors, including exchange rates and customs duties. The model is a multi-objective mixed-integer linear programming model under uncertain demand. A solution approach based on fuzzy programming is developed for solving the optimization problem. The model is then applied in a network, which is located in Southwestern Ontario, Canada. A sensitivity analysis is provided to validate the model. This model considers global factors, multi-objectives, and uncertainty simultaneously in a closed-loop supply chain network.     

Robust supply chain network design with multi-products for a company in the food sector

The paper aims to solve a problem faced by a company competing in the snacks market in Turkey. In line with the growth in this market, the company needs to make important decisions over the next few years about the timing and location of a new plant, its initial capacity, the timing and amount of additional capacity to be installed at the new and existing plants, the assignment of demand points to plants and the amount of raw materials to be shipped from suppliers to the plants in each period. The objective is to minimize the total cost of various components. The problem is formulated as a multi-period supply chain network design model with multi products. The resulting mixed-integer linear programming model is solved by the commercial solver CPLEX. This model enables us to carry out all analyses requested by the company in an efficient way. After this deterministic model is solved on the basis of a 9% annual increase in demand, it is extended to a minimax regret model to deal with uncertainty in demand quantities. The results suggest that opening the new plant in the city of İzmir is indeed a robust solution that is unaffected in different scenarios that are based on three distinct demand increase rates. Even though the location of the new plant remains unchanged with respect to scenarios, the optimal robust solution differs from the optimal solution of each scenario in terms of the capacity expansion decisions. After all obtained results had been communicated to the company managers and executives, the new plant construction was started in 2016 very close to the city that the mathematical model had determined. The new plant is expected to start operating in 2018.     

Closed-loop supply chain network design: A financial approach

The more common approaches used in the SCM consider only the physical logistic operations and ignore the financial aspects of the chain. This paper presents a financial approach to model a closed-loop supply chain design in which financial aspects are explicitly considered as exogenous variables. The model decides to determine the strategic decisions as well as the tactical decisions. The main contribution of this paper is to incorporate the financial aspects (i.e. current and fixed assets and liabilities) and a set of budgetary constraints representing balances of cash, debt, securities, payment delays, and discounts in the supply chain planning. Moreover, the financial approach applies the change in equity (instead of the measure of profit/cost in traditional approaches) as the objective function to be optimized in the presented model.To show the advantages of the presented approach, the results attributed to the financial approach and the traditional approach are compared, where the latter firstly decides on operations and fits finances afterwards. The results indicate that the traditional approach leads to lower change in equity compared to the financial approach. This fact illustrates the inadequacy of treating process operations and finances in isolated environments and pursuing as objective myopic performance indicators such as profit or cost. Moreover, a sensitivity analysis of the parameters using ANOVA for different levels of the parameters under different customer order patterns is performed to enhance the managerial insights of the study. The results clearly reveal the better improvement of using the financial approach over the traditional approach, and convince the decision makers to take advantage of the proposed approach.     

Robust supply chain network design with service level against disruptions and demand uncertainties: A real-life case

We have developed a stochastic mathematical formulation for designing a network of multi-product supply chains comprising several capacitated production facilities, distribution centres and retailers in markets under uncertainty. This model considers demand-side and supply-side uncertainties simultaneously, which makes it more realistic in comparison to models in the existing literature. In this model, we consider a discrete set as potential locations of distribution centres and retailing outlets and investigate the impact of strategic facility location decisions on the operational inventory and shipment decisions of the supply chain. We use a path-based formulation that helps us to consider supply-side uncertainties that are possible disruptions in manufacturers, distribution centres and their connecting links. The resultant model, which incorporates the cut-set concept in reliability theory and also the robust optimisation concept, is a mixed integer nonlinear problem. To solve the model to attain global optimality, we have created a transformation based on the piecewise linearisation method. Finally, we illustrate the model outputs and discuss the results through several numerical examples, including a real-life case study from the agri-food industry.     

A two-phase ant colony algorithm for multi-echelon defective supply chain network design

Supply chain system is an integrated production system of a product. In the past researches, this system was often assumed to be an equilibrium structure, but in real production process, some members in this system usually cannot effectively complete their production task because of the losses of production, which will reduce the performance of the whole supply chain production system. This supply chain with the losses of production is called the defective supply chain (DSC) system. This research will discuss the partner selection and the production–distribution planning in this DSC network system. Besides the cost of production and transportation, the reliability of the structure and the unbalance of this system caused by the losses of production are considered. Then a germane mathematical programming model is developed for solving this problem. Due to the complex problem and in order to get a satisfactory near-optimal solution with great speed, this research proposes seeking the solution with the solving model based on ant colony algorithm. The application results in real cases show that the solving model presented by this research can quickly and effectively plan the most suitable type of the DSC network and decision-making of the production–distribution. Finally, a comparative numerical experiment is performed by using the proposed approach and the common single-phase ant colony algorithm (SAC) to demonstrate the performance of the proposed approach. The analysis results show that the proposed approach can outperform the SAC in partner selection and production–distribution planning for DSC network design.     

Environmental supply chain network design using multi-objective fuzzy mathematical programming

The concern about environmental impact of business activities has spurred an interest in designing environmentally conscious supply chains. This paper proposes a multi-objective fuzzy mathematical programming model for designing an environmental supply chain under inherent uncertainty of input data in such problem. The proposed model is able to consider the minimization of multiple environmental impacts beside the traditional cost minimization objective to make a fair balance between them. A life cycle assessment-based (LCA-based) method is applied to assess and quantify the environmental impact of different options for supply chain network configuration. Also, to solve the proposed multi-objective fuzzy optimization model, an interactive fuzzy solution approach is developed. A real industrial case is used to demonstrate the significance and applicability of the developed fuzzy optimization model as well as the usefulness of the proposed solution approach.     

Make-or-buy service capacity decision in a supply chain providing after-sales service

We consider a supply chain comprising a manufacturer and a retailer. The manufacturer supplies a product to the retailer, while the retailer sells the product bundled with after-sales service to consumers in a fully competitive market. The sales volume is affected by the retailer’s service-level commitment. The retailer can build service capacity in-house at a deterministic price before service demand is realized, or buy the service from an outsourcing market at an uncertain price after service demand realization. We find that the outsourcing market encourages the retailer to make a higher level of service commitment, while prompting the manufacturer to reduce the wholesale price, resulting in more demand realization. We analyze how the expected cost of the service in the outsourcing market and the retailer’s risk attitude affect the decisions of both parties. We derive the conditions under which the retailer is willing to build service capacity in-house and under which it will buy the service from the outsourcing market. Moreover, we find that the manufacturer’s sharing with the retailer the cost to build service capacity improves the profits of both parties.     

Least-cost network topology design for a new service

We describe an implementation of the tabu search metaheuristic that effectively finds a low-cost topology for a communications network to provide a centralized new service. Our results are compared to those of a greedy algorithm which applies corresponding decision rules, but without the guidance of the tabu search framework. These problems are difficult computationally, representing integer programs that can involve as many as 10,000 integer variables and 2000 constraints in practical applications. The tabu search results approach succeeded in obtaining significant improvements over the greedy approach, yielding optimal solutions to problems small enough to allow independent verification of optimality status and, more generally, yielding both absolute and percentage cost improvements that did not deteriorate with increasing problem size.This research was partially supported by the Air Force Office of Scientific Research and the Office of Naval Research Contract No. F49629-90-C-0033.     

A profit-maximizing supply chain network design model with demand choice flexibility

We present a profit-maximizing supply chain design model in which a company has flexibility in determining which customers to serve. The company may lose a customer to competition if the price it charges is too high. We show the problem formulation and solution algorithm, and discuss computational results.     

Modeling a supply chain using a network of queues

In this paper, a supply chain is represented as a two-input, three-stage queuing network. An input order to the supply chain is represented by two stochastic variables, one for the occurrence time and the other for the quantity of items to be delivered in each order. The objective of this paper is to compute the minimum response time for the delivery of items to the final destination along the three stages of the network. The average number of items that can be delivered with this minimum response time constitute the optimum capacity of the queuing network. After getting serviced by the last node (a queue and its server) in each stage of the queuing network, a decision is made to route the items to the appropriate node in the next stage which can produce the least response time.     

A robust optimization approach to closed-loop supply chain network design under uncertainty

The concern about significant changes in the business environment (such as customer demands and transportation costs) has spurred an interest in designing scalable and robust supply chains. This paper proposes a robust optimization model for handling the inherent uncertainty of input data in a closed-loop supply chain network design problem. First, a deterministic mixed-integer linear programming model is developed for designing a closed-loop supply chain network. Then, the robust counterpart of the proposed mixed-integer linear programming model is presented by using the recent extensions in robust optimization theory. Finally, to assess the robustness of the solutions obtained by the novel robust optimization model, they are compared to those generated by the deterministic mixed-integer linear programming model in a number of realizations under different test problems.     

A new multi-criteria scenario-based solution approach for stochastic forward/reverse supply chain network design

Analyzing current trends in supply chain management, lead to find unavoidable steps toward closing the loop of supply chain. In order to expect best performance of Closed-Loop Supply Chain (CLSC) network, an integrated approach in considering design and planning decision levels is necessary. Further, real markets usually contain uncertain parameters such as demands and prices of products. Therefore, the next important step is considering uncertain parameters.     

Profit oriented supply chain network optimization

This paper proposes a novel mixed integer linear programming model to solve a supply chain network design problem. The proposed model deals with major issues for supply chains; product quality and cost. These issues are usually solved separately, but in this paper, we investigate effects of product quality on supply chain design and transportation flow. A trade-off between raw material quality, its purchasing and reprocessing costs was considered. Assuming decision maker (DM) wishes to work with a supplier which serves a low quality raw material; this raw material should be in need of reprocessing. To avoid the reprocessing costs, a supplier which serves a high quality raw material should be chosen but at this time the DM has to face a high purchasing cost. A supply chain network which consists of multiple suppliers, manufacturers, distribution centers and retailers is tried to be designed to accomplish aforementioned above trade-offs. The paper examines and discusses the relationship between product quality and supply chain design and offers several managerial insights.     

Integrated pricing and lot-sizing decisions in a serial supply chain

In this article, we consider a serial supply chain controlled by a decision-maker who is responsible for deciding the amount of raw material to order from the selected suppliers, the amount of product to transfer between consecutive stages in order to avoid any inventory shortages, and the final product's selling price so that the profit per time unit is maximized. Coordinating all these decisions simultaneously is a topic that has been neglected in literature. This integrated process is modeled as a mixed-integer nonlinear programming model. In addition, the model requires the order quantity received from each selected supplier to be an integer multiple of the order quantity delivered to the following stage, which means that a different multiplicative factor can be assigned to each supplier. This coordination mechanism shows an improvement in the objective function compared to existing models that assign the same multiplicative factor to each selected supplier. Moreover, we develop a heuristic algorithm that generates near optimal solutions in a timely manner. Two numerical examples are presented to illustrate the proposed model and the heuristic algorithm.     

Multi-commodity supply network planning in the forest supply chain

We consider in this paper a two echelon timber procurement system in which the first echelon consists of multiple harvesting blocks and the second echelon consists of multiple mills (e.g., sawmills), both distributed geographically. Demand is put forward by mills in the form of volumes of logs of specific length and species. Due to the impact of log handling and sorting on cut-to-length harvester and forwarder productivity [Gingras, J.-F., Favreau, J., 2002. Incidence du triage sur la productivité des systèmes par bois tronçonnés. Avantage 3], the harvesting cost per unit volume increases as the number of product variety harvested per block increases. The overall product allocation problem is a large scale mixed integer programming problem with the objective of minimizing combined harvesting and aggregated transportation costs, under demand satisfaction constraints. A heuristic is first introduced then, an algorithm based on the branch-and-price approach is proposed for larger scale problems. Experimentations compare solutions found with the heuristic with the corresponding optimal solutions obtained with both Cplex (using the branch-and-bound approach) and the branch-and-price approach. Results demonstrate the good performance level of the heuristic approach for small scale problems, and of the branch-and-price approach for large scale problems.     

A metaheuristic for stochastic service network design

This paper considers the time-dependent service network design problem with stochastic demand represented by scenarios. To our knowledge, this is the first attempt to address real life-size instances of this problem. The model integrates the balancing of empty vehicles, the cost of handling freight in intermediate terminals, the costs associated with moving freight using the selected services, and the penalty costs of not being able to deliver freight. A metaheuristic is presented and computational results are reported on a set of large new problem instances.