The integrated production-inventory-distribution-routing problem

The integration of production and distribution decisions presents a challenging problem for manufacturers trying to optimize their supply chain. At the planning level, the immediate goal is to coordinate production, inventory, and delivery to meet customer demand so that the corresponding costs are minimized. Achieving this goal provides the foundations for streamlining the logistics network and for integrating other operational and financial components of the system. In this paper, a model is presented that includes a single production facility, a set of customers with time varying demand, a finite planning horizon, and a fleet of vehicles for making the deliveries. Demand can be satisfied from either inventory held at the customer sites or from daily product distribution. In the most restrictive case, a vehicle routing problem must be solved for each time period. The decision to visit a customer on a particular day could be to restock inventory, meet that day's demand or both. In a less restrictive case, the routing component of the model is replaced with an allocation component only. A procedure centering on reactive tabu search is developed for solving the full problem. After a solution is found, path relinking is applied to improve the results. A novel feature of the methodology is the use of an allocation model in the form of a mixed integer program to find good feasible solutions that serve as starting points for the tabu search. Lower bounds on the optimum are obtained by solving a modified version of the allocation model. Computational testing on a set of 90 benchmark instances with up to 200 customers and 20 time periods demonstrates the effectiveness of the approach. In all cases, improvements ranging from 10-20% were realized when compared to those obtained from an existing greedy randomized adaptive search procedure (GRASP). This often came at a three- to five-fold increase in runtime, however.