Planning and consolidating shipments from a warehouse

A typical warehouse or distribution centre ships material to various customer locations across the country, using various modes of transportation. Each mode has different constraints on size of shipment, different cost structures and different transportation times. Typically, for a given warehouse there are certain customer locations that receive frequent shipments of material. It is often possible, therefore, for the warehouse to consolidate different orders for the same customer location into a single shipment. The transportation mode and the day of shipment must be chosen such that the consolidated shipment meets the size constraints and arrives within an agreed-upon ‘delivery window’. In preparing a warehouse distribution plan, a planner seeks to achieve transportation economies of scale (by consolidating two or more orders into fewer shipments) while levelling the workload on warehouse resources and ensuring that material arrives at a customer location during the acceptable delivery window.The problem of deciding what shipments to make daily can be formulated as a set partitioning problem with side constraints. This paper describes a heuristic solution approach for this problem. Computational experiments using actual warehouse select activity indicate that, for moderate-size problems, the heuristic produces solutions with transportation costs that are within a few percent of optimal. Larger problems found in practice are generally too large to be solved by optimal algorithms; the heuristic easily handles such problems. The heuristic has been integrated into the transportation planning system of a leading distributor of telecommunications products.     

A mathematical model of inter-terminal transportation

We present a novel integer programming model for analyzing inter-terminal transportation (ITT) in new and expanding sea ports. ITT is the movement of containers between terminals (sea, rail or otherwise) within a port. ITT represents a significant source of delay for containers being transshipped, which costs ports money and affects a port’s reputation. Our model assists ports in analyzing the impact of new infrastructure, the placement of terminals, and ITT vehicle investments. We provide analysis of ITT at two ports, the port of Hamburg, Germany and the Maasvlakte 1 & 2 area of the port of Rotterdam, The Netherlands, in which we solve a vehicle flow combined with a multi-commodity container flow on a congestion based time–space graph to optimality. We introduce a two-step solution procedure that computes a relaxation of the overall ITT problem in order to find solutions faster. Our graph contains special structures to model the long term loading and unloading of vehicles, and our model is general enough to model a number of important real-world aspects of ITT, such as traffic congestion, penalized late container delivery, multiple ITT transportation modes, and port infrastructure modifications. We show that our model can scale to real-world sizes and provide ports with important information for their long term decision making.     

A large-scale application of the partial coverage uncapacitated facility location problem

The traditional, uncapacitated facility location problem (UFLP) seeks to determine a set of warehouses to open such that all retail stores are serviced by a warehouse and the sum of the fixed costs of opening and operating the warehouses and the variable costs of supplying the retail stores from the opened warehouses is minimized. In this paper, we discuss the partial coverage uncapacitated facility location problem (PCUFLP) as a generalization of the uncapacitated facility location problem in which not all the retail stores must be satisfied by a warehouse. Erlenkotter's dual-ascent algorithm, DUALOC, will be used to solve optimally large (1600 stores and 13?000 candidate warehouses) real-world implemented PCUFLP applications in less than two minutes on a 500?MHz PC. Furthermore, a simple analysis of the problem input data will indicate why and when efficient solutions to large PCUFLPs can be expected.     

Service differentiation through selective lateral transshipments

We consider a multi-item spare parts problem with multiple warehouses and two customer classes, where lateral transshipments are used as a differentiation tool. Specifically, premium requests that cannot be met from stock at their preferred warehouse may be satisfied from stock at other warehouses (so-called lateral transshipments). We first derive approximations for the mean waiting time per class in a single-item model with selective lateral transshipments. Next, we embed our method in a multi-item model minimizing the holding costs and costs of lateral and emergency shipments from upstream locations in the network. Compared to the option of using only selective emergency shipments for differentiation, the addition of selective lateral transshipments can lead to significant further cost savings (14% on average).     

沿海港口集装箱空箱调运策略优化模型

我国沿海港口进出口箱分布非常不均衡,由此产生了集装箱空箱调运现象,合理的空箱调运策略能够有效地降低航运成本。本文研究了沿海港口间的空箱调运问题。在传统确定目的港策略的基础上,提出了一种新的空箱调运策略,不确定目的港策略。针对两种不同调运策略分别建立了以总调运费用最小为目标的规划模型。并以中国沿海港口空箱调运为例,运用遗传算法,在不同的空箱供需情况下,对两种调运策略费用进行了优化求解。结果表明,供需平衡模式下,固定目的港策略略有优势;在供需不平衡模式中,不确定目的港策略优势更加明显。此研究能够为港口间空箱调运提供辅助决策。     

Improved rounding procedures for the discrete version of the capacitated EOQ problem

We consider a transportation problem where different products have to be shipped from an origin to a destination by means of vehicles with given capacity. The production rate at the origin and the demand rate at the destination are constant over time and identical for each product. The problem consists in deciding when to make the shipments and how to fill the vehicles, with the objective of minimizing the sum of the average transportation and inventory costs at the origin and at the destination over an infinite horizon. This problem is the well known capacitated EOQ (economic order quantity) problem and has an optimal solution in closed form. In this paper we study a discrete version of this problem in which shipments are performed only at multiples of a given minimum time. It is known that rounding-off the optimal solution of the capacitated EOQ problem to the closest lower or upper integer value gives a tight worst-case ratio of 2, while the best among the possible single frequency policies has a performance ratio of 5/3. We show that the 5/3 bound can be obtained by a single frequency policy based on a rounding procedure which considers classes of instances and, for each class, identifies a shipping frequency by rounding-off in a different way the optimal solution of the capacitated EOQ problem. Moreover, we show that the bound can be reduced to 3/2 by using two shipping frequencies, obtained by a rounding procedure, in one class of instances only.     

Combined Sea and Land Transportation

An important problem today in the field of transportation is the standardization of the cargo, e.g. by using containers, and the design of the handling and transportation equipment for the specific cargo to be transported.The paper presents a method for determining the transportation system with emphasis on sea transport. Thus the cargo is to be transported by sea from the factory to customers spread over a large region, e.g. Europe. The problem is to select the ports of call, the quantities to be delivered at the ports, as well as the size and type of vessel.This problem resembles the warehouse location problem (the location of ports) but requires in addition the determination of ship size, type of ship and whether one or more ports should be called at on each journey with a single ship. A discussion is also presented as to the possibility of considering randomness in the system with respect to customer demand and weather conditions.The method used resembles that suggested by Baumol and Wolfe for the ware-house location problem. A concave function of the quantities delivered at each port is derived and this is then shown to converge to a local optimum.An example is solved to illustrate the method.     

Warehouse location with production,inventory, and distribution decisions: a case study in the lube oil industry

In this paper, a supply chain management problem from a real case study is modeled and solved. A company in Pakistan wanted to outsource part of its warehousing activity to a third party logistics (3PL) provider. Consequently, the company had to decide on where to rent space in the 3PL warehouses. Knowing that such a strategic decision is affected by tactical and operational decisions, the problem is presented as a facility location problem integrating production, inventory, and distribution decisions. The problem is formulated as a mixed integer linear programming model which minimizes the total cost composed of location, distribution, production, and inventory costs. Several constraints specific to the situation and policy of the company were considered. A thorough analysis was done on the results obtained with respect to formulation efficiency, sensitivity analysis, and distribution of costs. In addition to the solution of the company problem, a set of 1215 problem instances was generated by varying five types of relevant costs in a full factorial manner. The solution of the generated problems always suggests to open in the same two locations and the integrality gaps averaged 0.062 % with a maximum of 0.102 %. On average, the major components of the total cost are production cost (96.6 %), transportation costs (2.7 %), and inventory holding costs (0.38 %). The total warehouse opening cost accounted for less than 0.05 % of the total costs.     

A Mathematical Model for the Container Stowage and Ship Routing Problem

The main goal of this paper is to present a mathematical model for a fleet of containerships with no pre-defined routes, considering demands and delivery deadlines and overstowing prevention. The objective is to minimize the total distribution cost in the contest of the short sea shipping. The short sea shipping is a very complex problem that belongs to the class of routing problems, more precisely, to the Capacitated Vehicle Routing Problem with deadlines and loading constraints. In this problem two major decisions must be made: which ports should be visited by each vessel and the related visit sequence, and where to load the containers in vessels in order to prevent overstowing. A mixed integer programming model for the problem is presented and solved. This mathematical formulation intends to contribute to a better management of small fleets of containerships in order to reduce transportation time and delivering costs.     

Allocation of empty containers between multi-ports

Owing to imbalances in international trade activities, shipping companies accumulate a large number of unnecessary empty containers in the import-dominant ports, whilst request a large number of empty containers in export-dominant ports. The logistics challenge to shipping companies is to better manage and control their containers, which consist of company-owned containers and leased containers. The multi-port empty container allocation problem is concerned with the allocation of empty containers from supply ports to demand ports. In this paper, optimal pairs of critical policies, (U, D) for one port, which are importing empty containers up to U when the number of empty containers in the port is less than U, or exporting empty containers down to D when the number of empty containers is larger than D, doing nothing otherwise, are adapted to multi-port case so that decision-makers can make decisions about allocating the right amounts of empty containers to the right ports at the right time. This allocation problem has been formulated and the heuristic methods are designed according to that the average cost using (u, d) policy at one port is convex in u and d. Furthermore, the examples show that, using the heuristic algorithm, the result in the inland line case is quite close to the lower bound, even the distance is not so close in the global line case.     

Manufacturer’s mixed pallet design problem

We study a problem faced by a major beverage producer. The company produces and distributes several brands to various customers from its regional distributors. For some of these brands, most customers do not have enough demand to justify full pallet shipments. Therefore, the company decided to design a number of mixed or “rainbow” pallets so that its customers can order these unpopular brands without deviating too much from what they initially need. We formally state the company’s problem as determining the contents of a pre-determined number of mixed pallets so as to minimize the total inventory holding and backlogging costs of its customers over a finite horizon. We first show that the problem is NP-hard. We then formulate the problem as a mixed integer linear program, and incorporate valid inequalities to strengthen the formulation. Finally, we use company data to conduct a computational study to investigate the efficiency of the formulation and the impact of mixed pallets on customers’ total costs.     

Operations planning for a multi-stage kanban system

A multi-stage production line which operates under a just-in-time production philosophy with linear demand is considered here. The first workstation processes the raw materials after receiving them from suppliers, a kanban mechanism between the workstations transports the work-in-process to the succeeding workstation, and after processing them, delivers the finished products to a buyer or a warehouse. The problem is to find optimally the number of raw material orders, kanbans circulated between workstations, finished goods shipments to the buyers, and the batch size for each shipment (lot). A cost function is developed based on the costs incurred due to the raw materials, the work-in-process between workstations, and the finished goods. Optimal number of raw material orders that minimizes the total cost is obtained, which is then used to find the optimal number of kanbans, finished goods shipments, and the batch sizes for shipments. Numerical examples are used to demonstrate the computations of optimal parameters, and to configure the kanban mechanism on a timescale. Several avenues for future research are also indicated.     

Analysis of the Best Double Frequency Policy in the Single Link Problem with Discrete Shipping Times

We study an inventory–transportation problem where one product has to be shipped from an origin to a destination by vehicles of given capacity over an infinite time horizon. The product is made available at the origin and consumed at the destination at the same constant rate. The intershipment time must be not lower than a given minimum value. The problem is to decide when to make the shipments and how to load the vehicles to minimize the sum of the transportation and the inventory costs at the origin and at the destination per time unit. We study the case in which the intershipment time is a multiple of the minimum value, i.e., the problem with discrete shipping times. We show that, in this case, the best double frequency policy has a tight performance bound of about 1.1603 with respect to the optimal periodic policy and of about 1.1538 with respect to the best frequency-based policy. Moreover, we show that, from the worst-case point of view, the best double frequency policy is the optimal frequency-based policy.     

Airfreight forwarder shipment planning: A mixed 0–1 model and managerial issues in the integration and consolidation of shipments

The planning and management of air cargo logistics is a complex endeavor, involving collaboration of multiple logistics agents to deliver shipments timely, safely and economically. Airfreight forwarders are third-party brokers/operators who coordinate and manage cargo shipments for their clients. It is important for a forwarder to develop a shipment plan to evaluate the possible integrations and consolidations, to assess whether shipments can meet their respective target delivery dates, and to estimate the amount of costs involved. In this paper, we formulate a forwarder’s shipment planning problem as a mixed 0–1 LP. Effects of integration and consolidation – on the timely delivery of shipments during any phase of the shipping process – are explicitly addressed. A forwarder’s in-house capacity, as well as the available capacity of its partners and sub-contracting agents, are incorporated. We also consider the target cost for a shipment. Based on the special characteristics of the model, we design a customized tabu-search algorithm. We also provide an illustrative case to examine several managerial issues.     

Real-time split-delivery pickup and delivery time window problems with transfers

In this research we present the design and implementation of heuristics for solving split-delivery pickup and delivery time window problems with transfer (SDPDTWP) of shipments between vehicles for both static and real-time data sets. In the SDPDTWP each shipment is constrained with the earliest possible pickup time from the origin and the latest acceptable delivery time to a destination. Split-deliveries occur when two or more vehicles service the same origin or destination. The proposed heuristics were applied to both static and real-time data sets. The heuristics computed a solution, in a few seconds, for a static problem from the literature, achieving an improvement of 60% in distance in comparison to the published solution. In the real-time SDPDTWP problems, requests for pickup and delivery of a package, breakdown of a truck or insertion of a truck can occur after the vehicle has left the origin and is enroute to service the customers. Thirty data sets, each consisting of one to seven real-time customer or truck events, were used to test the efficiency of the heuristics. The heuristics obtained solutions to real-time data sets in under five seconds of CPU time.      

The warehouse-inventory-transportation problem for supply chains

Warehouses play a vital role in mitigating variations in supply and demand, and in providing value-added services in a supply chain. However, our observation of supply chain practice reveals that warehousing decisions are not included when developing a distribution plan for the supply chain. This lack of integration has resulted in a substantial variation in workload (42–220%) at our industry partner’s warehouse costing them millions of dollars. To address this real-world challenge, we introduce the warehouse-inventory-transportation problem (WITP) of determining an optimal distribution plan from vendors to customers via one or more warehouses in order to minimize the total distribution cost. We present a nonlinear integer programming model for the WITP considering supply chains with multiple vendors, stores, products, and time-periods, and one warehouse. The model also considers worker congestion at the warehouse that could affect worker productivity. A heuristic based on iterative local search is developed to solve industry-sized problems with up to 500 stores and 1000 products. Our experiments indicate that the distribution plans obtained via the WITP, as compared to a sequential approach, result in a substantial reduction in workload variance at the warehouse, while considerably reducing the total distribution cost. These plans, however, are sensitive to aisle configuration and technology at the warehouse, and the level and productivity of temporary workers.     

Note: An application of the EOQ model with nonlinear holding cost to inventory management of perishables

In this note, we consider a variation of the economic order quantity (EOQ) model where cumulative holding cost is a nonlinear function of time. This problem has been studied by Weiss [Weiss, H., 1982. Economic order quantity models with nonlinear holding costs. European Journal of Operational Research 9, 56–60], and we here show how it is an approximation of the optimal order quantity for perishable goods, such as milk, and produce, sold in small to medium size grocery stores where there are delivery surcharges due to infrequent ordering, and managers frequently utilize markdowns to stabilize demand as the product’s expiration date nears. We show how the holding cost curve parameters can be estimated via a regression approach from the product’s usual holding cost (storage plus capital costs), lifetime, and markdown policy. We show in a numerical study that the model provides significant improvement in cost vis-à-vis the classic EOQ model, with a median improvement of 40%. This improvement is more significant for higher daily demand rate, lower holding cost, shorter lifetime, and a markdown policy with steeper discounts.     

Marine inventory routing: shipments planning

This paper addresses a shipments-planning problem faced by producers of large volume liquid bulk products. Producing origins with limited tank storage capacity supply multiple products by ships (or barges) to consuming destinations that also have limited storage capacity. Timing, origin, destination, and product quantities of shipments have to be determined in a manner that minimizes costs and does not violate storage capacity constraints at both ends (neither stopping production at the origins, nor running out of stock at the destinations). A mixed integer-programming model is used to derive cost effective solutions within a few minutes. A cost-based heuristic algorithm is used to assure that acceptable solutions are obtained quickly.     

An integrated model for screening cargo containers

This paper focuses on detecting nuclear weapons on cargo containers using port security screening methods, where the nuclear weapons would presumably be used to attack a target within the United States. This paper provides a linear programming model that simultaneously identifies optimal primary and secondary screening policies in a prescreening-based paradigm, where incoming cargo containers are classified according to their perceived risk. The proposed linear programming model determines how to utilize primary and secondary screening resources in a cargo container screening system given a screening budget, prescreening classifications, and different device costs. Structural properties of the model are examined to shed light on the optimal screening policies. The model is illustrated with a computational example. Sensitivity analysis is performed on the ability of the prescreening in correctly identifying prescreening classifications and secondary screening costs. Results reveal that there are fewer practical differences between the screening policies of the prescreening groups when prescreening is inaccurate. Moreover, devices that can better detect shielded nuclear material have the potential to substantially improve the system’s detection capabilities.     

An integrated producer–buyer supply chain with delivery cost under stochastic transportation time

An integrated producer–buyer supply chain is used to simultaneously determine the optimum levels of the safety stock, delivery quantity, and number of shipments in this paper. The scenario is created by scheduling a single-setup at the producer with multiple deliveries to the buyer, and all shipments to the buyer are equal-sized batches. This study attempts to study the effects of delivery cost and transportation time, assumes that there is a stochastic transportation time between both producer and buyer, and that shortages are allowed. The transportation time is assumed to be Weibull distributed. The objective functions of the integrated model include the setup cost, inventory carrying cost, and delivery cost. We analyze the scenario where the delivery cost is explicitly considered in the model rather than considered as part of the fixed ordering cost or insignificant. A numerical example is also presented to demonstrate the proposed model using actual shipping rate data. In particular, the results show that when the producer's and buyer's carrying costs are low, and/or the mean time of transportation and delivery costs are high, then this can benefit both parties with regard to sharing total profit.