Determining the optimal run time for EPQ model with scrap,rework, and stochastic breakdowns

This paper is concerned with determination of optimal run time for an economic production quantity (EPQ) model with scrap, rework, and stochastic machine breakdowns. In real life manufacturing systems, generation of defective items and random breakdown of production equipment are inevitable. In this study, a portion of the defective items is considered to be scrap, while the other is assumed to be repairable. Total production-inventory cost functions are derived respectively for both EPQ models with breakdown (no-resumption policy is adopted) and without breakdown taking place. These cost functions are integrated and the renewal reward theorem is used to cope with the variable cycle length. Theorems on conditional convexity of the integrated overall costs and bounds of the production run time are proposed and proved. We conclude that the optimal run time falls within the range of bounds and it can be pinpointed by the use of the bisection method based on the intermediate value theorem. Numerical example is provided to demonstrate its practical usages.     

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.     

Optimal replenishment policy for imperfect quality EMQ model with rework and backlogging

This paper derives the optimal replenishment policy for imperfect quality economic manufacturing quantity (EMQ) model with rework and backlogging. The classic EMQ model assumes that all items produced are of perfect quality. However, in real‐life manufacturing settings, generation of imperfect quality items is almost inevitable. In this study, a random defective rate is assumed. All items produced are inspected and the defective items are classified as scrap and repairable. A rework process is involved in each production run when regular manufacturing process ends, and a rate of failure in repair is also assumed. Unit disposal cost and unit repairing and holding costs are included in our mathematical modelling and analysis. The renewal reward theorem is employed in this study to cope with the variable cycle length. The optimal replenishment policy in terms of lot‐size and backlogging level that minimizes expected overall costs for the proposed imperfect quality EMQ model is derived. Special cases of the model are identified and discussed. Numerical example is provided to demonstrate its practical usage. Copyright © 2006 John Wiley & Sons, Ltd.     

Designing an efficient supply chain network with uncertain data: a robust optimization—data envelopment analysis approach

Designing a supply chain network (SCN) is an important issue for organizations in competitive markets. In this paper, a novel robust SCN that considers the efficiencies and costs simultaneously is proposed. In order to estimate the efficiency of the producers and distributors, data envelopment analysis (DEA) model is incorporated into SCN. Moreover, to handle the uncertainty in data, a scenario-based robust optimization approach is applied. The proposed model finds out the efficient location of producers and distributors and determines the amount of purchases from each supplier in uncertain conditions. To illustrate the application of the proposed model, a numerical example is solved and results are analyzed.     

Multiproduct single-machine production system with stochastic scrapped production rate, partial backordering and service level constraint

In this paper, a multiproduct single-machine production system under economic production quantity (EPQ) model is studied in which the existence of only one machine causes a limited production capacity for the common cycle length of all products, the production defective rates are random variables, shortages are allowed and take a combination of backorder and lost sale, and there is a service rate constraint for the company. The aim of this research is to determine the optimal production quantity, the allowable shortage level, and the period length of each product such that the expected total cost, including holding, shortage, production, setup and defective items costs, is minimized. The mathematical model of the problem is derived for which the objective function is proved to be convex. Then, a derivative approach is utilized to obtain the optimal solution. Finally, two numerical examples in each of which a sensitivity analysis is performed on the model parameters, are provided to illustrate the practical usage of the proposed methodology.     

Evaluation of cycle-count policies for supply chains with inventory inaccuracy and implications on RFID investments

Inventory record inaccuracy leads to ineffective replenishment decisions and deteriorates supply chain performance. Conducting cycle counts (i.e., periodic inventory auditing) is a common approach to correcting inventory records. It is not clear, however, how inaccuracy at different locations affects supply chain performance and how an effective cycle-count program for a multi-stage supply chain should be designed. This paper aims to answer these questions by considering a serial supply chain that has inventory record inaccuracy and operates under local base-stock policies. A random error, representing a stock loss, such as shrinkage or spoilage, reduces the physical inventory at each location in each period. The errors are cumulative and are not observed until a location performs a cycle count. We provide a simple recursion to evaluate the system cost and propose a heuristic to obtain effective base-stock levels. For a two-stage system with identical error distributions and counting costs, we prove that it is more effective to conduct more frequent cycle counts at the downstream stage. In a numerical study for more general systems, we find that location (proximity to the customer), error rates, and counting costs are primary factors that determine which stages should get a higher priority when allocating cycle counts. However, it is in general not effective to allocate all cycle counts to the priority stages only. One should balance cycle counts between priority stages and non-priority stages by considering secondary factors such as lead times, holding costs, and the supply chain length. In particular, more cycle counts should be allocated to a stage when the ratio of its lead time to the total system lead time is small and the ratio of its holding cost to the total system holding cost is large. In addition, more cycle counts should be allocated to downstream stages when the number of stages in the supply chain is large. The analysis and insights generated from our study can be used to design guidelines or scorecard systems that help managers design better cycle-count policies. Finally, we discuss implications of our study on RFID investments in a supply chain.     

Supply chain network sustainability under competition and frequencies of activities from production to distribution

In this paper, we develop a competitive supply chain network model with multiple firms, each of which produces a differentiated product by brand and weights the emissions that it generates through its supply chain network activities in an individual way. The supply chain network activities of production, transport and distribution, and storage have associated with them distinct capacities and the firms seek to determine their optimal product flows and frequencies of operation so that their utilities are maximized where the utilities consist of profits and weighted emissions. Multiple production, storage, and transport mode options are allowed. The governing equilibrium concept is that of Cournot–Nash equilibrium. We provide both path and link flow variational inequality formulations of the equilibrium conditions and then propose an algorithm, which, at each iteration, yields closed form expressions for the underlying variables. Numerical examples illustrate the generality of the model and the information provided to managerial decision-makers and policy-makers. This paper adds to the growing literature on sustainable supply chains through the development of a computable general competitive supply chain network game theory model, which brings a greater realism to the evaluation of profit and emission trade-offs through the incorporation of frequencies.     

Integrated markdown pricing and aggregate production planning in a two echelon supply chain: A hybrid fuzzy multiple objective approach

Given high variability of demands for short life cycle products, a retailer has to decide about the products’ prices and order quantities from a manufacturer. In the meantime, the manufacturer has to determine an aggregate production plan involving for example, production, inventory and work force levels in a multi period, multi product environment. Due to imprecise and fuzzy nature of products’ parameters such as unit production and replenishment costs, a hybrid fuzzy multi-objective programming model including both quantative and qualitative constraints and objectives is proposed to determine the optimalprice markdown policy and aggregate production planning in a two echelon supply chain. The model aims to maximize the total profit of manufacturer, the total profit of retailer and improving service aspects of retailing simultaneously. After applying appropriate strategies to defuzzify the original model, the equivalent multi-objective crisp model is then solved by a fuzzy goal programming method. An illustrative example is also provided to show the applicability and usefulness of the proposed model and solution method.     

多商品流多期供应链网络均衡模型

针对具有多种商品流的三层供应链网络结构模型,考虑时间变量和库存问题,分别对制造商、零售商和需求市场的决策者的多期独立决策行为及其相互作用进行了分析,利用变分不等式构建了各层均衡模型以及系统均衡模型,得到了系统达到均衡的条件,给出了具体算例并进行了求解,最后与相关文献的模型进行了比较.     

Economic production quantity model with repair failure and limited capacity

We develop an economic production quantity (EPQ) model with random defective items and failure in repair. The existence of only one machine results with limited production capacity and shortages. The aim of this research is to derive the optimal cycle length, the optimal production quantity and the optimal back ordered quantity for each product so as to minimize the total expected cost (holding, shortage, production, setup, defective items and repair costs). The convexity of the model is derived and the objective function is proved convex. Two numerical examples illustrate the practical usage of the proposed method.     

Supply chain performance assessment and supplier and component importance identification in a general competitive multitiered supply chain network model

In this paper, we develop a multitiered competitive supply chain network game theory model, which includes the supplier tier. The firms are differentiated by brands and can produce their own components, as reflected by their capacities, and/or obtain components from one or more suppliers, who also are capacitated. The firms compete in a Cournot–Nash fashion, whereas the suppliers compete a la Bertrand since firms are sensitive to prices. All decision-makers seek to maximize their profits with consumers reflecting their preferences through the demand price functions associated with the demand markets for the firms’ products. We construct supply chain network performance measures for the full supply chain and the individual firm levels that assess the efficiency of the supply chain or firm, respectively, and also allow for the identification and ranking of the importance of suppliers as well as the components of suppliers with respect to the full supply chain or individual firm. The framework is illustrated through a series of numerical supply chain network examples.     

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.     

Matching product architecture with supply chain design

Product architecture is typically established in the early stages of the product development (PD) cycle. Depending on the type of architecture selected, product design, manufacturing processes, and ultimately supply chain configuration are all significantly affected. Therefore, it is important to integrate product architecture decisions with manufacturing and supply chain decisions during the early stage of the product development. In this paper, we present a multi-objective optimization framework for matching product architecture strategy to supply chain design. In contrast to the existing operations management literature, we incorporate the compatibility between the supply chain partners into our model to ensure the long term viability of the supply chain. Since much of the supplier related information may be very subjective in nature during the early stages of PD, we use fuzzy logic to compute the compatibility index of a supplier. The optimization model is formulated as a weighted goal programming (GP) model with two objectives: minimization of total supply chain costs, and maximization of total supply chain compatibility index. The GP model is solved by using genetic algorithm. We present case examples for two different products to demonstrate the model’s efficacy, and present several managerial implications that evolved from this study.     

竞争市场下考虑再制造产品售后服务的供应链运营策略

在同时生产新产品和再制造产品的原始制造企业(企业1)与生产具有替代性产品的企业(企业2)构成竞争关系下的供应链系统中,探讨供应链在不同售后服务策略下供应链的运营策略,分析在竞争市场下供应链定价策略和再制造产品的售后服务对定价策略及供应链中各企业利润的影响。揭示再制造产品售后服务对定价策略和供应链各企业最优利润的影响。得到如下主要研究结论:(1)当制造企业为再制造产品提供售后服务时,再制造产品销售量增加,新产品和竞争替代产品销售量降低;有趣的是新产品和再制造产品的市场零售价格同时增加,竞争替代产品的市场零售价格降低。(2)制造企业为再制造产品提供售后服务时的利润总是大于没有售后服务时的利润,且不受单位产品生产成本影响。同时当单位产品生产成本较高时,制造企业为再制造产品提供售后服务策略会带来竞争对手企业利润增加。这些结论对具有再制造产品供应链如何提供再制造产品售后服务具有一定指导作用和管理启示。     

Coordinated supply chain management

Historically, the three fundamental stages of the supply chain, procurement, production and distribution, have been managed independently, buffered by large inventories. Increasing competitive pressures, and market globalization are forcing firms to develop supply chains that can quickly respond to customer needs. To remain competitive, these firms must reduce operating costs while continuously improving customer service. With recent advances in communications and information technology, as well as a rapidly growing array of logistics options, firms have an opportunity to reduce operating costs by coordinating the planning of these stages. In this paper, we review the literature addressing coordinated planning between two or more stages of the supply chain, placing particular emphasis on models that would lend themselves to a total supply chain model. Finally, we suggest directions for future research.     

低碳环境下供应链差异化定价与协调机制研究

以低碳和普通产品两个制造商和一个零售商组成的两级供应链系统为研究对象,探讨了供应链的差异化定价与协调机制问题。求解得到了两制造商和零售商的最优定价策略及可行的低碳产品生产成本范围。研究发现:1)分散决策的差异化定价策略无法达到供应链协调;2)在可行的低碳产品生产成本范围内,低碳产品制造商、零售商和整个供应链系统的利润都随低碳产品生产成本的增加而减少,只有普通产品制造商的利润随低碳产品生产成本的增加而增加。因此,降低低碳产品生产成本是促进低碳产品推广的关键。针对分散决策造成供应链效率损失的情况,采用Shapley值法进行协调,并给出了契约协调机制。最后,通过算例分析了消费者价格敏感性变化和低碳产品生产成本上升对最优决策和供应链利润的影响。     

基于Kriging模型的供应链优化设计

供应链优化的目的之一是确定使得总成本最小的最佳运作水平.供应链系统是复杂的动态系统,由于库存系统的复杂性和供应链本身的不确定性,利用传统优化方法往往需要耗费一定的计算成本和经济成本.而元模型则能以简单的数学表达式较精确地刻画仿真系统的输入输出关系,为研究者分析复杂系统提供了一种分析方法.针对供应链优化问题,给出了一种基于计算机试验设计中的元模型一Kriging模型的供应链优化方法,并通过一个三级供应链问题对所提方法进行了实证研究.研究结果表明了所提方法的有效性和可用性,为供应链优化提供了一种新的研究思路.     

多层级乳品供应链网络均衡问题研究

以乳品供应链网络为研究对象,构建包含原奶供应商、乳品加工企业、乳品分销商、终端消费市场四层决策主体的乳品供应链网络均衡模型。利用均衡理论和变分不等式理论,描述每个决策者的独立行为以及决策者之间相互影响的竞争行为,采用修正投影法求出均衡解,并给出经济解释,通过数值算例验证模型的合理性和正确性。这一均衡模型有助于协调供应链中各成员之间的利益关系,提升乳品供应链整体运作效率,提高乳品行业的竞争力。     

由零售商负责回收的多期闭环供应链网络均衡

本文研究了零售商回收模式下多期闭环供应链网络均衡问题。制造商通过零售渠道将产品销售给消费者,以满足消费市场需求,同时消费产生的废旧品由零售商回收返回制造商处进行再制造,通过产品库存和回收废旧品连接相邻规划期。运用变分不等式理论和互补理论,分别刻画了制造市场、零售市场和消费市场的均衡,接着构建了多期闭环供应链网络均衡模型。利用变分不等式的投影收缩算法,对模型进行求解。算例着重分析了废旧品利用率对网络均衡状态和供应链成员利润的影响。结果表明:当制造商的废旧品利用率逐渐增加时,回收量逐渐增加,制造商的利润先减后增,零售商利润一直增加,而供应链总利润一直增加,供应链网络中的最优决策变量主要受到回收量约束的影响。     

Supply chain dynamic configuration as a result of new product development

This study considers supply chain network configuration in an innovative environment while the new product development (NPD) will affect the supply chain configuration (SCC). The time of new product introduction has a significant effect on the market performance while it has an effect on the supply chain configuration. Supplier integration into the new product introduction is the key parameter for successfully new product introduction, which may contribute to supply chain reconfiguration. Consequently By considering the new product development concept, we may face with dynamic supply chain configuration during a planning horizontal time. In this study, a new model is presented to consider the dynamic configuration of a supply chain by developing new products. In the proposed model, the dynamic configuration of a supply chain and the new product launching time is optimized simultaneously. The proposed model considers production, sales and transportation planning for the entire supply chain in order to achieve an integrative and efficient supply as well. Then some numerical analyses have been done to show the applicability of the proposed model. The results show that the new product development has a significant effect on the configuration of supply chain.