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SUPPLY CHAIN NETWORK DESIGN

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FACTORS INFLUENCING DISTRIBUTION NETWORK DESIGN

Distribution network performance evaluated along two dimensions

1. Value provided to the customer

2. Cost of meeting customer needs

Evaluate the impact on customer service and cost for different distribution

network options

Profitability of the delivery network determined by revenue from met

customer needs and network costs

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FACTORS INFLUENCING DISTRIBUTION NETWORK DESIGN

Elements of customer service Supply chain costs affected by


influenced by network structure: network structure:
Response time Inventories
Product variety
Transportation
Product availability
Facilities and handling
Customer experience
Information
Time to market

Order visibility

Returnability

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DESIRED RESPONSE TIME & NUMBER OF FACILITIES

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INVENTORY COSTS AND NUMBER OF FACILITIES

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TRANSPORTATION COSTS AND NUMBER OF FACILITIES

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FACILITY COSTS AND NUMBER OF FACILITIES

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LOGISTICS COST, RESPONSE TIME & NUMBER OF FACILITIES

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DESIGN OPTIONS FOR A DISTRIBUTION NETWORK

Distribution network choices from the manufacturer to the end consumer

Two key decisions

1. Will product be delivered to the customer location or picked up from a

prearranged site?

2. Will product flow through an intermediary (or intermediate location)?

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DESIGN OPTIONS FOR A DISTRIBUTION NETWORK

One of six designs may be used

1. Manufacturer storage with direct shipping

2. Manufacturer storage with direct shipping and in-transit merge

3. Distributor storage with carrier delivery

4. Distributor storage with last-mile delivery

5. Manufacturer/distributor storage with customer pickup

6. Retail storage with customer pickup

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MANUFACTURER STORAGE WITH DIRECT SHIPPING

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MANUFACTURER STORAGE WITH DIRECT SHIPPING

Cost Factor Performance

Inventory Lower costs because of aggregation. Benefits of aggregation are


highest for low-demand, high-value items. Benefits are large if
product customization can be postponed at the manufacturer.

Transportation Higher transportation costs because of increased distance and


disaggregate shipping.

Facilities and handling Lower facility costs because of aggregation. Some saving on
handling costs if manufacturer can manage small shipments or
ship from production line.

Information Significant investment in information infrastructure to integrate


manufacturer and retailer.

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MANUFACTURER STORAGE WITH DIRECT SHIPPING
Service Factor Performance
Response time Long response time of one to two weeks because of increased distance and
two stages for order processing. Response time may vary by product, thus
complicating receiving.
Product variety Easy to provide a high level of variety.
Product availability Easy to provide a high level of product availability because of aggregation
at manufacturer.
Customer experience Good in terms of home delivery but can suffer if order from several
manufacturers is sent as partial shipments.
Time to market Fast, with the product available as soon as the first unit is produced.
Order visibility More difficult but also more important from a customer service
perspective.
Returnability Expensive and difficult to implement.

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IN-TRANSIT MERGE NETWORK

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IN-TRANSIT MERGE NETWORK

Cost Factor Performance

Inventory Similar to drop-shipping.

Transportation Somewhat lower transportation costs than drop-shipping.

Facilities and handling Handling costs higher than drop-shipping at carrier; receiving
costs lower at customer.

Information Investment is somewhat higher than for drop-shipping.

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IN-TRANSIT MERGE NETWORK

Service Factor Performance

Response time Similar to drop-shipping; may be marginally higher.

Product variety Similar to drop-shipping.

Product availability Similar to drop-shipping.

Customer experience Better than drop-shipping because only a single delivery is


received.

Time to market Similar to drop-shipping.

Order visibility Similar to drop-shipping.

Returnability Similar to drop-shipping.

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DISTRIBUTOR STORAGE WITH CARRIER DELIVERY

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DISTRIBUTOR STORAGE WITH CARRIER DELIVERY

Cost Factor Performance

Inventory Higher than manufacturer storage. Difference is not large


for faster moving items but can be large for very slow-
moving items.

Transportation Lower than manufacturer storage. Reduction is highest for


faster moving items.

Facilities and handling Somewhat higher than manufacturer storage. The


difference can be large for very slow-moving items.

Information Simpler infrastructure compared to manufacturer storage.

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DISTRIBUTOR STORAGE WITH CARRIER DELIVERY

Service Factor Performance

Response time Faster than manufacturer storage.

Product variety Lower than manufacturer storage.

Product availability Higher cost to provide the same level of availability as manufacturer
storage.

Customer experience Better than manufacturer storage with drop-shipping.

Time to market Higher than manufacturer storage.

Order visibility Easier than manufacturer storage.

Returnability Easier than manufacturer storage.

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DISTRIBUTOR STORAGE WITH LAST MILE DELIVERY

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DISTRIBUTOR STORAGE WITH LAST MILE DELIVERY

Cost Factor Performance

Inventory Higher than distributor storage with package carrier delivery.

Transportation Very high cost given minimal scale economies. Higher than any
other distribution option.

Facilities and handling Facility costs higher than manufacturer storage or distributor
storage with package carrier delivery, but lower than a chain of
retail stores.

Information Similar to distributor storage with package carrier delivery.

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DISTRIBUTOR STORAGE WITH LAST MILE DELIVERY
Service Factor Performance

Response time Very quick. Same day to next-day delivery.

Product variety Somewhat less than distributor storage with package carrier delivery but
larger than retail stores.

Product availability More expensive to provide availability than any other option except
retail stores.

Customer experience Very good, particularly for bulky items.

Time to market Slightly higher than distributor storage with package carrier delivery.

Order visibility Less of an issue and easier to implement than manufacturer storage or
distributor storage with package carrier delivery.

Returnability Easier to implement than other previous options. Harder and more
expensive than a retail network. 23
MANUFACTURER OR DISTRIBUTOR STORAGE WITH CUSTOMER PICKUP

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MANUFACTURER OR DISTRIBUTOR STORAGE WITH CUSTOMER PICKUP

Cost Factor Performance

Inventory Can match any other option, depending on the location of


inventory.

Transportation Lower than the use of package carriers, especially if using


an existing delivery network.

Facilities and handling Facility costs can be high if new facilities have to be built.
Costs are lower if existing facilities are used. The increase in
handling cost at the pickup site can be significant.

Information Significant investment in infrastructure required.

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MANUFACTURER OR DISTRIBUTOR STORAGE WITH CUSTOMER PICKUP

Service Factor Performance

Response time Similar to package carrier delivery with manufacturer or distributor storage.
Same-day delivery possible for items stored locally at pickup site.

Product variety Similar to other manufacturer or distributor storage options.

Product availability Similar to other manufacturer or distributor storage options.

Customer experience Lower than other options because of the lack of home delivery. Experience is
sensitive to capability of pickup location.

Time to market Similar to manufacturer storage options.

Order visibility Difficult but essential.

Returnability Somewhat easier, given that pickup location can handle returns.

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RETAIL STORAGE WITH CUSTOMER PICKUP

Cost Factor Performance

Inventory Higher than all other options.

Transportation Lower than all other options.

Facilities and Higher than other options. The increase in handling


handling cost at the pickup site can be significant for online and
phone orders.

Information Some investment in infrastructure required for online


and phone orders.

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MANUFACTURER OR DISTRIBUTOR STORAGE WITH CUSTOMER PICKUP
Service Factor Performance
Response time Same-day (immediate) pickup possible for items stored locally at
pickup site.
Product variety Lower than all other options.
Product availability More expensive to provide than all other options.
Customer experience Related to whether shopping is viewed as a positive or negative
experience by customer.
Time to market Highest among distribution options.
Order visibility Trivial for in-store orders. Difficult, but essential, for online and
phone orders.
Returnability Easier than other options because retail store can provide a
substitute.

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COMPARATIVE PERFORMANCE OF DELIVERY NETWORK DESIGNS
DELIVERY NETWORKS FOR DIFFERENT PRODUCT/ CUSTOMER CHARACTERISTICS

4-30
THE ROLE OF NETWORK DESIGN

Facility role Factors Influencing Network Design


What role, what processes? Strategic factors

Facility location Technological factors


Where should facilities be located? Macroeconomic factors
Tariffs and tax incentives
Capacity allocation
Exchange-rate and demand risk
How much capacity at each facility?
Freight and fuel costs
Market and supply allocation Political
What markets? Which supply sources?
Infrastructure factors
Competitive factors
Revisit design decisions after market Positive externalities between firms
changes, mergers, or factor cost changes! Locating to split the market

Customer response time and local presence


Logistics and facility costs

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FRAMEWORK FOR NETWORK DESIGN DECISIONS

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MODELS FOR FACILITY LOCATION & CAPACITY ALLOCATION INFORMATION
REQUIRED
o Location of supply sources and markets

o Location of potential facility sites

o Demand forecast by market

o Facility, labor, and material costs by site

o Transportation costs between each pair of sites

o Inventory costs by site and as a function of quantity

o Sale price of product in different regions

o Taxes and tariffs

o Desired response time and other service factors

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NETWORK OPTIMIZATION MODELS

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CAPACITATED PLANT LOCATION MODEL
n = number of potential plant locations/capacity
m = number of markets or demand points yi = 1 if plant i is open, 0 otherwise
D j = annual demand from market j xij = quantity shipped from plant
i to market j
K i = potential capacity of plant i
f i = annualized fixed cost of keeping plant i open
cij = cost of producing and shipping one unit from plant i to market j (cost
includes production, inventory, transportation, and tariffs)
n n m
Min f i yi + c x ij ij
i=1 i=1 j=1
subject to
n

x ij
= D j for j = 1,...,m
i=1
m

x ij
= K i yi for i = 1,...,n
j=1

yi {0,1} for i = 1,...,n, x ij 0 35


CAPACITATED PLANT LOCATION MODEL

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CAPACITATED PLANT LOCATION MODEL

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CAPACITATED PLANT LOCATION MODEL

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CAPACITATED PLANT LOCATION MODEL

Constraints

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CAPACITATED PLANT LOCATION MODEL

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CAPACITATED PLANT LOCATION MODEL

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GRAVITY LOCATION MODEL

xn, yn: coordinate location of either a market or supply source


n
Fn: cost of shipping one unit for one mile between the
facility and either market or supply source n
Dn: quantity to be shipped between facility and market or
supply source n
(x, y) is the location selected for the facility, the distance dn between
the facility at location (x, y) and the supply source or market n is
given by

(x x ) + ( y y )
2 2
dn = n n

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GRAVITY LOCATION MODEL

Transportation Quantity in Coordinates


Sources/Markets Cost $/Ton Mile (Fn) Tons (Dn) xn yn
Supply sources
Buffalo 0.90 500 700 1,200
Memphis 0.95 300 250 600
St. Louis 0.85 700 225 825
Markets
Atlanta 1.50 225 600 500
Boston 1.50 150 1,050 1,200
Jacksonville 1.50 250 800 300
Philadelphia 1.50 175 925 975
New York 1.50 300 1,000 1,080

k
Total transportation cost TC = d D Fn n n
n=1
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GRAVITY LOCATION MODEL

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GRAVITY LOCATION MODEL

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GRAVITY LOCATION MODEL

1. For each supply source or market n, evaluate dn


2. Obtain a new location (x, y) for the facility, where
k k
Dn Fn xn Dn Fn yn
d d
x = n=1
k
n
and y = n=1
k
n

Dn Fn Dn Fn
d d
n=1 n n=1 n

3. If the new location (x , y ) is almost the same as


(x, y) stop. Otherwise, set (x, y) = (x , y ) and go
to step 1
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NETWORK OPTIMIZATION MODEL

Demand City
Monthly Monthly
Production and Transportation
Capacity Fixed Cost
Cost per Thousand Units (Thousand $)
(Thousand (Thousand
Supply City Atlanta Boston Chicago Denver Omaha Portland Units) K $) f
Baltimore 1,675 400 985 1,630 1,160 2,800 18 7,650
Cheyenne 1,460 1,940 970 100 495 1,200 24 3,500
Salt Lake 1,925 2,400 1,450 500 950 800 27 5,000
City
Memphis 380 1,355 543 1,045 665 2,321 22 4,100
Wichita 922 1,646 700 508 311 1,797 31 2,200
Monthly 10 8 14 6 7 11
demand
(thousand
units) Dj

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NETWORK OPTIMIZATION MODEL

Allocating demand to production facilities

n = number of factory locations


m = number of markets or demand points xij = quantity shipped from
D j = annual demand from market j factory i to market j

K i = capacity of factory i
cij = cost of producing and shipping one unit from factory i to
market j

n m subject to
Min cij xij
n
i=1 j=1 x = D j for j = 1,..., m
ij
i=1
m

x ij Ki for i = 1,..., n
j=1

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NETWORK OPTIMIZATION MODEL

Optimal Demand Allocation

Atlanta Boston Chicago Denver Omaha Portland

TelecomOne Baltimore 0 8 2

Memphis 10 0 12

Wichita 0 0 0

HighOptic Salt Lake 0 0 11

Cheyenne 6 7 0

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NETWORK OPTIMIZATION MODEL CAPACITATED PLANT LOCATION
Merge the companies
Solve using location-specific costs

yi = 1 if factory i is open, 0 otherwise


xij = quantity shipped from factory i to market j

n n m
Min f i yi + c x ij ij
i=1 i=1 j=1

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NETWORK OPTIMIZATION MODEL CAPACITATED PLANT LOCATION

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NETWORK OPTIMIZATION MODEL CAPACITATED PLANT LOCATION

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NETWORK OPTIMIZATION MODEL CAPACITATED PLANT LOCATION

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NETWORK OPTIMIZATION MODEL CAPACITATED PLANT LOCATION

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NETWORK OPTIMIZATION MODEL CAPACITATED PLANT LOCATION

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CAPACITATED MODEL WITH SINGLE SOURCING

Market supplied by only one factory


Modify decision variables

yi = 1 if factory i is open, 0 otherwise


xij = 1 if market j is supplied by factory i, 0 otherwise
n n m
Min f i yi + D j cij xij
i=1 i=1 j=1
subject to

x ij = 1 for j = 1,..., m
i=1
m

D x j ij K i yi for i = 1,..., n
j=1

xij , yi {0,1}

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CAPACITATED MODEL WITH SINGLE SOURCING

Optimal network configuration with single sourcing

Open/
Closed Atlanta Boston Chicago Denver Omaha Portland
Baltimore Closed 0 0 0 0 0 0
Cheyenne Closed 0 0 0 0 0 0
Salt Lake Open 0 0 0 6 0 11
Memphis Open 10 8 0 0 0 0
Wichita Open 0 0 14 0 7 0

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LOCATING PLANTS AND WAREHOUSES SIMULTANEOUSLY

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LOCATING PLANTS AND WAREHOUSES SIMULTANEOUSLY

Model inputs

m = number of markets or demand points


n = number of potential factory locations
l = number of suppliers
t = number of potential warehouse locations
Dj = annual demand from customer j
Ki = potential capacity of factory at site i
Sh = supply capacity at supplier h
We = potential warehouse capacity at site e
Fi = fixed cost of locating a plant at site i
fe = fixed cost of locating a warehouse at site e
chi = cost of shipping one unit from supply source h to factory i
cie = cost of producing and shipping one unit from factory i to
warehouse e
cej = cost of shipping one unit from warehouse e to customer j

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LOCATING PLANTS AND WAREHOUSES SIMULTANEOUSLY

Goal is to identify plant and warehouse locations and quantities


shipped that minimize the total fixed and variable costs

yi = 1 if factory is located at site i, 0 otherwise


ye = 1 if warehouse is located at site e, 0 otherwise
xej = quantity shipped from warehouse e to market j
xie = quantity shipped from factory at site i to warehouse e
xhi = quantity shipped from supplier h to factory at site i

n t l n n t t m
Min Fi yi + fe ye + chi xhi + cie xie + cej xej
i=1 e=1 h=1 i=1 i=1 e=1 e=1 j=1

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LOCATING PLANTS AND WAREHOUSES SIMULTANEOUSLY

subject to

n m

x hi
Sh for h = 1,...,l x ej
We ye for e = 1,...,t
i=1 j=1
l t t

x hi
xie 0 for i = 1,...,n x ej
= D j for j = 1,...,m
h=1 e=1 e=1
t

x ie
Ki yi for i = 1,...,n yi , ye {0,1},xej ,xie ,xhi 0
e=1
n m

x xie ej
0 for e = 1,...,t
i=1 j=1
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ACCOUNTING FOR TAXES, TARIFFS, AND CUSTOMER REQUIREMENTS
A supply chain network should maximize profits after tariffs and
taxes while meeting customer service requirements
Modified objective and constraint

m n n n m
Max rj xij Fi yi cij xij
j=1 i=1 i=1 i=1 j=1

x ij
D j for j = 1,...,m
i=1

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INVENTORY MANAGEMENT

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ROLE OF CYCLE INVENTORY IN A SUPPLY CHAIN

Lot or batch size is the quantity that a Cycle inventory =


lot size Q
=
stage of a supply chain either 2 2
produces or purchases at a time
Cycle inventory is the average average inventory
inventory in a supply chain due to Average flow time =
average flow rate
either production or purchases in lot
sizes that are larger than those
demanded by the customer Average flow time cycle inventory Q
= =
Q: Quantity in a lot or batch size resulting from demand 2D
cycle inventory
D: Demand per unit time

What is the flow time for lot sizes of 1,000 and daily demand of 100?

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ROLE OF CYCLE INVENTORY IN A SUPPLY CHAIN
Primary role of cycle inventory is to allow
different stages to purchase product in lot
Lower cycle inventory has sizes that minimize the sum of material,
Shorter average flow time ordering, and holding costs
Lower working capital requirements
Ideally, cycle inventory decisions should
Lower inventory holding costs
consider costs across the entire supply
Cycle inventory is held to chain
Take advantage of economies of scale
Reduce costs in the supply chain In practice, each stage generally makes its
own supply chain decisions
Increases total cycle inventory and total
costs in the supply chain

Cycle inventory exists in a supply chain because different stages


exploit economies of scale to lower total cost. The costs considered
include material cost, fixed ordering cost, and holding cost.
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LOT SIZING FOR A SINGLE PRODUCT THE EOQ MODEL

Economic Order Quantity

2DS
Optimal lot size, Q* =
hC
Optimal ordering frequency

D DhC
n* = =
Q* 2S
Annual demand, D = 1,000 x 12 = 12,000 units
Order cost per lot, S = $4,000 Determine (a) EOQ (b) Cycle Inventory
(c) No. of order per year (d) Total cost
Unit cost per computer, C = $500
(e) Average flow time
Holding cost per year as a fraction of unit cost, h = 0.2
What happens if the lot size is
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reduced to 200?
PRODUCTION LOT SIZING THE EPQ MODEL

The entire lot does not arrive at the same time


Production occurs at a specified rate P
Inventory builds up at a rate of P D

2DS
Q =P

(1 D / P)hC
Annual setup cost Annual holding cost
D QP
P S (1 D / P) hC
Q 2

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LOT SIZING WITH MULTIPLE PRODUCTS OR CUSTOMERS

1. Each product manager orders his or her model independently

2. The product managers jointly order every product in each lot

3. Product managers order jointly but not every order contains


every product; that is, each lot contains a selected subset of the
products

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MULTIPLE PRODUCTS ORDERED & DELIVERED INDEPENDENTLY

Demand
DL = 12,000/yr, DM = 1,200/yr, DH = 120/yr
Common order cost
S = $4,000
Product-specific order cost What is the total cost for the system?
sL = $1,000, sM = $1,000, sH = $1,000
Holding cost
h = 0.2
Unit cost
CL = $500, CM = $500, CH = $500

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MULTIPLE PRODUCTS ORDERED & DELIVERED INDEPENDENTLY
Litepro Medpro Heavypro
Demand per year 12,000 1,200 120
Fixed cost/order $5,000 $5,000 $5,000
Optimal order size 1,095 346 110
Cycle inventory 548 173 55
Annual holding cost $54,772 $17,321 $5,477
Order frequency 11.0/year 3.5/year 1.1/year
Annual ordering cost $54,772 $17,321 $5,477
Average flow time 2.4 weeks 7.5 weeks 23.7 weeks
Annual cost $109,544 $34,642 $10,954

Total annual cost = $155,140


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LOTS ORDERED AND DELIVERED JOINTLY

S* = S + sL + sM + sH Annual order cost = S * n

DL hC L DM hCM DH hC H
Annual holding cost = + +
2n 2n 2n

DL hC L DM hCM DH hC H
Total annual cost = + + +S*n
2n 2n 2n


k
DL hC L + DM hCM + DH hC H Di hCi
n* = n* = i=1

2S * 2S *
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PRODUCTS ORDERED AND DELIVERED JOINTLY

S* = S + sA + sB + sC = $7,000 per order

12,000 100 +1,200 100 +120 100


n* = = 9.75
2 7,000

Annual order cost = 9.75 x 7,000 = $68,250

Annual ordering
and holding cost = $61,512 + $6,151 + $615 + $68,250
= $136,528

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PRODUCTS ORDERED AND DELIVERED JOINTLY

Litepro Medpro Heavypro

Demand per year (D) 12,000 1,200 120

Order frequency (n) 9.75/year 9.75/year 9.75/year

Optimal order size (D/n) 1,230 123 12.3

Cycle inventory 615 61.5 6.15

Annual holding cost $61,512 $6,151 $615

Average flow time 2.67 weeks 2.67 weeks 2.67 weeks

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AGGREGATION WITH CAPACITY CONSTRAINT

Demand per product, Di = 10,000


Holding cost, h = 0.2
Unit cost per product, Ci = $50
Common order cost, S = $500
Supplier-specific order cost, si = $100

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AGGREGATION WITH CAPACITY CONSTRAINT
Total required capacity per truck = 4 x 671 =
2,684 units
S* = S + s1 + s2 + s3 + s4 = $900 per order
Truck capacity = 2,500 units

4
D1hC1 4 10,000 0.2 50
n* = i=1
= = 14.91 Order quantity from each supplier = 2,500/4 =
2S * 2 900
625
900
Annual order cost = 14.91 = $3,355
4 Order frequency increased to 10,000/625 = 16
Annual holding cost hCi Q 671
per supplier = = 0.2 50 = $3,355 Annual order cost per supplier increases to
2 2
$3,600

Annual holding cost per supplier decreases to


$3,125

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LOTS ORDERED AND DELIVERED JOINTLY FOR A SELECTED SUBSET
Step 1: Identify the most frequently ordered hCi Di
product assuming each product is ni =
ordered independently 2(S + si )

hCi Di
Step 2: For all products i i*, evaluate the ordering frequency ni =
2si
Step 3: For all i i*, evaluate the frequency of product i relative to the most frequently ordered
product i* to be mi
mi = n ni

l
hCi mi D
Step 4: Recalculate the ordering frequency of the most n =
i=1

frequently ordered product i* to be n (2 S + )


i=1 si / mi
l

Step 5: Evaluate an order frequency of ni = n/mi and the total l l D


cost of such an ordering policy TC = nS + ni si + i hC1
i=1 i-1 2ni

Tailored Aggregation: Higher-demand products ordered more


frequently and lower-demand products ordered less frequently
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LOTS ORDERED AND DELIVERED JOINTLY FOR A SELECTED SUBSET
Applying Step 1

hC L DL hCM DM hC H DH n = 11.0
nL = = 11.0 nM = = 3.5 nL = = 1.1
2(S + sL ) 2(S + sM ) 2(S + sH )

Applying Step 2 hCM DM hC H DH


nM = = 7.7 and nH = = 2.4
2sM 2sH
Applying Step 3
n 11.0 n 11.0
mM = = = 2 and mH = = = 5
nM 7.7 nH 2.4
Applying Step 4
n = 11.47
Applying Step 5 nL = 11.47 / yr nM = 11.47 / 2 = 5.74 / yr nH = 11.47 / 5 = 2.29 / yr

Annual Order Cost: nS + nL sL + nM sM + nH sH = $65,383.5 77


LOTS ORDERED AND DELIVERED JOINTLY FOR A SELECTED SUBSET
Litepro Medpro Heavypro

Demand per year (D) 12,000 1,200 120

Order frequency (n) 11.47/year 5.74/year 2.29/year

Optimal order size (D/n) 1,046 209 52

Cycle inventory 523 104.5 26

Annual holding cost $52,307 $10,461 $2,615

Average flow time 2.27 weeks 4.53 weeks 11.35 weeks


Annual ordering and holding cost = $130,767

A key to reducing cycle inventory is the reduction of lot size. A key to reducing lot size
without increasing costs is reducing the fixed cost associated with each lot. This may be
achieved by reducing the fixed cost itself or by aggregating lots across multiple products,
customers, or suppliers. When aggregating across multiple products, customers, or
suppliers, simple aggregation is effective when product-specific order costs are small,
and tailored aggregation is best if product-specific order costs are large. 78

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