Build-to-order supply chain network design under supply and demand uncertainties

Supply chain disruptions are unintended, unwanted situations resulting in a negative supply chain performance. We study the supply chain network design under supply and demand uncertainty with embedded supply chain disruption mitigation strategies, postponement with downward substitution, centralized stocking and supplier sourcing base. We designed an integrated supply-side, manufacturing and demand-side operations network in such that the total expected operating cost is minimized. We modeled it in a deterministic equivalent formulation. An L-shaped decomposition with an additional decomposition step in the master problem is proposed. The computational results showed that parallel sourcing has a cost advantage against single sourcing under supply disruptions. In addition, the build-to-order (BTO) manufacturing mitigation process has its greatest impact with high variations on demands and is integrated with the component downward substitution. Lastly, the manufacturer needs to order differentiated components to cover its requirement for maximal product demand to prevent the loss of sale, even with fewer modules in stock.     

Competition and disruption in a dynamic urban supply chain

Rapid changes and complexities in business environments have stressed the importance of interactions between partners and competitors, leading supply chains to become the most important element of contemporary business environments. There is a concomitant need for foresight in describing supply chain performance in all operating environments, including those involving punctuated disruptions. Furthermore, the urban metropolis is now widely recognized to be an environment which is especially vulnerable to supply chain disruptions and for which integrated supply chain decisions can produce very substantial net benefits. Accordingly, this paper presents a dynamic supply chain network model formulated as a differential variational inequality; the model is fashioned to allow consideration of supply chain disruption threats to producers, freight carriers, and retail enterprises. The DVI is solved using a fixed-point algorithm, and a simple numerical example, introduced to illustrate how the impacts of supply chain disruptions may be quantified, is presented.     

Strategies for customer service level protection under multi-echelon supply chain disruption risk

We model a multi-echelon system where disruptions can occur at any stage and evaluate multiple strategies for protecting customer service if a disruption should occur. The strategies considered take advantage of the network itself and include satisfying demand from an alternate location in the network, procuring material or transportation from an alternate source or route, and holding strategic inventory reserves throughout the network. Unmet demand is modeled using a mix of backordering and lost sales. We conduct numerical analysis and provide recommendations on selecting strategic mitigation methods to diminish the impact of disruptions on customer service. We demonstrate that the greatest service level improvements can be made by providing both proactive inventory placement to cover short disruptions or the start of long disruptions, and reactive back-up methods to help the supply chain recover after long or permanent disruptions.     

A bi-criteria indicator to assess supply chain network performance for critical needs under capacity and demand disruptions

In this paper, we develop a supply chain/logistics network model for critical needs in the case of disruptions. The objective is to minimize the total network costs, which are generalized costs that may include the monetary, risk, time, and social costs. The model assumes that disruptions may have an impact on both the network link capacities as well as on the product demands. Two different cases of disruption scenarios are considered. In the first case, we assume that the impacts of the disruptions are mild and that the demands can be met. In the second case, the demands cannot all be satisfied. For these two cases, we propose two individual performance indicators. We then construct a bi-criteria indicator to assess the supply chain network performance for critical needs. An algorithm is described which is applied to solve a spectrum of numerical examples in order to illustrate the new concepts.     

Measuring supply chain risk: Predicting motor carriers’ ability to withstand disruptive environmental change using conjoint analysis

Supply chain risk measurement is an expanding research stream that considers the ability of networked firms to anticipate and respond to significant environmental risks, including major disruptions and unexpected events. However measuring and quantifying supply chain risk has proved an enormous challenge and this research contributes to this goal by developing a risk assessment scorecard, using conjoint analysis, for motor carrier firms. The resultant motor-carrier scorecard has been scaled from 300 to 900, to resemble the well-known FICO score for assessing consumer creditworthiness. Our scoring model enables motor carriers – and the firms that depend upon them in intermodal supply chains – to assess carriers’ ability to withstand major disruptive events, which are broadly defined as events which might lead to a significant drop in carriers’ income and profitability (e.g., such as that which occurred on September 11, 2001). Carriers with weaker risk scores (<600, on a 300–900 scale) are more likely to experience financial distress (and as a result possibly exit the industry itself); those with scores above 600 are less likely to depart. The model correctly identified 77 percent of motor carriers that ultimately exited the trucking industry following the significant environmental disruption caused by 9/11. Our computational experience indicates that the model accuracy, quantified in terms of Type I and Type II errors, compares favorably to prior results reported in the credit scoring literature.     

A carbon footprint-based closed-loop supply chain model under uncertainty with risk analysis: A case study

The management of products’ end-of-life and the recovery of used products has gained significant importance in recent years. In this paper, we address the carbon footprint-based problem that arises in a closed-loop supply chain where returned products are collected from customers. These returned products can either be disposed of or be remanufactured to be resold as new ones. Given this environment, an optimization model for a closed-loop supply chain (CLSC) in which carbon emission is expressed in terms of environmental constraints, i.e., carbon emission constraints, is developed. These constraints aim to limit the carbon emission per unit of product supplied with different transportation modes. Here, we design a closed-loop network where capacity limits, single-item management and uncertainty on product demands and returns are considered. First, fuzzy mathematical programming is introduced for uncertain modeling. Then, the statistical approach to the possibility to synthesize fuzzy information is utilized. Therefore, using a defined possibilistic mean and variance, we transform the proposed fuzzy mathematical model into a crisp form to facilitate efficient computation and analysis. Finally, the risk caused by violating the estimated resource constraints is analyzed so that decision makers (DMs) can trade off between the expected cost savings and the expected risk. We utilize data from a company located in Iran.     

A heterogeneous reliable location model with risk pooling under supply disruptions

This paper investigates a facility location model that considers the disruptions of facilities and the cost savings from the inventory risk-pooling effect and economies of scale. Facilities may have heterogeneous disruption probabilities. When a facility fails, its customers may be reassigned to other surviving ones to hedge against lost-sales costs. We first develop both an exact and an approximate expression for the nonlinear inventory cost, and then formulate the problem as a nonlinear integer programming model. The objective is to minimize the expected total cost across all possible facility failure scenarios. To solve this problem, we design two methods, an exact approach using special ordered sets of type two (SOS2) and a heuristic based on Lagrangian relaxation. We test the model and algorithms on data sets with up to 150 nodes. Computational results show that the proposed algorithms can solve the problem efficiently in reasonable time. Managerial insights on the optimal facility deployment, customer assignments and inventory control strategies are also drawn.     

A single-period analysis of a two-echelon inventory system with dependent supply uncertainty

Disruptions and random supplies have been important sources of uncertainty that should be considered in the design and control of supply chains. There have been many real world examples in which a single catastrophic event has simultaneously degraded the capabilities of several suppliers leading to considerable erosion of profits and goodwill for a company. However, the literature on analytical models that account for the dependence nature of disruptions and its impact on supply chain performance is sparse.In this paper, we consider an m-manufacturer, 1-retailer, newsvendor inventory system with stochastically dependent manufacturing capacities, caused by random disruptions that may simultaneously inflict damages to the capacities of the manufacturers. We develop the structural/analytical properties of key performance measures and optimal inventory policies for the multi-source and assembly inventory systems. We show that stochastic dependence in disruptions can have opposite effects on system performance in the multi-source and assembly systems. While risk diversification is preferred in the multi-source system, risk concentration is preferred in the assembly system. Our results also suggest that, if the retailer ignores the effect of dependent disruptions, then in the multi-source structure, it would underestimate the cost, overestimate the fill rate, and order more units than the optimum; however, in the assembly structure, the opposite would happen. We perform a comprehensive numerical study to validate our analytical results and generate useful managerial and operational insights for effective risk management of supply chains in the presence of dependent supply uncertainty.     

Green supply chain network design to reduce carbon emissions

We consider a supply chain network design problem that takes CO₂ emissions into account. Emission costs are considered alongside fixed and variable location and production costs. The relationship between CO₂ emissions and vehicle weight is modeled using a concave function leading to a concave minimization problem. As the direct solution of the resulting model is not possible, Lagrangian relaxation is used to decompose the problem into a capacitated facility location problem with single sourcing and a concave knapsack problem that can be solved easily. A Lagrangian heuristic based on the solution of the subproblem is proposed. When evaluated on a number of problems with varying capacity and cost characteristics, the proposed algorithm achieves solutions within 1% of the optimal. The test results indicate that considering emission costs can change the optimal configuration of the supply chain, confirming that emission costs should be considered when designing supply chains in jurisdictions with carbon costs.     

Optimal pricing for build-to-order supply chain design under price-dependent stochastic demand

Build to order (BTO) is a supply chain disruption mitigation strategy. Whereas cost minimization is an operational objective, the goal of the BTO manufacturer is to maximize its profit by using pricing as its competitive decision-making strategy. In this paper, we study a BTO manufacturer who simultaneously determines its product prices and designs its supply chain network to maximize its expected profit under price-dependent stochastic demand. We propose an L-shaped decomposition with complete enumeration to solve for optimality and show that the expanded master problem remains convex programming, although the optimality cuts are quadratic inequalities. The computational results demonstrate that stocking up on differentiated components and allocating modules appropriately to meet realized demand is a resilient policy that sustains variations in demand. Furthermore, the pricing decision balances the expected revenue and expected operating cost with an increase in expected profit. The integration of pricing and operational planning results in a higher expected profit than by individual decisions. We also demonstrate that cost minimization may not provide the same level of profit if the manufacturer overestimates or underestimates its most profitable demand.     

Reliable logistics networks design with facility disruptions

This paper studies a strategic supply chain management problem to design reliable networks that perform as well as possible under normal conditions, while also performing relatively well when disruptions strike. We present a mixed-integer programming model whose objective is to minimize the nominal cost (the cost when no disruptions occur) while reducing the disruption risk using the p-robustness criterion (which bounds the cost in disruption scenarios). We propose a hybrid metaheuristic algorithm that is based on genetic algorithms, local improvement, and the shortest augmenting path method. Numerical tests show that the heuristic greatly outperforms CPLEX in terms of solution speed, while still delivering excellent solution quality. We demonstrate the tradeoff between the nominal cost and system reliability, showing that substantial improvements in reliability are often possible with minimal increases in cost. We also show that our model produces solutions that are less conservative than those generated by common robustness measures.     

Incorporating institutional and spatial factors in the selection of the optimal locations of public electric vehicle charging facilities: A case study of Beijing,China

In this paper, we present a case study on planning the locations of public electric vehicle (EV) charging stations in Beijing, China. Our objectives are to incorporate the local constraints of supply and demand on public EV charging stations into facility location models and to compare the optimal locations from three different location models. On the supply side, we analyse the institutional and spatial constraints in public charging infrastructure construction to select the potential sites. On the demand side, interviews with stakeholders are conducted and the ranking-type Delphi method is used when estimating the EV demand with aggregate data from municipal statistical yearbooks and the national census. With the estimated EV demand, we compare three classic facility location models – the set covering model, the maximal covering location model, and the p-median model – and we aim to provide policy-makers with a comprehensive analysis to better understand the effectiveness of these traditional models for locating EV charging facilities. Our results show that the p-median solutions are more effective than the other two models in the sense that the charging stations are closer to the communities with higher EV demand, and, therefore, the majority of EV users have more convenient access to the charging facilities. From the experiments of comparing only the p-median and the maximal covering location models, our results suggest that (1) the p-median model outperforms the maximal covering location model in terms of satisfying the other’s objective, and (2) when the number of charging stations to be built is large, or when minor change is required, the solutions to both models are more stable as p increases.     

Multi-period planning of closed-loop supply chain with carbon policies under uncertainty

Climate change and greenhouse gases emissions have caused countries to implement various carbon regulatory mechanisms in some industrial sectors around the globe to curb carbon emissions. One effective method to reduce industry environmental footprint is the use of a closed-loop supply chain (CLSC). The decision concerning the design and planning of an optimal network of the CLSC plays a vital role in determining the total carbon footprint across the supply chain and also the total cost. In this context, this research proposes an optimization model for design and planning a multi-period, multi-product CLSC with carbon footprint consideration under two different uncertainties. The demand and returns uncertainties are considered by means of multiple scenarios and uncertainty of carbon emissions due to supply chain related activities are considered by means of bounded box set and solve using robust optimization approach. The model extends further to investigate the impact of different carbon policies such as including strict carbon cap, carbon tax, carbon cap-and-trade, and carbon offset on the supply chain strategic and operational decisions. The model captures trade-offs that exist among supply chain total cost and carbon emissions. Also, the proposed model optimizes both supply chain total cost and carbon emissions across the supply chain activities. The numerical results reveal some insightful observations with respect to CLSC strategic design decisions and carbon emissions under various carbon policies and at the end we highlighted some managerial insights.     

Infrastructure deployment under uncertainties and competition: The biofuel industry case

Technological paradigm shifts often come with a newly emerging industry that seeks a viable infrastructure deployment plan to compete against established competitors. Such phenomenon has been repeatedly seen in the field of transportation systems, such as those related to the booming bioenergy production, among others. We develop a game-theoretic modeling framework using a continuum approximation scheme to address the impacts of competition on the optimal infrastructure deployment. Furthermore, we extend the model to incorporate uncertainties in supply/demand and the risk of facility disruptions. Analytical properties of the optimal infrastructure system are obtained, based on which fast numerical solution algorithms are developed. Several hypothetical problem instances are used to illustrate the effectiveness of the proposed algorithms and to quantify the impacts of various system parameters. A large-scale biofuel industry case study for the U.S. Midwest is conducted to obtain additional managerial insights.     

Product substitution and dual sourcing under random supply failures

Product substitution can mitigate supply chain disruptions. However, it may not be very effective without multiple sourcing. In this paper, we consider a supply chain with two downward substitutable products. The products can be ordered from an unreliable supplier or a reliable but more expensive supplier. It is found that in an optimal sourcing policy the higher-grade product should be preferred over the lower-grade product. A sufficient condition is given for an optimal policy where only the higher-grade product is dual-sourced. The effect of substitution is contrasted with the non-substitution case. Numerical study shows the impact of demand variability and correlation on the effect of product substitution and the corresponding optimal sourcing policy.     

Estimating economic losses of industry clusters due to port disruptions

Seaport operations are highly important for industries which rely heavily on imports and exports. A reliable evaluation of port risks is essential to govern the normal running of seaborne transportation and thus the industrial economies. The occurrence of a breakdown in the trade facilitators, such as ports, will disrupt the smooth flow of supply chains for the industries. The estimation of the economic loss for an industry when a port gets disrupted is a challenging task as the relationship between the port and industry clusters is complex. This study aims to develop a systematic framework for performing economic loss estimation of industry clusters due to port disruptions. The whole risk assessment is split into three stages focusing on the establishment of a network flow model, economic estimations and evaluating risk mitigation strategies. The proposed idea is demonstrated by a case study on Shenzhen port and its related manufacturing industries. A dynamic inventory control strategy used by manufacturers is found to be beneficial for mitigating port disruption risks.     

Location planning for transit-based evacuation under the risk of service disruptions

The effectiveness of transit-based emergency evacuation highly depends on the location of pick-up facilities, resource allocation, and management. These facilities themselves are often subject to service disruptions during or after the emergency. This paper proposes a reliable emergency facility location model that determines both pre-emergency facility location planning and the evacuation operations afterwards, while facilities are subject to the risk of disruptions. We analyze how evacuation resource availability leverages individual evacuees’ response to service disruptions, and show how equilibrium of the evacuee arrival process could be reached at a functioning pick-up facility. Based on this equilibrium, an optimal resource allocation strategy is found to balance the tradeoff between the evacuees’ risks and the evacuation agency’s operation costs. This leads to the development of a compact polynomial-size linear integer programming formulation that minimizes the total expected system cost from both pre-emergency planning (e.g., facility set-up) and the evacuation operations (e.g., fleet management, transportation, and exposure to hazardous surroundings) across an exponential number of possible disruption scenarios. We also show how the model can be flexibly used to plan not only pre-disaster evacuation but also post-disaster rescue actions. Numerical experiments and an empirical case study for three coastal cities in the State of Mississippi (Biloxi, Gulfport, and D’lberville) are conducted to study the performance of the proposed models and to draw managerial insights.     

Planning for the unexpected: The value of reserve capacity for public transport network robustness

Public transport networks (PTN) are subject to recurring service disruptions. Most studies of the robustness of PTN have focused on network topology and considered vulnerability in terms of connectivity reliability. While these studies provide insights on general design principles, there is lack of knowledge concerning the effectiveness of different strategies to reduce the impacts of disruptions. This paper proposes and demonstrates a methodology for evaluating the effectiveness of a strategic increase in capacity on alternative PTN links to mitigate the impact of unexpected network disruptions. The evaluation approach consists of two stages: identifying a set of important links and then for each identified important link, a set of capacity enhancement schemes is evaluated. The proposed method integrates stochastic supply and demand models, dynamic route choice and limited operational capacity. This dynamic agent-based modelling of network performance enables to capture cascading network effects as well as the adaptive redistribution of passenger flows. An application for the rapid PTN of Stockholm, Sweden, demonstrates how the proposed method could be applied to sequentially designed scenarios based on their performance indicators. The method presented in this paper could support policy makers and operators in prioritizing measures to increase network robustness by improving system capacity to absorb unexpected disruptions.     

Decomposition of general facility disruption correlations via augmentation of virtual supporting stations

Infrastructure facilities may be subject to probabilistic disruptions that compromise individual facility functionality as well as overall system performance. Disruptions of distributed facilities often exhibit complex spatial correlations, and thus it is difficult to describe them with succinct mathematical models. This paper proposes a new methodological framework for analyzing and modeling facility disruptions with general correlations. This framework first proposes pairwise transformations that unify three probabilistic representations (i.e., based on conditional, marginal, and scenario probabilities) of generally correlated disruption profile among multiple distributed facilities. Then facilities with any of these disruption profile representations can be augmented into an equivalent network structure consisting of additional supporting stations that experience only independent failures. This decomposition scheme largely reduces the complexity associated with system evaluation and optimization. We prove analytical properties of the transformations and the decomposition scheme, and illustrate the proposed methodological framework using a set of numerical case studies and sensitivity analyses. Managerial insights are also drawn.     

Integrated transit services for minimum cost operation considering heterogeneous demand

Abstract

In large metropolitan areas, public transit is a major mode choice of commuters for their daily travel, which has an important role in relieving congestion on transportation corridors. The purpose of this study is to develop a model which optimizes service patterns (SPs) and frequencies that yield minimum cost transit operation. Considering a general transit route with given stops and origin-destination demand, the proposed model consists of an objective total cost function and a set of constraints to ensure frequency conservation and sufficient capacity subject to operable fleet size. A numerical example is provided to demonstrate the effectiveness of the developed model, in which the demand and facility data of a rail transit route were given. Results show that the proposed model can be applied to optimize integrated SPs and headways that significantly reduce the total cost, while the resulting performance indicators are generated.