Optimisation of integrated reverse logistics networks with different product recovery routes

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

An integrated approach for supplier selection in multi-item/multi-supplier environment

One of the important stages in supply chain management which regards all the activities from the purchasing of raw material to final delivery of the product is the supplier selection process. Since it is the first stage of the supply chain management, it is a critical process affecting the consecutive stages. It is simply desired to select the best supplier for a specific product. But since there are a lot of criteria and alternatives to be considered, numerous decision making models have been proposed to provide a solution to this problem. Within this study, an integrated approach including fuzzy Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) and a mixed integer linear programming model is developed to select the best supplier in a multi-item/multi-supplier environment. The importance value of each supplier with respect to each product is obtained via fuzzy TOPSIS in the first stage. Then in the second stage, these values are used as an input in the mathematical model which determines the suppliers and the quantities of products to be provided from the related suppliers. So as to validate the proposed methodology, an application is performed in air filter sector.     

Robust optimal dynamic production/pricing policies in a closed-loop system

Hybrid manufacturing/remanufacturing systems play a key role in implementing closed-loop production systems which have been considered due to increasingly environmental concerns and latent profit of used products. Manufacturing and remanufacturing rates, selling price of new products, and acquisition price of used products are the most critical variables to optimize in such hybrid systems. In this paper, we develop a dynamic production/pricing problem, in which decisions should be made in each period confronting with uncertain demand and return. The manufacturer is able to control the demand and return by adjusting selling price and acquisition price respectively, also she can stock inventories of used and new products to deal with uncertainties. Modeling a nominal profit maximization problem, we go through robust optimization approach to reformulate it for the uncertain case. Final robust optimization model is obtained as a quadratic programming model over discrete periods which can be solved by optimization packages of QP. A numerical example is defined and sensitivity analysis is performed on both basic parameters and parameters associated with uncertainty to create managerial views.     

A dynamic model for optimal design quality and return policies

A clearly explained and generous return policy has been established as a competitive weapon to enhance sales. From the firm’s point of view, a generous return policy will increase sales revenue, but will also increase cost due to increased likelihood of return. Design quality of the product has been used as a competitive weapon for a long time. This paper recognizes the relationship between design quality and price of the product, and the firm’s return policy. Quality level in the product would influence the amount of return directly. When the product quality is higher, the customer satisfaction rate will increase and the probability of return will decrease. We develop a profit-maximization model to jointly obtain optimal policies for the product quality level, price and the return policy over time. The model presented in this paper is dynamic in nature and considers the decisions as the product moves through the life cycle. We obtain a number of managerial guidelines for using marketing and operational strategy variables to obtain the maximum benefit from the market. We mention several future research possibilities.     

A multi-objective facility location model for closed-loop supply chain network under uncertain demand and return

A closed-loop supply chain (CLSC) network consists of both forward and reverse supply chains. In this paper, a CLSC network is investigated which includes multiple plants, collection centres, demand markets, and products. To this aim, a mixed-integer linear programming model is proposed that minimizes the total cost. Besides, two test problems are examined. The model is extended to consider environmental factors by weighed sums and ε-constraint methods. In addition, we investigate the impact of demand and return uncertainties on the network configuration by stochastic programming (scenario-based). Computational results show that the model can handle demand and return uncertainties, simultaneously.     

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.     

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.     

A fuzzy optimization approach for procurement transport operational planning in an automobile supply chain

We consider a real-world automobile supply chain in which a first-tier supplier serves an assembler and determines its procurement transport planning for a second-tier supplier by using the automobile assembler’s demand information, the available capacity of trucks and inventory levels. The proposed fuzzy multi-objective integer linear programming model (FMOILP) improves the transport planning process for material procurement at the first-tier supplier level, which is subject to product groups composed of items that must be ordered together, order lot sizes, fuzzy aspiration levels for inventory and used trucks and uncertain truck maximum available capacities and minimum percentages of demand in stock. Regarding the defuzzification process, we apply two existing methods based on the weighted average method to convert the FMOILP into a crisp MOILP to then apply two different aggregation functions, which we compare, to transform this crisp MOILP into a single objective MILP model. A sensitivity analysis is included to show the impact of the objectives weight vector on the final solutions. The model, based on the full truck load material pick method, provides the quantity of products and number of containers to be loaded per truck and period. An industrial automobile supply chain case study demonstrates the feasibility of applying the proposed model and the solution methodology to a realistic procurement transport planning problem. The results provide lower stock levels and higher occupation of the trucks used to fulfill both demand and minimum inventory requirements than those obtained by the manual spreadsheet-based method.     

An analytical method for cost analysis in multi-stage supply chains: A stochastic network model approach

This paper studies the cost distribution characteristics in multi-stage supply chain networks. Based on the graphical evaluation and review technique, we propose a novel stochastic network mathematical model for cost distribution analysis in multi-stage supply chain networks. Further, to investigate the effects of cost components, including the procurement costs, inventory costs, shortage costs, production costs and transportation costs of supply chain members, on the total supply chain operation cost, we propose the concept of cost sensitivity and provide corresponding algorithms based on the proposed stochastic network model. Then the model is extended to analyze the cost performance of supply chain robustness under different order compensation ability scenarios and the corresponding algorithms are developed. Simulation experiment shows the effectiveness and flexibility of the proposed model, and also promotes a better understanding of the model approach and its managerial implications in cost management of supply chains.