INVENTORY CONTROL IN A TWO-STAGE GREEN SUPPLY CHAIN

Abstract

Recycling, remanufacturing and repair processes increase the profitability of companies by providing less energy use and less waste generation, and have a positive effect on the total cost of the supply chain. In the present study, an integrated inventory model, which considers economic and environmental objectives together, was developed for a two-level supply chain system consisting of a single manufacturer and a single retailer located in different countries. The problem is the simultaneous calculation of the manufacturer's number of shipments and the buyer's shipment sizes, that is, the parameters of the integrated production-inventory policy, to minimize the total cost of the system. Each batch the retailer received contains both good quality products and defective products. Some of the defective products are scrapped and sent back to the manufacturer to enter the recycling/remanufacturing process, while the other part is added to the inventory after being repaired at a local company. The carbon emission costs of transporting products from manufacturer to retailer and defective products from retailer to manufacturer and repair center were included in the model. Our aim was to model the joint effects of outsourcing repair, recycling/remanufacturing, and carbon emissions on supply chain performance. Theoretical results were obtained with the help of a numerical example and sensitivity analysis was carried out. Numerical analysis showed that the repair process together with the recycling/remanufacturing process has a positive effect on the total inventory cost of the supply chain.

Keywords

• Repair
• Recycling
• Remanufacturing
• Carbon emissions
• Mathematical Model

İKİ AŞAMALI YEŞİL BİR TEDARİK ZİNCİRİNDE STOK KONTROLÜ

Abstract

Geri dönüşüm, yeniden üretim ve tamir işlemleri, daha az enerji kullanımı ve daha az atık oluşumunu sağlayarak işletmelerin karlılığını artırmaktadır ve tedarik zinciri toplam maliyeti üzerinde olumlu yönde etki yapmaktadır. Bu çalışmada, farklı ülkelerde bulunan tek bir üretici ve tek bir perakendeciden oluşan iki aşamalı tedarik zinciri sistemi için ekonomik ve çevresel hedefleri birlikte gözeten bir bütünleşik stok kontrol modeli geliştirilmektedir. Bu çalışmadaki problem, sistemin toplam stok maliyetini enküçükleyecek şekilde üreticinin parti sayısının ve perakendecinin parti büyüklüğünün, yani bütünleşik üretim-stok kontrol politikası parametrelerinin birlikte hesaplanmasıdır. Perakendecinin teslim aldığı her parti iyi kaliteli ürünlerle birlikte kusurlu ürünler de içermektedir. Kusurlu ürünlerin bir kısmı hurdaya ayrılmakta ve geri dönüşüm/yeniden üretim sürecine girmek üzere üreticiye geri gönderilmektedir, diğer kısmı ise yerel bir firmada tamir edildikten sonra eldeki stoğa eklenmektedir. Ürünlerin üreticiden perakendeciye ve kusurlu ürünlerin perakendeciden üreticiye ve tamir merkezine taşınmasından kaynaklanan karbon emisyon maliyetleri modele dahil edilmiştir. Bu çalışmadaki amaç, dışkaynak tamir, geri dönüşüm/yeniden üretim ve karbon emisyonunun birlikte tedarik zinciri performansı üzerindeki etkisini modellemektir. Sayısal bir örnek yardımıyla teorik sonuçlar elde edilmiş ve duyarlılık analizleri verilmiştir. Sayısal analiz sonucunda, tamir işleminin geri dönüşüm/yeniden üretim işlemiyle birlikte tedarik zinciri toplam stok maliyeti üzerinde olumlu yönde etkisinin olduğu gözlemlenmiştir.

Keywords

• Tamir
• Geri dönüşüm
• Yeniden üretim
• Karbon emisyonu
• Matematik model

References

1. Ala, D. M., & İkiz, Y. (2015). Dokuma üretimi süresince oluşan kumaş hatalarının belirlenmesine yönelik istatistiksel bir araştırma. Pamukkale Üniversitesi Mühendislik Bilimleri Dergisi, 21(7), 282-287.
2. Aljazzar, S. M., Gurtu, A., & Jaber, M. Y. (2018). Delay-in-payments-A strategy to reduce carbon emissions from supply chains. Journal of Cleaner Production, 170, 636-644.
3. Bazan, E., Jaber, M. Y., & Zanoni, S. (2017). Carbon emissions and energy effects on a two-level manufacturer-retailer closed-loop supply chain model with remanufacturing subject to different coordination mechanisms. International Journal of Production Economics, 183, 394-408.
4. Büyüközkan, G., & Vardaloğlu, Z. (2008). Yeşil tedarik zinciri yönetimi. Lojistik Dergisi, 8, 66-73.
5. Chen, H. Y., Li, A. J., & Finlow, D. E. (2009). The lead and lead-acid battery industries during 2002 and 2007 in China. Journal of Power Sources, 191(1), 22-27.
6. Chen, T. H. (2017). Optimizing pricing, replenishment and rework decision for imperfect and deteriorating items in a manufacturer-retailer channel. International Journal of Production Economics, 183, 539-550.
7. Cheng, Y. L., Wang, W. T., Wei, C. C., & Lee, K. L. (2018). An integrated lot-sizing model for imperfect production with multiple disposals of defective items. Scientia Iranica, 25(2), 852-867.
8. Chiu, C. Y., Yang, M. F., Tang, C. J., & Lin, Y. (2013). Integrated imperfect production inventory model under permissible delay in payments depending on the order quantity. Journal of Industrial & Management Optimization, 9(4), 945.

9. Çoban, O., & Şahbaz Kılınç, N. (2016). Enerji kullanımının çevresel etkilerinin incelenmesi. Marmara Coğrafya Dergisi, 33, 589-606.
10. Dağ, S. & Kabadayı, N. (220). ISO 44001 işbirlikçi iş ilişkileri yönetim sistemi standardının tedarik zinciri ortaklık süreçlerine etkisinin değerlendirilmesi. Beykoz Akademi Dergisi, 8(2), 60-81.
11. Daniel, J. S. R., & Rajendran, C. (2005). A simulation‐based genetic algorithm for inventory optimization in a serial supply chain. International Transactions in Operational Research, 12(1), 101-127.
12. Dey, O., & Giri, B. C. (2014). Optimal vendor investment for reducing defect rate in a vendor–buyer integrated system with imperfect production process. International Journal of Production Economics, 155, 222-228.
13. Diaz, A., & Fu, M. C. (1997). Models for multi-echelon repairable item inventory systems with limited repair capacity. European Journal of Operational Research, 97(3), 480-492.
14. Erkök, B. (2018). Türkiye sanayisinin küresel değer zincirine entegrasyonu. Ankara Üniversitesi SBF Dergisi, 75(2), 637-666.
15. Fanuc. (2020, Haziran 1). FANUC Türkiye tamir merkezi açıldı. Erişim adresi https://www.fanuczone.com/2020/06/01/fanuc-turkiye-tamir-merkezi-acildi/.
16. Gautam, P., Kishore, A., Khanna, A., & Jaggi, C. K. (2019). Strategic defect management for a sustainable green supply chain. Journal of Cleaner Production, 233, 226-241.
17. Gersil, A. (2007). Üretim sistemleri ve teknolojilerindeki gelişmelerin ve küreselleşmenin geleneksel maliyet muhasebesine etkileri. Ankara Üniversitesi SBF Dergisi, 62(4), 107-123.
18. Giri, B. C., Chakraborty, A., & Maiti, T. (2017). Consignment stock policy with unequal shipments and process unreliability for a two-level supply chain. International Journal of Production Research, 55(9), 2489-2505.
19. Glock, C. H. (2012). The joint economic lot size problem: A review. International Journal of Production Economics, 135(2), 671-686.
20. Goonatilake, P. C. L. (1984). Inventory control problems in developing countries. International Journal of Operations & Production Management, 4(4), 57-64.
21. Goonatilake, L. (1990). Inventory management in the manufacturing sector in developing countries. Engineering Costs and Production Economics, 19(1-3), 19-24.
22. Goyal, S. K. (1976). An integrated inventory model for a single supplier-single customer problem. International Journal of Production Research, 15(1), 107-111.
23. Guide Jr, V. D. R. (2000). Production planning and control for remanufacturing: industry practice and research needs. Journal of Operations Management, 18(4), 467-483.
24. Gurtu, A., Jaber, M. Y., & Searcy, C. (2015). Impact of fuel price and emissions on inventory policies. Applied Mathematical Modelling, 39(3-4), 1202-1216.
25. Güner, E. D., & Turan, E. S. (2017). Yenilenebilir enerji kaynaklarının küresel iklim değişikliği üzerine etkisi. Doğal Afetler ve Çevre Dergisi, 3(1), 48-55.
26. Harris, F. W. (1990). How many parts to make at once. Operations Research, 38(6), 947-950.
27. Hill, R. M. (1997). The single-vendor single-buyer integrated production-inventory model with a generalised policy. European Journal of Operational Research, 97(3), 493-499.
28. Hsu, J. T., & Hsu, L. F. (2013). An integrated vendor–buyer inventory model with imperfect items and planned backorders. The International Journal of Advanced Manufacturing Technology, 68(9), 2121-2132.
29. Huang, C. K. (2002). An integrated vendor-buyer cooperative inventory model for items with imperfect quality. Production Planning & Control, 13(4), 355-361.
30. Jaber, M. Y., Glock, C. H., & El Saadany, A. M. (2013). Supply chain coordination with emissions reduction incentives. International Journal of Production Research, 51(1), 69-82.
31. Jaber, M. Y., Zanoni, S., & Zavanella, L. E. (2014). Economic order quantity models for imperfect items with buy and repair options. International Journal of Production Economics, 155, 126-131.
32. Jaber, M. Y. ve Zolfaghari, S. (2008). Quantitative models for centralised supply chain coordination. V. Kordic (Ed.). Supply chains: Theory and applications içinde (s. 307-338). Vienna, Austria: I-Tech Education and Publishing.
33. Jauhari, W. A., Pujawan, I. N., & Suef, M. (2022). Sustainable inventory management with hybrid production system and investment to reduce defects. Annals of Operations Research, doi:10.1007/s10479-022-04666-8
34. Khan, M., Jaber, M. Y., Zanoni, S., & Zavanella, L. (2016). Vendor managed inventory with consignment stock agreement for a supply chain with defective items. Applied Mathematical Modelling, 40(15-16), 7102-7114.
35. Kobu, B. (1994). Üretim yönetimi (8. Baskı). İstanbul: Avcıol Basım-Yayın.
36. Konstantaras, I., Skouri, K., & Benkherouf, L. (2021). Optimizing inventory decisions for a closed–loop supply chain model under a carbon tax regulatory mechanism. International Journal of Production Economics, 239, 108185, 1-13.
37. Lai, X., Chen, Z., Giri, B. C., & Chiu, C. H. (2015). Two-echelon inventory optimization for imperfect production system under quality competition environment. Mathematical Problems in Engineering, 2015.
38. Lin, F., Jia, T., Fung, R. Y., & Wu, P. (2021). Impacts of inspection rate on integrated inventory models with defective items considering capacity utilization: Rework-versus delivery-priority. Computers & Industrial Engineering, 156, 107245.
39. Liu, X., & Cetinkaya, S. (2011). The supplier–buyer integrated production-inventory model with random yield. International Journal of Production Research, 49(13), 4043-4061.
40. Malleeswaran, B., & Uthayakumar, R. (2022). An integrated vendor–buyer supply chain model for backorder price discount and price-dependent demand using service level constraints and carbon emission cost. International Journal of Systems Science: Operations & Logistics, 9(1), 111-120.
41. Orak, İ. M., & Çelik, A. (2017). Üretim aşamasında ray ve profilde oluşan kusurlarının tespitine yönelik bir paralel kusur algılama algoritması. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 32(2), 439-448.
42. Ouyang, L. Y., Chuang, C. J., Ho, C. H., & Wu, C. W. (2014). An integrated inventory model with quality improvement and two-part credit policy. Top, 22(3), 1042-1061.
43. Ouyang, L. Y., Wu, K. S., & Ho, C. H. (2006). Analysis of optimal vendor-buyer integrated inventory policy involving defective items. The International Journal of Advanced Manufacturing Technology, 29(11), 1232-1245.
44. Özkan, Ş. (2012). Yöneylem araştırması (3. Baskı). Ankara: Nobel Akademik Yayıncılık.
45. Öztürk, H. (2021). A study and comparison of shipment policies with repair options in a two-tier supply chain model. Engineering Management Journal, 33(2), 96-125.
46. Paksoy, T., Altıparmak, F. (2003). Dağıtım ağlarının tasarımı ve eniyilemesi kapsamında tedarik zinciri ve lojistik yönetimine bir bakış: Son gelişmeler ve genel durum. YTÜD, 4, 149-169.
47. Plambeck, E. L. (2012). Reducing greenhouse gas emissions through operations and supply chain management. Energy Economics, 34, S64-S74.
48. Rizky, N., Wangsa, I. D., Jauhari, W. A., & Wee, H. M. (2021). Managing a sustainable integrated inventory model for imperfect production process with type one and type two errors. Clean Technologies and Environmental Policy, 23(9), 2697-2712.
49. Rout, C., Paul, A., Kumar, R. S., Chakraborty, D., & Goswami, A. (2020). Cooperative sustainable supply chain for deteriorating item and imperfect production under different carbon emission regulations. Journal of Cleaner Production, 272, 122170.
50. Salameh, M. K., & Jaber, M. Y. (2000). Economic production quantity model for items with imperfect quality. International Journal of Production Economics, 64(1-3), 59-64.
51. Sarkar, B., Shaw, B. K., Kim, T., Sarkar, M., & Shin, D. (2017). An integrated inventory model with variable transportation cost, two-stage inspection, and defective items. Journal of Industrial & Management Optimization, 13(4), 1975-1990.
52. Savaskan, R. C., Bhattacharya, S., & Van Wassenhove, L. N. (2004). Closed-loop supply chain models with product remanufacturing. Management Science, 50(2), 239-252.
53. Sgarbossa, F., Grosse, E. H., Neumann, W. P., Battini, D., & Glock, C. H. (2020). Human factors in production and logistics systems of the future. Annual Reviews in Control, 49, 295-305.
54. Sharafali, M., & Co, H. C. (2000). Some models for understanding the cooperation between the supplier and the buyer. International Journal of Production Research, 38(15), 3425-3449.
55. Singh, R., & Mishra, V. K. (2022). Sustainable integrated inventory model for substitutable deteriorating items considering both transport and industry carbon emissions. Journal of Systems Science and Systems Engineering, 1-21.
56. Soruşbay, C. (2007). Karayolu ulaşımından kaynaklanan karbondioksit emisyonlarının çevreye etkisi ve kontrolü. Mühendis ve Makine, 48(564), 22-26.
57. Taft, E. W. (1918). The most economical production lot. Iron Age, 101(18), 1410-1412.
58. Taleizadeh, A. A., Hazarkhani, B., & Moon, I. (2020). Joint pricing and inventory decisions with carbon emission considerations, partial backordering and planned discounts. Annals of Operations Research, 290(1), 95-113.
59. Tiwari, S., Daryanto, Y., & Wee, H. M. (2018). Sustainable inventory management with deteriorating and imperfect quality items considering carbon emission. Journal of Cleaner Production, 192, 281-292.
60. Toktas-Palut, P. (2021). İki kısımlı tarife kontratı ile yeşil endüstri 4.0 tedarik zincirinin koordinasyonu. International Journal of Advances in Engineering and Pure Sciences, 33(4), 556-567.
61. Udayakumar, R., & Geetha, K. V. (2018). Supply chain coordination with controllable lead time under imperfect production process. Journal of Intelligent & Fuzzy Systems, 34(3), 2003-2019.
62. Wahab, M. I. M., Mamun, S. M. H., & Ongkunaruk, P. (2011). EOQ models for a coordinated two-level international supply chain considering imperfect items and environmental impact. International Journal of Production Economics, 134(1), 151-158.
63. Wangsa, I. D., & Wee, H. M. (2019). A vendor-buyer inventory model for defective items with errors in inspection, stochastic lead time and freight cost. INFOR: Information Systems and Operational Research, 57(4), 597-622.
64. Yıldız, A. (2018). Endüstri 4.0 ve akıllı fabrikalar. Sakarya Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 22(2), 546-556.
65. Yıldız Çankaya, S. (2015). Tedarik zinciri yönetimine sürdürülebilirlik perspektifinden bakış ve yeşil uygulamalar (Yayımlanmamış doktora tezi), Gebze Teknik Üniversitesi Sosyal Bilimler Enstitüsü.
66. Yıldıztekin, İ. (2005). Kalite maliyetleri ölçümlerinde belirlenen fırsat maliyetleri. Atatürk Üniversitesi İktisadi ve İdari Bilimler Dergisi, 19(1), 401-422.
67. Zanoni, S., Mazzoldi, L., & Jaber, M. Y. (2014). Vendor-managed inventory with consignment stock agreement for single vendor–single buyer under the emission-trading scheme. International Journal of Production Research, 52(1), 20-31.