A single-product network design model with lead time and safety stock considerations

Most existing network design and facility location models have focused on the trade-off between the fixed costs of locating facilities and variable transportation costs between facilities and customers. However, operational performance measures such as service levels and lead times are what motivates customers to bring business to a company and should be considered in the design of a distribution network. While some previous work has considered lead times and safety stocks separately, they are closely related in practice, since safety stocks are often set relative to the distribution of demand over the lead time. In this paper we consider a two-stage supply chain with a production facility that replenishes a single product at retailers. The objective is to locate Distribution Centers (DCs) in the network such that the sum of the location and inventory (pipeline and safety stock) costs is minimized. The replenishment lead time at the DCs depends on the volume of flow through the DC. We require the DCs to carry enough safety stock to maintain the prescribed service levels at the retailers they serve. The explicit modeling of the relationship between the flows in the network, lead times and safety stocks allows us to capture the trade-off between them. We develop a Lagrangian heuristic to obtain near-optimal solutions with reasonable computational requirements for large problem instances.     

Developing a resilient supply chain through supplier flexibility and reliability assessment

In this study, we examine the optimal allocation of demand across a set of suppliers in a supply chain that is exposed to supply risk and environmental risk. A two-stage mixed-integer programming model is used to develop a flexible sourcing strategy under disruptions. Our model integrates supplier selection and demand allocation with transportation channel selection and provides contingency plans to mitigate the negative impacts of disruptions and minimise total network costs. Finally, a numerical example is presented to illustrate the model and provide insights. The findings suggest that developing contingency plans using flexibility in suppliers’ production capacity is an effective strategy for firms to mitigate the severity of disruptions. We also show that flexibility and reliability of the suppliers and regions play a significant role in determining contingency plans for during disruption. Findings generally show that highly flexible suppliers receive less allocation, and their flexible capacity is reserved for disruptions. For firms that do not incorporate risk management into supplier selection and allocation, the recommendation is to source from fewer, more reliable suppliers with less risk of disruption. Our findings also emphasise that the type of disruption has important implications for supplier selection and demand allocation. This study highlights the supply chain risk management strategy of regionalising as a means for minimising the impact of environmental disruptions.     

Incorporating supplier selection and order allocation into the vehicle routing and multi-cross-dock scheduling problem

In the vehicle routing problem with cross-docking (VRPCD), it is assumed that the selected suppliers and the quantity of the products purchased from each supplier are known. This paper presents an MILP model which incorporates supplier selection and order allocation into the VRPCD in a multi-cross-dock system minimising the total costs, including purchasing, transportation, cross-docking, inventory and early/tardy delivery penalty costs. The sensitivity of the model on the key parameters of the objective function is analysed and the supply decisions are evaluated when the coefficients of the distribution cost are changed. A two-stage solution algorithm (TSSA) is proposed and the results of the TSSA for small-sized instances are compared with the exact solutions. Finally, a large-sized real case of an urban freight transport is solved using the TSSA.     

Newsvendor problem with multiple unreliable suppliers

This paper focuses on supplier-related decisions in a newsvendor setting. We build upon the current literature by analysing the newsvendor problem with multiple unreliable and non-identical suppliers. We also incorporate both fixed ordering costs and capacity limits for supplier selection. We develop an exact algorithm to solve the problem optimally and a heuristic algorithm to solve the problem efficiently. Through structural properties of the optimal solution and a numerical study, we provide useful managerial implications regarding optimal sourcing strategies in complex supply chains. Previous literature concludes that with multiple unreliable (independent) suppliers, cost is the order qualifier and reliability is the order winner. We found that when fixed ordering costs and supply capacities exist, this insight no longer holds. We also examine the sensitivity of the sourcing decisions to supplier capacity levels, demand uncertainty, salvage value and shortage cost. Our results show that high levels of demand uncertainty lead firms to turn to a single-sourcing strategy whereas high salvage values and high shortage cost suggest multi-sourcing strategy.     

Supplier selection under risk of delivery failure: a decision-support model considering managers’ risk sensitivity

This paper studies the problem of supplier selection and order allocation in a retail supply chain (comprising suppliers, a central purchasing unit and outlets) under disruption risk. The final demand is deterministic. Suppliers are located in different geographic areas, and supplies are subject to a positive probability of disruption. Different capacity and failure probabilities for each supplier are considered. Our analysis focuses on the insurance versus profitability trade-off faced by a supply manager who buys from suppliers for the outlets. Instead of determining optimal decisions given an objective function and the risk sensitivity of the decision-maker, we use a mixed integer linear programming approach to provide decision-making support that shows a supply manager the ‘elasticity of (expected) losses versus (expected) profits’. Under this model, and depending on the profit-and-loss targets, a supply manager of known risk sensitivity (i.e. risk aversion and loss aversion) can make better decisions when choosing suppliers. Moreover, taking into account, the impact of the share of fixed costs that must be covered by the operation, we consider the net values of expected profit and loss. We discuss the potential influence of the level of the firm’s fixed costs on the supply strategy. In particular, we show how the minimum value of the gross margin needed for the strategy’s profitability affects that strategy. A numerical application is conducted to illustrate the contribution of our decision-making support mechanism, and several managerial insights are obtained.     

Warehouse location and two-echelon inventory management with concave operating cost

In this paper, we study a location–inventory network design problem which jointly optimises the warehouse location, the warehouse–retailer assignments, the warehouse–retailer echelon inventory replenishment and the safety stock-level decisions over an infinite planning horizon. The consideration of the facility operating cost, the safety stock cost and the two-echelon inventory cost results in an MIP model with several nonlinear terms. Due to the complex trade-offs among the various costs and multiple nonlinear terms in the model, traditional solution approaches no longer work for this problem. We outline a polymatroid cutting-plane approach based on the submodular property of the cost terms to address this problem. Computational results demonstrate that the cutting-plane method based on polymatroid inequalities can efficiently solve randomly generated instances with moderate sizes.     

Maintenance supplier selection considering life cycle costs and risks: a fuzzy goal programming approach

In this study, we address a new variant of supplier selection problem named maintenance supplier selection problem faced by a manufacturer. The production system consists of different multi-component equipments whose maintenance activities require several components (parts) each of which could be provided by multiple suppliers. A multi-objective mathematical model is developed to decide about the supply base of each part as well as the purchasing quantity of each part from each selected supplier. The model accounts for the total life cycle costs of purchased parts and various risks threatening the candidate suppliers. A fuzzy/soft lexicographic goal programming approach with soft priorities between objectives is proposed to enable the decision-maker to make preferred trade-offs between objectives by which the effects of various risks in each phase of life cycle of procured parts are investigated. The capability and effectiveness of the proposed model is validated through a case study. Some sensitivity analyses are also carried out for investigating the impact of cost, risk and objectives’ priorities on the final preferred compromise solution. Finally, some managerial insights and concluding remarks are provided.     

A four-phase AHP–QFD approach for supplier assessment: a sustainability perspective

Recently, companies have become increasingly aware of the need to evaluate suppliers from a sustainability perspective. Introducing the triple bottom line (economic, social, and environmental performance) into supplier assessment and selection decisions embeds a new set of trade-offs, complicating the decision-making process. Although many tools have been developed to help purchasing managers make more effective decisions, decision support tools, and methodologies which integrate sustainability (triple bottom line) into supplier assessment and selection are still sparse in the literature. Moreover, most approaches have not taken into consideration the impact of business objectives and requirements of company stakeholders on the supplier evaluation criteria. To help advance this area of research and further integrate sustainability into the supplier selection modelling area, we develop an integrated analytical approach, combining Analytical Hierarchy Process (AHP) with Quality Function Deployment (QFD), to enable the ‘voice’ of company stakeholders in the process. Drawing on the sustainable purchasing strategy development process, our AHP–QFD approach comprises four hierarchical phases: linking customer requirements with the company's sustainability strategy, determining the sustainable purchasing competitive priority, developing sustainable supplier assessment criteria, and lastly assessing the suppliers. An illustrative example is provided to demonstrate the application of the proposed approach.     

Impact of risk aversion and backup supplier on sourcing decisions of a firm

This study focuses on a newsvendor problem with multiple suppliers, considering the risk-neutral and risk-averse objectives in a mean-risk optimisation model. The firm first decides order quantities from the primary (unreliable) suppliers and reserve capacity from the secondary (reliable) backup supplier. After the state of its primary suppliers and customer demand is revealed, the firm purchases from the available suppliers and uses the backup supplier subject to the reserved capacity. For the special case of normal distribution and risk-neutral objective, optimality properties were developed. A comprehensive numerical study examines the sensitivity of the sourcing strategies of firms to risk, shortage cost, demand uncertainty, salvage value, and capacity reserve options; various managerial insights are offered based on this.     

产能约束下的多级装配供应链优化配置方法研究

针对具有产能约束的多级装配型供应链优化配置问题,在考虑安全库存与产能约束、净补货时间关系基础上,研究最优供应商选择和交货期设置方法。面向不确定需求,建立对具有最大产能约束的供应链优化配置混合规划数学模型,并提出一种有较高求解精度的改进遗传算法求解。研究结果表明：在价格和时间不具有优势的情况下,供应链应该避免选择剩余产能小的供应商;在需求波动较大的情况下,为节点设定宽松的交货期往往能够降低供应链成本。     

A branch-and-bound algorithm for the concave cost supply problem

Effective supplier selection and allocation of order quantity among multiple suppliers are indispensable to the success of a manufacturing company. While companies have begun to turn into a comprehensive multi-criteria approach, most buyers still consider purchasing cost to be their primary concern in selecting their suppliers. In this paper, we consider the concave cost supply problem where a manufacturer seeks to select the suppliers and simultaneously procure the quantity of material/component required for production at the minimum total cost during a standard production period. We provide and validate an effective and efficient branch-and-bound algorithm that is finite and that finds the global optimal solution of the problem without any restrictions on the cost functions or on the set of input parameters used in the problem. Numerical experiments are conducted to evaluate the performance of the proposed algorithm.     

A hybrid risks-informed approach for the selection of supplier portfolio

In conventional supplier selection approaches, cost consideration is usually emphasised and it renders a vulnerable supply chain with various risks. This article aims to develop a quantitative approach for modelling both supply chain operational risks and disruption risks to support decision-making with regard to order allocation and risk mitigation. We introduce two types of risk evaluation models: value-at-risk (VaR) and conditional value-at-risk (CVaR). Specifically, VaR is used to measure operational risks caused by improper selection and operations of a supplier portfolio to the stochastic demand, which may frequently occur but result in relatively small losses to supply chains; CVaR is used to evaluate disruption risks that are less frequent and tend to cause significant damage. After incorporating risk factors into a probability-based multi-criteria optimisation model, different methods and parameters are compared and tested to determine the factors that may influence the supplier selection process. Computational examples by simulation are presented to illustrate the approach and how decision-makers make trade-offs between costs and hybrid risks.     

Supply chain design to guarantee quoted lead time and inventory replenishment: model and insights

Do lead time constraints only lead to re-think and re-optimise the inventory positioning along the supply chain or can they impact on the design of the supply chain itself? To answer such a question, we integrate the lead time constraints in a multi-echelon supply chain design model and challenge the difficulty of combining in the same model the long-term decisions (facility location, supplier selection) with the midterm decisions (inventory placement and replenishment, delivery lead time). The model guarantees the respect of the quoted lead time associated with each customer order and the replenishment of the different stocks (raw materials, intermediate and final products) in the different stages of the supply chain between any pair of consecutive orders. We use the model to investigate the impact of the quoted lead time and customer’s order frequency on supply chain design decisions and costs. Some of our results indicate that the lead time constraints can lead to bringing the sites of manufacturing and distribution close to the demand zone and to select local suppliers in spite of their higher cost.     

Order allocation in purchasing management: a review of state-of-the-art studies from a supply chain perspective

Supplier selection (SS) and order allocation (OA) are strategic decisions that have a substantial effect on a company’s performance. However, order allocation is often neglected, since it results from supplier selection and is considered supplementary: little attention has been paid to its specific nature and complexity. Consequently, the authors conducted a systematic literature review specifically regarding order allocation methods. The research aimed to evaluate how often and when the issue has been dignified with an individual focus, independently of the supplier selection problem. This study conducted a comprehensive examination of the order allocation models and solutions, criteria for order quantity allocation, features of suppliers, items, planning periods, and demand most commonly considered in the literature. Finally, it aimed to discover whether supply chain configurations and trends have been considered in efforts to find a solution to the problem. The scientific contribution of this study is threefold: (i) to expand the review of scientific literature regarding order allocation models, (ii) to identify research gaps and highlight research opportunities, and (iii) to suggest a research agenda for the development of order allocation models according to the requirements of current trends in supply chain management.     

An integrated inventory optimization model for facility location-allocation problem

This paper presents an integrated inventory distribution optimisation model for multiple products in a multi-echelon supply chain environment. Inventory, transportation and location decisions are considered. The objective is to offer practical guideline to the steel retail supply chain practitioners in choosing the correct distribution centre, finding out inventory level at individual inventory keeping points (retailers and distribution centres) point thereby helping them in reducing overall distribution cost. The framework presented endorses systems approach and suggests near-optimal approach to calculating inventory for an individual distributor and his retailers. Two algorithms are used to solve this problem, a novel hybrid Multi-objective Self-learning particle swarm optimiser and Non-dominated sorting genetic algorithm-II. The model and solution methods are tested on real data-sets obtained from organisations in the steel retail environment. The actual data on inventory holding, ordering and transportation costs of distributors and retailers are used as inputs. The decisions like choosing correct set of Distribution centres, keeping optimal regular and safety stock inventory levels are arrived at by applying practical constraints in the supply chain. Model developed assists in effective and efficient distribution of the products manufactured from the optimal location at minimal cost.     

Optimal design methodologies for configuration of supply chains

This paper describes a methodology developed for designing an optimal configuration for a supply chain. A typical configuration for a supply chain consists of defining components of the system, assigning values to characteristics parameters of each component and setting operation policies for governing the interrelationships among these components. As such, each configuration will be defined by a set of values for quantitative parameters of the system as well as a set of policy and qualitative characteristics. Examples of quantitative variable include inventory levels and frequency of ordering where as location of distribution centres and mode of transportation between suppliers and the original equipment manufacturers (OEM) are the decision variables of policy and qualitative nature. The methodology presented here consists of a supply chain model builder coupled with two optimisation algorithms that automatically build a sequence of configurations that systematically move towards an optimum design. A combination of mixed integer programming and a genetic algorithm is used to determine simultaneously the values of quantitative as well as policy variables. The solution consists of strategic decisions regarding facility locations, stocking locations, supplier selection, production policies, production capacities, and transportation modes.     

Two-phase selection framework that considers production costs of suppliers and quality requirements of buyers

Buyers are faced with selecting the optimal supplier, while suppliers are left to consider production costs. In this study, we developed a two-phase selection framework that allows buyers to evaluate the performance of suppliers while taking production costs into account for value maximisation. This scheme is a win-win solution capable of promoting long-term relationships between buyers and suppliers. Under the assumption of normality, the first phase involves constructing a new Six Sigma quality capability analysis chart (SSQCAC) which takes production costs into account. The objective is to evaluate all potential suppliers using the 100?×?(1–α)% upper confidence limit (UCL) of an integrated Six Sigma quality index (SSQI) Q_PIh when dealing with products with smaller-the-better (STB), larger-the-better (LTB), or nominal-the-best (NTB) quality characteristics. According to interval estimation theory, this method can have a significant impact on the consumption of resources; i.e. the production costs of the supplier can be decreased by reducing the production quality to below that required by the buyer. The proposed method also filters out unsuitable suppliers in order to simplify the decision problem and reduce computational demands and operational risks/costs without compromising the quality of the final product. In the second phase, a detailed analysis is conducted using Euclidean distance measure to select the optimal supplier from among the remaining candidates. We conducted a real-world case study to evaluate the efficacy of the proposed method. We also conducted comparisons with existing methods to demonstrate the advantages of the proposed method and its managerial implications. Suggestions for future study are also provided.     

A dynamic programming approach to integrated assembly planning and supplier assignment with lead time constraints

As manufacturers face fierce competition in the global market, responsiveness has become an important competitiveness factor in addition to quality and cost. One essential responsiveness strategy is to reduce product development and lead times by integrating assembly planning with supplier assignment. This paper addresses the problem of integrated assembly and supply chain design under lead-time constraints by formulating and solving an optimisation problem with minimal total supply chain costs. This new time-constrained joint optimisation problem belongs to an NP-hard resource-constrained scheduling problem. To model this problem effectively, we develop a novel Hyper AND/OR graph and apply it for integrating assembly and supply chain decisions. We also develop a dynamic programming model and associated algorithm in order to solve the integrated optimisation problem with pseudo-polynomial time complexity in practice. Numerical case studies validate that the methods developed can solve the integrated decision-making problem optimally and efficiently. This paper overcomes the limitations of previous studies on concurrent assembly decomposition and supplier selection, which optimises cost without time constraints. The models and results of this research can be applied to a variety of areas including assembly design, maintenance module planning and supply chain restructuring.     

Integrated model for supplier selection and negotiation in a make-to-order environment

The paper deals with the development of an integrated supplier selection and negotiation process for multiple parts/materials procurement. The main objective is to integrate decisions in the internal supply chain of a make-to-order manufacturer. Two main decisions during the negotiation process are considered: (1) the manufacturing planning decision responsible for determining the production schedule and fabrication lot size and (2) the supplier selection decision concerning which suppliers are selected for company business and the order volume allocated to each selected supplier. The model is designed to support the negotiation process by generating a set of effective alternatives in each negotiation period. Its structure is multi-objective and non-linear. The combination of the interactive weighted Tchebycheff method and Benders decomposition method is applied to generate a set of effective alternatives to support the decision-maker in each negotiation period.     

A novel approach for supplier selection based on the Kano model and fuzzy MCDM

This paper proposes a three-phase approach for supplier selection based on the Kano model and fuzzy Multi Criteria Decision-Making. Since the supplier selection problem involves different criteria, quality attributes have been assumed to denote the importance weight of the criteria for supplier selection. Furthermore, to consider the inherent vagueness of human thought, a fuzzy logic has been utilised. Initially, the importance weight of the criteria has been calculated using a fuzzy Kano questionnaire and fuzzy analytic hierarchy process. In the second phase, the Fuzzy TOPSIS technique has been used to screen out in capable suppliers. Finally, in the third phase, the filtered suppliers which are qualified, once again will be evaluated by the same approach for the final ranking. The proposed approach has also been examined in a case study.