Part logistics in the automotive industry: Decision problems, literature review and research agenda

With the ongoing trend of mass-customization and an increasing product variety, just-in-time part logistics more and more becomes one of the greatest challenges in today’s automobile production. Thousands of parts and suppliers, a multitude of different equipments, and hundreds of logistics workers need to be coordinated, so that the final assembly lines never run out of parts. This paper describes the elementary process steps of part logistics in the automotive industry starting with the initial call order to the return of empty part containers. In addition to a detailed process description, important decision problems are specified, existing literature is surveyed, and open research challenges are identified.

[1]  Marius M. Solomon,et al.  On the worst-case performance of some heuristics for the vehicle routing and scheduling problem with time window constraints , 1986, Networks.

[2]  Daniele Vigo,et al.  Chapter 6 Vehicle Routing , 2007, Transportation.

[3]  Nicolas Jozefowiez,et al.  The vehicle routing problem: Latest advances and new challenges , 2007 .

[4]  Tamás Kis,et al.  Scheduling of inventory releasing jobs to minimize a regular objective function of delivery times , 2012, Journal of Scheduling.

[5]  Ann van Ackere,et al.  Trading off between heijunka and just-in-sequence , 2009 .

[6]  Florian Klug.  Logistikmanagement in der Automobilindustrie , 2010 .

[7]  Matthias Holweg,et al.  Linking Product Variety to Order-Fulfillment Strategies , 2004, Interfaces.

[8]  Nils Boysen,et al.  Optimally locating in-house logistics areas to facilitate JIT-supply of mixed-model assembly lines , 2012 .

[9]  Young Hae Lee,et al.  Vehicle routing scheduling for cross-docking in the supply chain , 2006, Comput. Ind. Eng..

[10]  Ángel Corberán,et al.  Recent results on Arc Routing Problems: An annotated bibliography , 2010, Networks.

[11]  Seyed Jafar Sadjadi,et al.  An efficient genetic algorithm for determining the optimal price discrimination , 2006, Appl. Math. Comput..

[12]  Nils Boysen,et al.  Jena Research Papers in Business and Economics Truck Scheduling in Cross Docking Terminals with fixed Outbound Departures , 2010 .

[13]  Nils Boysen,et al.  Jena Research Papers in Business and Economics Scheduling Inbound and Outbound Trucks at Cross Docking Terminals , 2007 .

[14]  Nils Boysen,et al.  The Car Resequencing Problem with Pull-Off Tables , 2011 .

[15]  Candace A. Yano,et al.  Facility Layout to Support Just-in-Time , 1996, Transp. Sci..

[16]  C. Carter,et al.  REVERSE LOGISTICS: A REVIEW OF THE LITERATURE AND FRAMEWORK FOR FUTURE INVESTIGATION , 1998 .

[17]  Nils Boysen,et al.  Resequencing of mixed-model assembly lines: Survey and research agenda , 2012, Eur. J. Oper. Res..

[18]  Christoph H. Glock,et al.  Storage policies and order picking strategies in U-shaped order-picking systems with a movable base , 2012 .

[19]  Leon F. McGinnis,et al.  Kitting versus line stocking: A conceptual framework and a descriptive model☆ , 1992 .

[20]  Maurizio Faccio,et al.  “Supermarket warehouses”: stocking policies optimization in an assembly-to-order environment , 2010 .

[21]  Marc Goetschalckx,et al.  Solving the forward-reserve allocation problem in warehouse order picking systems , 2010, J. Oper. Res. Soc..

[22]  H. Lorenz,et al.  Jena Research Papers in Business and Economics Sequencing Mixed-Model Assembly Lines : Survey , Classification and Model Critique , 2007 .

[23]  Norman C. Otto,et al.  Simulation models of material delivery systems , 1991, 1991 Winter Simulation Conference Proceedings..

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

[25]  Jayashankar M. Swaminathan,et al.  Managing Product Variety in Automobile Assembly: The Importance of the Sequencing Point , 2007, Interfaces.

[26]  Steven Nahmias,et al.  Production and Operations Analysis, 6th Edition , 2014 .

[27]  Nils Boysen,et al.  Jena Research Papers in Business and Economics Optimally Routing and Scheduling Tow Trains for JIT-Supply of Mixed-Model Assembly Lines , 2010 .

[28]  Nils Boysen,et al.  Just-in-Time supermarkets for part supply in the automobile industry , 2013 .

[29]  Russell D. Meller,et al.  A space allocation algorithm for assembly line components , 2005 .

[30]  Veronique Limère,et al.  To kit or not to kit: optimizing part feeding in the automotive assembly industry , 2013, 4OR.

[31]  Heungsoon Felix Lee,et al.  Retrieval sequencing for unit-load automated storage and retrieval systems with multiple openings , 1996 .

[32]  Bruce L. Golden,et al.  The vehicle routing problem : latest advances and new challenges , 2008 .

[33]  Marc Gravel,et al.  A review of optimisation models of Kanban-based production systems , 1994 .

[34]  Hans-Christian Krcal,et al.  Strategische Implikationen einer geringen Fertigungstiefe für die Automobilindustrie , 2008 .

[35]  Nils Boysen,et al.  Jena Research Papers in Business and Economics Scheduling Just-inTime Part Supply for Mixed-Model Assembly Lines , 2009 .

[36]  Ann-Christine Falck,et al.  The impact of poor assembly ergonomics on product quality: A cost–benefit analysis in car manufacturing , 2010 .

[37]  Rosario Domingo,et al.  Materials flow improvement in a lean assembly line: a case study , 2007 .

[38]  Lars Medbo,et al.  Impact of materials exposure on assembly workstation performance , 2011 .

[39]  Oleg Gusikhin,et al.  Optimization of workcell layouts in a mixed-model assembly line environment , 2007 .

[40]  Gilbert Laporte,et al.  Vehicle routing with cross-docking , 2009, J. Oper. Res. Soc..

[41]  Ángel Corberán,et al.  Recent results on Arc Routing Problems: An annotated bibliography , 2010 .

[42]  Sanne Wøhlk.  A Decade of Capacitated Arc Routing , 2008 .

[43]  Candace Arai Yano,et al.  Optimizing dock configuration and staffing in decentralized receiving , 1998 .

[44]  Feryal Erhun,et al.  An overview of design and operational issues of kanban systems , 1999 .

[45]  Ann-Christine Falck,et al.  The impact of poor assembly ergonomics on product quality: A cost-benefit analysis in car manufacturing: Poor Assembly Ergonomics and Product Quality , 2010 .

[46]  Michael Drexl,et al.  Synchronization in Vehicle Routing - A Survey of VRPs with Multiple Synchronization Constraints , 2012, Transp. Sci..

[47]  Oleg Yurievitch Gusikhin,et al.  Optimization of workcell layouts in a mixed-model assembly line environment , 2005 .

[48]  Andreas Drexl,et al.  Facility location models for distribution system design , 2005, Eur. J. Oper. Res..

[49]  Sule Itir Satoglu,et al.  Design of a just-in-time periodic material supply system for the assembly lines and an application in electronics industry , 2013 .

[50]  Marc Goetschalckx,et al.  Research on warehouse operation: A comprehensive review , 2007, Eur. J. Oper. Res..

[51]  Feng Chen,et al.  Minimizing makespan in two-stage hybrid cross docking scheduling problem , 2009, Comput. Oper. Res..

[52]  Kun-Peng Wang,et al.  Scheduling a single vehicle in the just-in-time part supply for a mixed-model assembly line , 2013, Comput. Oper. Res..

[53]  Nils Boysen,et al.  Jena Research Papers in Business and Economics Scheduling of Inventory Releasing Jobs to Satisfy Time-varying Demand Scheduling of Inventory Releasing Jobs to Satisfy Time-varying Demand , 2022 .

[54]  Armin Scholl,et al.  Reducing ergonomic risks by job rotation scheduling , 2012, OR Spectrum.

[55]  Bharath S. Vaidyanathan,et al.  A capacitated vehicle routing problem for just-in-time delivery , 1999 .

[56]  J A Eklund,et al.  Relationships between ergonomics and quality in assembly work. , 1995, Applied ergonomics.

[57]  M. Dror.  Arc Routing : Theory, Solutions and Applications , 2000 .

[58]  Gilbert Laporte,et al.  The vehicle routing problem: An overview of exact and approximate algorithms , 1992 .

[59]  M. Cusumano,et al.  Supplier relations and management: A survey of Japanese, Japanese-transplant, and U. S. auto plants , 1991 .

[60]  Colin G. Drury,et al.  Ergonomics and quality in paced assembly lines , 2001 .

[61]  Erhan Kozan.  An integrated material handling system for a truck assembly plant , 2000, J. Oper. Res. Soc..

[62]  David Simchi-Levi,et al.  The logic of logistics , 1997 .

[63]  Herbert Meyr,et al.  Supply chain planning in the German automotive industry , 2004 .

[64]  Moshe Dror,et al.  A computational comparison of algorithms for the inventory routing problem , 1985 .

[65]  Gunter P. Sharp,et al.  Forward-reserve allocation in a warehouse with unit-load replenishments , 1998, Eur. J. Oper. Res..

[66]  Nils Boysen,et al.  Jena Research Papers in Business and Economics Production Planning of Mixed-Model Assembly Lines : Overview and Extensions , 2007 .

[67]  Maurizio Faccio,et al.  Design and simulation of assembly line feeding systems in the automotive sector using supermarket, kanbans and tow trains: a general framework , 2013 .

[68]  Pius J. Egbelu,et al.  Scheduling of inbound and outbound trucks in cross docking systems with temporary storage , 2008, Eur. J. Oper. Res..

[69]  Nils Boysen,et al.  Optimally loading tow trains for just-in-time supply of mixed-model assembly lines , 2012 .

[70]  Kees Jan Roodbergen,et al.  A survey of literature on automated storage and retrieval systems , 2009, Eur. J. Oper. Res..

[71]  Seyed Jafar Sadjadi,et al.  A new mathematical modeling and a genetic algorithm search for milk run problem (an auto industry supply chain case study) , 2009 .

[72]  Nils Boysen,et al.  Cross dock scheduling: Classification, literature review and research agenda , 2010 .

[73]  Diwakar Gupta,et al.  Appointment scheduling in health care: Challenges and opportunities , 2008 .

[74]  Andrew Lim,et al.  Truck dock assignment problem with operational time constraint within crossdocks , 2006, Eur. J. Oper. Res..

[75]  B. J. Berkley,et al.  A REVIEW OF THE KANBAN PRODUCTION CONTROL RESEARCH LITERATURE , 2009 .

[76]  Marc Goetschalckx,et al.  Research on warehouse design and performance evaluation: A comprehensive review , 2010, Eur. J. Oper. Res..

[77]  Thomas Spengler,et al.  Planning of capacities and orders in build-to-order automobile production: A review , 2013, Eur. J. Oper. Res..

[78]  Hans-Otto Günther,et al.  Part feeding at high-variant mixed-model assembly lines , 2012 .

[79]  Ching-Jong Liao,et al.  Vehicle routing with cross-docking in the supply chain , 2010, Expert Syst. Appl..

[80]  Maurício C. de Souza,et al.  Packing items to feed assembly lines , 2008, Eur. J. Oper. Res..

[81]  Henri Pierreval,et al.  Facility layout problems: A survey , 2007, Annu. Rev. Control..

[82]  L. McGinnis,et al.  Optimising part feeding in the automotive assembly industry: deciding between kitting and line stocking , 2012 .

[83]  Thomas Y. Choi,et al.  An exploration of supplier selection practices across the supply chain , 1996 .

[84]  K. Richter,et al.  The reverse Wagner/Whitin model with variable manufacturing and remanufacturing cost , 2001 .

[85]  Kees Jan Roodbergen,et al.  Design and control of warehouse order picking: A literature review , 2006, Eur. J. Oper. Res..

[86]  Zuhua Jiang,et al.  Routing for the Milk-Run Pickup System in Automobile Parts Supply , 2009, DET.

[87]  Meir J. Rosenblatt,et al.  Allocating Items to an Automated Storage and Retrieval System , 1990 .

[88]  Chung-Yee Lee,et al.  Minimizing the makespan in a two-machine cross-docking flow shop problem , 2009, Eur. J. Oper. Res..

[89]  Nils Boysen,et al.  The discrete forward-reserve problem - Allocating space, selecting products, and area sizing in forward order picking , 2013, Eur. J. Oper. Res..

[90]  Timon C. Du,et al.  A real-time vehicle-dispatching system for consolidating milk runs , 2007 .

[91]  Yasuhiro Monden,et al.  Toyota Production System: An Integrated Approach to Just-In-Time , 1993 .

[92]  Stella Y. Hua,et al.  Research issues on factors influencing the choice of kitting versus line stocking , 2010 .

[93]  Armin Scholl,et al.  Incorporating ergonomic risks into assembly line balancing , 2011, Eur. J. Oper. Res..

[94]  John J. Bartholdi,et al.  Allocating space in a forward pick area of a distribution center for small parts , 2008 .

[95]  Nils Boysen,et al.  Truck scheduling at zero-inventory cross docking terminals , 2010, Comput. Oper. Res..

[96]  Wonjoon Choi,et al.  A dynamic part-feeding system for an automotive assembly line , 2002 .

[97]  Shigeo Shingo,et al.  Zero Quality Control: Source Inspection and the Poka-Yoke System , 1986 .

[98]  Jon C. Yingling,et al.  Routing for a Just-in-Time Supply Pickup and Delivery System , 2005, Transp. Sci..

[99]  Ury Passy,et al.  The forward-reserve problem , 1994 .

[100]  Knut Richter,et al.  Remanufacturing planning for the reverse Wagner/Whitin models , 2000, Eur. J. Oper. Res..

[101]  Daria Battini,et al.  Design of the optimal feeding policy in an assembly system , 2009 .

[102]  Mohsen Akbarpour Shirazi,et al.  Harmony search optimization algorithm for a novel transportation problem in a consolidation network , 2014 .