Inventory management in a two-echelon closed-loop supply chain with correlated demands and returns

Reverse logistics or closed-loop supply chains where product returns are integrated with traditional forward supply chains have been one of the major topics of research since about the last one and a half decades. In this paper, we address the inventory management issue in closed-loop supply chains, and develop deterministic and stochastic models for a two-echelon system with correlated demands and returns under generalized cost structures. In particular, we address the following questions - Do closed-loop supply chains cost more than traditional forward supply chains? Does a higher rate of return always translate into lower demand variability and hence lower expected costs? What is the relationship between expected costs and correlations between demands and returns? Models developed and numerical examples shown in the paper reveal that although a higher rate of return and a higher correlation between demand and return reduce the variability of net demand, it may not necessarily lead to cost savings; rather the movement of costs will depend on the values of system parameters. We also quantify the cost savings in case the actual demand and return information is available at the time of decision-making. We conclude the paper by providing managerial implications and directions for future research.

[1]  Shad Dowlatshahi,et al.  A cost-benefit analysis for the design and implementation of reverse logistics systems: case studies approach , 2010 .

[2]  Shaligram Pokharel,et al.  Strategic network design for reverse logistics and remanufacturing using new and old product modules , 2009, Comput. Ind. Eng..

[3]  J. Linton,et al.  Sustainable supply chains: An introduction , 2007 .

[4]  Stephan Vachon,et al.  Supply chain management and environmental technologies: the role of integration , 2007 .

[5]  Manoj Kumar Tiwari,et al.  Selection of a reverse logistics project for end-of-life computers: ANP and goal programing approach , 2008 .

[6]  Askiner Gungor,et al.  Issues in environmentally conscious manufacturing and product recovery: a survey , 1999 .

[7]  Arthur F. Veinott,et al.  Analysis of Inventory Systems , 1963 .

[8]  Y. Gao,et al.  Inventory decision-making models for a closed-loop supply chain system , 2010 .

[9]  E. Silver,et al.  Forecasting the returns of reusable containers , 1989 .

[10]  M. Jaber,et al.  The production, remanufacture and waste disposal model with lost sales , 2009 .

[11]  Michael E. Ketzenberg,et al.  Value of Information in Closed Loop Supply Chains , 2006 .

[12]  David F. Pyke,et al.  Periodic review, push inventory policies for remanufacturing , 2002, Eur. J. Oper. Res..

[13]  L. V. Wassenhove,et al.  Sustainable Operations Management , 2005 .

[14]  Luk N. Van Wassenhove,et al.  Closed - Loop Supply Chain Models with Product Remanufacturing , 2004, Manag. Sci..

[15]  K. Inderfurth,et al.  How to set the holding cost rates in average cost inventory models with reverse logistics , 2000 .

[16]  V. Daniel R. Guide,et al.  The Reverse Supply Chain , 2002 .

[17]  Vaidyanathan Jayaraman,et al.  Production planning for closed-loop supply chains with product recovery and reuse: an analytical approach , 2006 .

[18]  Carsten Nagel,et al.  Caught between ecology and economy: end-of-life aspects of environmentally conscious manufacturing , 1999 .

[19]  Hing Kai Chan,et al.  Implementing just-in-time philosophy to reverse logistics systems: a review , 2010 .

[20]  Marc A. Rosen,et al.  The economic order quantity repair and waste disposal model with entropy cost , 2008, Eur. J. Oper. Res..

[21]  Ming-Lang Tseng,et al.  Evaluating firm's sustainable production indicators in uncertainty , 2009, Comput. Ind. Eng..

[22]  Ruozhen Qiu,et al.  Dynamic models of closed-loop supply chain and robust H∞ control strategies , 2009 .

[23]  Erwin van der Laan,et al.  Quantitative models for reverse logistics: A review , 1997 .

[24]  Mohamad Y. Jaber,et al.  An economic production and remanufacturing model with learning effects , 2011 .

[25]  M. El-Sayed,et al.  A stochastic model for forward-reverse logistics network design under risk , 2010, Comput. Ind. Eng..

[26]  Elif Akçali,et al.  Quantitative models for inventory and production planning in closed-loop supply chains , 2011 .

[27]  Surendra M. Gupta,et al.  A multi-echelon inventory system with returns , 1998 .

[28]  David F. Pyke,et al.  Inventory management and production planning and scheduling , 1998 .

[29]  Simme Douwe P. Flapper,et al.  Managing closed-loop supply chains , 2005 .

[30]  Manoj Kumar Tiwari,et al.  Analyzing alternatives in reverse logistics for end-of-life computers: ANP and balanced scorecard approach , 2005, Comput. Ind. Eng..

[31]  Albert Corominas,et al.  Optimal manufacturing-remanufacturing policies in a lean production environment , 2008, Comput. Ind. Eng..

[32]  Joy M. Field,et al.  The use of recycled materials in manufacturing: implications for supply chain management and operations strategy , 2007 .

[33]  W. C. Benton,et al.  Supply-Chain Management for Recoverable Manufacturing Systems , 2000, Interfaces.

[34]  G. Kannan,et al.  Analysis of closed loop supply chain using genetic algorithm and particle swarm optimisation , 2009 .

[35]  Subrata Mitra,et al.  Analysis of a two-echelon inventory system with returns , 2009 .

[36]  L. Wein,et al.  Inventory Management of Remanufacturable Products , 2000 .

[37]  Marc Salomon,et al.  Strategic Issues in Product Recovery Management , 1995 .

[38]  Hao Xiong,et al.  Optimal Model and Genetic Algorithm of Two-Echelon Inventory System with Correlated Demands , 2010, 2010 International Conference on Management and Service Science.

[39]  S. Minner Strategic safety stocks in reverse logistics supply chains , 2001 .

[40]  Mohamad Y. Jaber,et al.  Lot sizing for a recoverable product with inspection and sorting , 2010, Comput. Ind. Eng..

[41]  Sergio Rubio,et al.  Characteristics of the research on reverse logistics (1995–2005) , 2008 .

[42]  V. Daniel R. Guide,et al.  OR FORUM - The Evolution of Closed-Loop Supply Chain Research , 2009, Oper. Res..

[43]  R. Dekker,et al.  Reverse logistics : quantitative models for closed-loop supply chains , 2004 .

[44]  Adel A. Alamri Theory and methodology on the global optimal solution to a General Reverse Logistics Inventory Model for deteriorating items and time-varying rates , 2011, Comput. Ind. Eng..

[45]  D. Guide,et al.  Business Aspects of Closed-Loop Supply Chains , 2003 .

[46]  Ashis Kumar Chatterjee,et al.  Leveraging information in multi-echelon inventory systems , 2004, Eur. J. Oper. Res..

[47]  S. Seuring,et al.  End-of-life returns of long-lived products from end customer—insights from an ideally set up closed-loop supply chain , 2007 .

[48]  Roelof Kuik,et al.  On optimal inventory control with independent stochastic item returns , 2003, Eur. J. Oper. Res..

[49]  Otto Rentz,et al.  Towards sustainable production networks , 2007 .

[50]  Bongju Jeong,et al.  Supply planning model for remanufacturing system in reverse logistics environment , 2006, Comput. Ind. Eng..

[51]  Mohamad Y. Jaber,et al.  A production/remanufacturing inventory model with price and quality dependant return rate , 2010, Comput. Ind. Eng..

[52]  Shad Dowlatshahi,et al.  The role of transportation in the design and implementation of reverse logistics systems , 2010 .

[53]  Mitsuo Gen,et al.  Network model and optimization of reverse logistics by hybrid genetic algorithm , 2009, Comput. Ind. Eng..

[54]  J. Quariguasi Frota Neto,et al.  From closed-loop to sustainable supply chains: the WEEE case , 2007 .

[55]  Mohamad Y. Jaber,et al.  A production/remanufacture model with returns’ subassemblies managed differently , 2011 .

[56]  R. Lackes,et al.  Supply chain management and reverse logistics , 2004 .

[57]  Hokey Min,et al.  The spatial and temporal consolidation of returned products in a closed-loop supply chain network , 2006, Comput. Ind. Eng..

[58]  Wen-Hsien Tsai,et al.  Treatment and recycling system optimisation with activity-based costing in WEEE reverse logistics management: an environmental supply chain perspective , 2009 .

[59]  Wei Yan,et al.  An investigation into sustainable product conceptualization using a design knowledge hierarchy and Hopfield network , 2009, Comput. Ind. Eng..

[60]  Gregory A. DeCroix Optimal Policy for a Multiechelon Inventory System with Remanufacturing , 2006, Oper. Res..

[61]  John A. Muckstadt,et al.  An analysis of single item inventory systems with returns , 1981 .

[62]  Hongman Gao,et al.  An empirical study of impacts of production mix, product route efficiencies on operations performance and profitability: a reverse logistics approach , 2010 .