Strategic robust supply chain design based on the Pareto-optimal tradeoff between efficiency and risk

The strategic design of a robust supply chain has to determine the configuration of the supply chain so that its performance remains of a consistently high quality for all possible future conditions. The current modeling techniques often only consider either the efficiency or the risk of the supply chain. Instead, we define the strategic robust supply chain design as the set of all Pareto-optimal configurations considering simultaneously the efficiency and the risk, where the risk is measured by the standard deviation of the efficiency. We model the problem as the Mean–Standard Deviation Robust Design Problem (MSD-RDP). Since the standard deviation has a square root expression, which makes standard maximization algorithms based on mixed-integer linear programming non-applicable, we show the equivalency to the Mean–Variance Robust Design Problem (MV-RDP). The MV-RDP yields an infinite number of mixed-integer programming problems with quadratic objective (MIQO) when considering all possible tradeoff weights. In order to identify all Pareto-optimal configurations efficiently, we extend the branch-and-reduce algorithm by applying optimality cuts and upper bounds to eliminate parts of the infeasible region and the non-Pareto-optimal region. We show that all Pareto-optimal configurations can be found within a prescribed optimality tolerance with a finite number of iterations of solving the MIQO. Numerical experience for a metallurgical case is reported.     

An analysis of the structural complexity of supply chain networks

Each enterprise in a supply chain network needs quantitative indicators to analyze and manage its interactions with different business partners in the network. Supply chains exhibit the characteristics of complex systems. In a supply chain network, a large number of firms cooperate simultaneously with many suppliers and customers, and interact through a variety of information and material flows to achieve a balance between supply and demand. However, the complexity of a supply chain is not a simple linear structure where a small change often results in a chain reaction. When supply chain complexity increases, monitoring and managing the interaction between different elements of the chain becomes more difficult. An entropy model based on information theory provides an appropriate means of quantifying the complexity of a supply chain system by delivering information required to describe the state of the system. The entropy measure links uncertainty and complexity so that, as a system grows in uncertainty, it becomes more complex and more information is required to describe and monitor it. In this paper, we propose an entropy-based measure for analyzing the structural complexity in relation to the structure and system uncertainty. The method provides guidelines for estimating the complexity throughout the supply chain structure.     

Measurement and optimization of robust stability of multiclass queueing networks: Applications in dynamic supply chains

Multiclass queueing networks are an essential tool for modeling and analyzing complex supply chains. Roughly speaking, stability of these networks implies that the total number of customers/jobs in the network remains bounded over time. In this context robustness characterizes the ability of a multiclass queueing network to remain stable, if the expected values of the interarrival and service times distributions are subject to uncertain shifts. A powerful starting point for the stability analysis of multiclass queueing networks is the associated fluid network. Based on the fluid network analysis we present a measure to quantify the robustness, which is indicated by a single number. This number will be called the stability radius. It represents the magnitude of the smallest shift of the expected value of the interarrival and/or service times distributions so that the associated fluid network looses the property of stability. The stability radius is a worst case measure and is a conceptual adaptation from the dynamical systems literature. Moreover, we provide a characterization of the shifts that destabilize the network. Based on these results, we formulate a mathematical program that minimizes the required network capacity, while ensuring a desired level of robustness towards shifts of the expected values of the interarrival times distributions. This approach provides a new view on long-term robust production capacity allocation in supply chains. The capabilities of our method are demonstrated using a real world supply chain.     

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.     

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.     

Capacity augmentation of a supply chain for a short lifecycle product: A system dynamics framework

For an innovative product characterized by short product lifecycle and high demand uncertainty, investment in capacity buildup has to be done cautiously. Otherwise either the product’s market diffusion is impeded or the manufacturer is left with unutilized capacity. Using the right information for making capacity augmentation decisions is critical in facing this challenge. In this paper, we propose a method for identifying critical information flows using the system dynamics model of a two-echelon supply chain. The fundamental premise of system dynamics methodology is that (system) structure determines (its) behavior. Using loop dominance analysis method we study the feedback loop structure of the supply chain system. The outcome is a set of dominant loops that determine the dynamics of capacity growth. It is revealed that the delivery delay information has little effect while the loop that connects retail sales with production order affects the dynamics significantly. Modifying this loop yields appropriate capacity augmentation decisions resulting in higher performance. What-if analyses bring out effects of modifying other structural elements. In conclusion, we claim that the information feedback based methodology is general enough to be useful in designing decision support systems for capacity augmentation. The limitations of the model are also discussed and possible extensions identified.     

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 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.     

Time-dependent optimization of a multi-item uncertain supply chain network: A hybrid approximation algorithm

We consider the uncertain least cost shipping problem. The input is a multi-item supply chain network with time-evolving uncertain costs and capacities. Exploiting the operational law of uncertainty theory, a mathematical model of the problem is established and the indeterminacy factors are tackled. We use the scaling idea together with transformation approach and uncertainty programming to develop a hybrid algorithm to optimize and obtain the uncertainty distribution of the total shipping cost. We analyze the practical performance of the algorithm and present an illustrative example.     

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 supply chain under limited-time promotion: The effect of customer sensitivity

We consider a two-echelon supply chain with a supplier and a retailer facing stochastic customer demands. The supplier is a leader who determines a wholesale price. In response, the retailer orders products and sets a price which affects customer demands. The goal of both players is to maximize their profits. We find the Stackelberg equilibrium and show that it is unique, not only when the supply chain is in a steady-state but also when it is in a transient state induced by a supplier’s promotion. There is a maximum length to the promotion, however, beyond which the equilibrium ceases to exist. Moreover, if customer sensitivity increases, then the wholesale equilibrium price decreases, product orders increase and product prices drop. This effect, well-observed in real life, does not, however, necessarily imply that the promotion is always beneficial. Conditions for the profitability of a limited-time promotion are shown and analyzed numerically. We discuss both open-loop and feedback policies and derive the conditions necessary for them to remain optimal under stochastic demand fluctuations.     

Designing a sustainable closed-loop supply chain network based on triple bottom line approach: A comparison of metaheuristics hybridization techniques

Recently, there is a growing concern about the environmental and social footprint of business operations. While most of the papers in the field of supply chain network design focus on economic performance, recently, some studies have considered environmental dimensions.     

Integrating deterioration and lifetime constraints in production and supply chain planning: A survey

Items with short lifetimes that are subject to deterioration are important in the business world. Research has a long tradition in integrating deterioration and value loss effects into mathematical models for inventory planning and control where such effects are understood as a general loss or shrinkage of inventory. However, there has been little work in the modeling of lifetime restrictions of items to prevent wastage and disposals, especially in a dynamic planning context. Globalization and other trends extend the consideration of single companies to whole supply chains, implying increased coordination and information needs. This is important as planning decisions impact lead times and thus the quality of items in the whole supply chain. Products that exceed their useful lifetime can impose high costs due to inventory loss or the need to rework them. This implies increased utilization of (scarce) resources, e.g., machine time, metals, and/or energy, thereby increasing CO₂${\text{CO}}_2$-levels. We survey the state-of-the-art regarding depreciation effects and the modeling of lifetime constraints as well as a classification of models following business planning functions of the value chain. A critical evaluation of approaches and their limitations is provided, highlighting directions for future research.     

Design of regional production networks for second generation synthetic bio-fuel - A case study in Northern Germany

In the medium-term, second generation synthetic bio-diesel will make an important contribution to sustainable mobility. However, attributed to political, technical, and market related uncertainties, it is still not clear which interest groups will invest in production capacities and which technologies will be used. Hence, a multi-period MIP-model is presented for integrated location, capacity and technology planning for the design of production networks for second generation synthetic bio-diesel. The approach is applied to the region of Niedersachsen, Germany. Principle network configurations are developed for this region considering different scenarios and different risk attitudes of interest groups. As results of the investigation, recommendations are drawn regarding advantageous plant concepts, as well as strategies for the capacity installation. Finally, recommendations for political decision makers as well as for potential investors are deduced.     

A continuous DC programming approach to the strategic supply chain design problem from qualified partner set

We present a new continuous approach based on the DC (difference of convex functions) programming and DC algorithms (DCA) to the problem of supply chain design at the strategic level when production of a new market opportunity has to be launched among a set of qualified partners. A well known formulation of this problem is the mixed integer linear program. In this paper, we reformulate this problem as a DC program by using an exact penalty technique. The proposed algorithm is a combination of DCA and Branch and Bound scheme. It works in a continuous domain but provides mixed integer solutions. Numerical simulations on many empirical data sets show the efficiency of our approach with respect to the standard Branch and Bound algorithm.     

Optimisation of gravity-fed water distribution network design: A critical review

This paper surveys the literature on the optimisation of water distribution network design. The water distribution network design (WDND) optimisation problem entails finding the material and diameter of each pipe in the network so that the total cost of the network is minimised without violating any hydraulic constraints. This is a difficult combinatorial optimisation problem, in which decision variables are discrete and both cost function and constraints are non-linear. Over the past 30 years, a large number of methods, especially in the field of (meta) heuristics, have been developed to solve this problem, most of which obtain good results on the available benchmark networks. In addition to outlining the basic features of each method, a detailed computational comparison is presented. Based on this comparison, some issues with the current state of the art in this domain are discussed, and some future research directions are suggested. Additionally, the need for an adequate set of benchmark instances is motivated, and the minimal requirements for an instance set generator are discussed.     

Application of fuzzy optimization to a supply chain network design: A case study of an edible vegetable oils manufacturer

This study applies fuzzy sets to integrate the supply chain network of an edible vegetable oils manufacturer. The proposed fuzzy multi-objective linear programming model attempts to simultaneously minimize the total transportation costs. The first part of the total transportation costs is between suppliers and silos; and rest one is between manufacturer and warehouses. The approach incorporates all operating realities and actual flow patterns at production/distribution network with reference to demands of warehouses, capacities of tin and pet packaging lines. The model has been formulated as a multi objective linear programming model where data are modeled by triangular fuzzy numbers. Finally, the developed fuzzy model is applied for the case study, compiled the results and discussed.     

Optimal design of the auto parts supply chain for JIT operations: Sequential bifurcation factor screening and multi-response surface methodology

This research proposes a solution framework based on discrete-event simulation, sequential bifurcation (SB) and response surface methodology (RSM) to address a multi-response optimization problem inherent in an auto parts supply chain. The objective is to identify the most efficient operating setting that would maximize the logistics performance after the expansion of the assembly plant’s capacity due to market growth. In the proposed framework, we first construct a comprehensive simulation as a platform to model the physical flow of the auto parts operations. We then apply the SB to identify the most important factors that influence system performance. To determine the optimal levels of these key factors, we employ RSM to develop metamodels that best describe the relationship between key decision variables and the multiple system responses. We adapt the Derringer–Suich’s desirability function to find the optimal solution of the metamodels. Computational study shows that our method enables the greatest improvement on system performance. The proposed method helps the case firm develop insights into system dynamics and to optimize the operating condition. It realizes the performance objective of the auto parts supply chain without the need for additional fiscal investment.