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FACTORS INFLUENCING DISTRIBUTION NETWORK DESIGN
Evaluate the impact on customer service and cost for different distribution
network options
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FACTORS INFLUENCING DISTRIBUTION NETWORK DESIGN
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
prearranged site?
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DESIGN OPTIONS FOR A DISTRIBUTION NETWORK
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MANUFACTURER STORAGE WITH DIRECT SHIPPING
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MANUFACTURER STORAGE WITH DIRECT 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.
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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
Facilities and handling Handling costs higher than drop-shipping at carrier; receiving
costs lower at customer.
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IN-TRANSIT MERGE NETWORK
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DISTRIBUTOR STORAGE WITH CARRIER DELIVERY
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DISTRIBUTOR STORAGE WITH CARRIER DELIVERY
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DISTRIBUTOR STORAGE WITH CARRIER DELIVERY
Product availability Higher cost to provide the same level of availability as manufacturer
storage.
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DISTRIBUTOR STORAGE WITH LAST MILE DELIVERY
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DISTRIBUTOR STORAGE WITH LAST MILE 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.
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DISTRIBUTOR STORAGE WITH LAST MILE DELIVERY
Service Factor Performance
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.
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
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.
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MANUFACTURER OR DISTRIBUTOR STORAGE WITH CUSTOMER PICKUP
Response time Similar to package carrier delivery with manufacturer or distributor storage.
Same-day delivery possible for items stored locally at pickup site.
Customer experience Lower than other options because of the lack of home delivery. Experience is
sensitive to capability of pickup location.
Returnability Somewhat easier, given that pickup location can handle returns.
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RETAIL STORAGE WITH CUSTOMER PICKUP
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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
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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
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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
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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
(x x ) + ( y y )
2 2
dn = n n
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GRAVITY LOCATION MODEL
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
Dn Fn Dn Fn
d d
n=1 n n=1 n
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
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
TelecomOne Baltimore 0 8 2
Memphis 10 0 12
Wichita 0 0 0
Cheyenne 6 7 0
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NETWORK OPTIMIZATION MODEL CAPACITATED PLANT LOCATION
Merge the companies
Solve using location-specific costs
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
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
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
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LOCATING PLANTS AND WAREHOUSES SIMULTANEOUSLY
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
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
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
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
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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
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
Annual ordering
and holding cost = $61,512 + $6,151 + $615 + $68,250
= $136,528
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PRODUCTS ORDERED AND DELIVERED JOINTLY
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AGGREGATION WITH CAPACITY CONSTRAINT
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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
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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
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 )
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