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Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·1
7-Mar-03 Logistics Systems Design Marc Goetschalckx
1. Introduction
Logistics Systems Design:Supply Chain Systems
3. Transportation Systems4. Transportation Models
2. Forecasting
5. Inventory Systems6. Supply Chain Systems
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Networks
CustomerDistribution Center
FactorySupplier
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Common Logistics QuestionsWhere to purchase ?Where to produce ?Where to assemble ?Where to hold in inventory ?How to transport ?How to deliver ?How to expand or retreat ?How to recycle ?
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chains Are Globaland Ever Changing
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·2
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Duty Relieves
4.9% duty avoided in Europe
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Taxes
34%17%
12%
40% or more
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chains DesignsIntegrated and Comprehensive
Products
Facilities
Channels
Customers Countries
Time Periods
Inventory
Objectives
Vendors
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Traditional Design Stages
Service Goals
Material Deployment Strategy
Network Design
Transportation
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·3
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Modern Design Stages
Service Goals
Material Deployment Strategy
Network Design
Transportation&
&
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Objectives for Given Demand
Cost minimizationSt. Service constraints
Return on investment maximizationSt. Service constraints
Reliability
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Objectives for Variable Demand
Profit maximizationSt. Budget constraints
Service maximizationSt. Budget constraints
ResponsivenessFlexibility
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Total System CostTotal cost of achieving a mission• Mission = set of customer service goals
for a particular productTraditional accounting insufficient• Arbitrary allocation of overhead costs• Functional areas based rather than
output basedBased on activity based costing (ABC)Reduced to a common time frame
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·4
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Cost Categories
Controllable vs. Non-controllable• Avoided if the mission were
discontinued• Transportation vs. Pension liabilities
Fixed vs. Variable• Fixed are incurred when an activity is
executed• Variable change with the intensity of the
activity7-Mar-03 Logistics Systems Design Marc Goetschalckx
Total System Cost Components
Raw material costsProduction costsLinehaul transportation costsLocal delivery costsFacility costsStorage and handling costsSystem inventory costs
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Costs Schematic
DC Fixed Location CostsDC Variable Storage & Handling CostsSafety Stock CostCycle Inventory Cost
Linehaul Transportation CostPipeline Inventory Cost
Delivery CostFixed Opening/Closing CostProduction CostCycle Inventory CostProduction Capability CostSupplies Cost
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Depot Technology or Size Costs
Cost
Throughput Quantity
Manual
Mechanized
Automated
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·5
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Direct Shipping Cost Tradeoff
Plant Customer
Warehouse
Expensive Delivery
Cheap Linehaul
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Cross Docking Material Handling Tradeoff
Storage
Receiving Shipping
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain and Warehousing Trends
TransactionsTransportation
Information
InventoryFacilitiesHandling
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Data Sources
Business operating documentsSales orders, customer data, freight bills
Business documentsAnnual report, accounting (activity-based-costing)
Logistics research dataPublished reference data
Trade magazines, census data, press
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·6
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Data Encoding
Group technology and codingProduct coding
Bar codes, radio frequency tags, smart cards
GeocodingZip codesCity and state names
7-Mar-03 Logistics Systems Design Marc Goetschalckx
GeocodingConverts alphanumeric location data into geographical data
From zip codes and city, stateTo longitude-latitude or rectangular coordinates
Grid overlay, spreadsheets, or reference databasesUser interface and displayNumerical computations
7-Mar-03 Logistics Systems Design Marc Goetschalckx
DEC Incinerator Data
7-Mar-03 Logistics Systems Design Marc Goetschalckx
DEC Incineration Geographical Schematic with Excel
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
DEC Incineration Geographical Schematic with Visio Maps
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Geocoding Example: Customer Demand History Database
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Geocoding Example: Customer Locations
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Geocoding Example: Demand Summed by State
Below - 500,000.00500,000.00 - 1,000,000.001,000,000.00 - 2,000,000.002,000,000.00 - 3,000,000.003,000,000.00 - 5,000,000.00Above - 5,000,000.00
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·8
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Geocoding Example: Average Customer Demand by State
Below - 1,250.001,250.00 - 2,500.002,500.00 - 5,000.005,000.00 - 10,000.0010,000.00 - 20,000.00Above - 20,000.00
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Constraints
Conservation of flowCapacity and demandConsistency or linkageElastic or soft constraints with penalty cost
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Units of Analysis
Units of material flow and storageMonetary unitsUnits of time (major and minor)Information units
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Model Characteristics
Multi-countryMulticommodityMulti-echelonMulti-periodCapacitated facilitiesCapacitated channelsDeterministic or stochastic
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·9
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Logistics Objects
Products - commoditiesIn transformationIn transportationIn storage
CountriesPeriodsResources
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Logistics Objects Continued
FacilitiesSources = suppliersSinks = customersIntermediate = transformers (manufacturing and distribution)
Transportation channels
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Period Characteristics
Major periodStrategic planningYear, seasonOrdered sequence
Minor periodDemand processDay, week
Consistency
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Period Edit Window
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·10
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Country Characteristics
Differs from other countries byCurrency (exchange rate)Tax rateDutiesMinimum profitLocal content lawsDuty relief
Limited number
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Country Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Country-Period Edit Window(Input)
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Country-Period Edit Window(Output)
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Marc Goetschalckx
Product Types
Convenience and commoditiesMultiple sales pointsFood items, office supplies
Comparison shoppingFewer sales pointsCars, fork lift trucks
Specialty productsVery limited distributionArt, specialized machines
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Product Life Cycle Graph
Time
Sales
Maturity
Decline
Growth
Introduction
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Product Life Cycle Characteristics
IntroductionLimited availabilityFew sales points and channelsCentralize distribution
GrowthExpanding channels and sales pointsFlow quantity more important than cost
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Product Life Cycle Characteristics (2)
MaturityStable sales volumeMany sales points and channelsOptimization opportunity
DeclineDeclining sales volumeDecreasing sales points and channelsCentralized distribution
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·12
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Product Characteristics
Differs from other products• Size• Weight• Value• Urgency• Risk characteristics• Obsolescence
Limited number, less than 12 to 20
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Product Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Product-Country-PeriodEdit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Customer Types
Customer typesConsumer productsIndustrial products
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·13
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Customer Characteristics
Ultimate sink for all materialsDiffers from other customers• Location• Product demand• Service level
Fixed location Demand for individual products• Customer-product matrix
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Customer Characteristics (2)
Single sourcing restrictions• None• By product• All products combined (depot)
Service constraints• Maximum time• Maximum distance
No more than a few hundred
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Customer Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Customer Demand Edit Window(Input)
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·14
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Customer Demand Edit Window(Output)
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Concentration / differentiation phenomenonAlso called 80-20, ABC, fast-medium-slow
Product Sales Pareto Analysis
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Product Sales Pareto Curves With Benders Formula
0.000
0.100
0.200
0.300
0.400
0.500
0.600
0.700
0.800
0.900
1.000
0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000
SalesBenders
7-Mar-03 Logistics Systems Design Marc Goetschalckx
X=cumulative products,Y=cumulative sales,A=parameter
Benders
Power
Exponential
Pareto Curve Formulations
Y A XA X
= ++
( )1
Y X A=
Y e AX= − −1
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·15
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Pareto Formulation
Curve
Parameter
Y A XA X
= ++
( )1
A X YY X
= −−
( )1
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Least Squares Parameter Estimation
Minimize sum of squared deviations
Set partial derivative equal to zero
( )2
2 (1 )ˆ ii i i
i i i
A XMin SSE Y Y YA X
+= − = − + ∑ ∑
2 2 3
2 3
( ) (1 )( ) 0( ) ( )
N Ni i i i i
i ii i
dSSE Y X X A X XdA A X A X
− + −= − =+ +∑ ∑
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Pareto Curves for Different A Parameters
0.0000
0.1000
0.2000
0.3000
0.4000
0.5000
0.6000
0.7000
0.8000
0.9000
1.0000
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
1001010.10.010.001
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Bender’s Pareto Curve Observations
More concentration / differentiationSmaller A parameterMore skewed curve
ABC classification and curve nameClass breakpoints based on slope
Data - information - knowledge example
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·16
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Pareto Curve Example: Data
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Pareto Curve Example: Curve Fitting
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Pareto Curve Example: Excel Solver
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Pareto Curve Example: Solver Options
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
Benders Pareto Curve Example: Excel Graph
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Customer Service
Many componentsMany definitionsVery qualitative
7-Mar-03 Marc Goetschalckx
Customer Service Stages
Pre-transactionDeclaring policies and procedures
TransactionInventory levels and locationTransportation channelsOrdering and billing systems
Post-transactionMaintenance and service (CALS)Warranties
7-Mar-03 Marc Goetschalckx
Order Cycle Time
Time between order placement and product receiptWide range (instantaneous to 30 months)Components
Order processingProductionOrder assembly and order pickingTransportation
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·18
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Sales-Service Curve
Service
Sales
Sales Revenue
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Sales-Cost-Service Curves
Service
Sales
Sales Revenue
Logistics Costs
Maximum Profit
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Service Constraints
Percentage of goods delivered out of stockPercentage of orders delivered within time limitMaximum time or distance from supply pointSingle sourcing
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supplier Characteristics
Initial source of all materialsDiffers from other supplier• Location• Fixed facility cost (opening or closing)• Total supply capacity• Supply parameters
Fixed location
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·19
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Characteristics cont.
Commodity Supply Parameters• Cost• Resource requirement
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supplier Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Edit Supplier-Period Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supplier-Period-Product Edit Window (Input)
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·20
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supplier-Period-Product Edit Window (Output)
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supplier-Period-ResourceEdit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supplier-Period-Product-Resource Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformation Facilities
Transformation typesManufacturingDistribution
Intermediate facilitiesNo creation or destruction of flowChange of commodity
Moveable or fixed facilitiesDifferent possible types at a site
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformation Facilities Characteristics
Fixed and variable costsThroughput and storage capacitiesResources
Resource costsResource consumption
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformation FacilityEdit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformation Facility TypeEdit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformer-Type-PeriodEdit Window
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformer-Type-Period-Product Edit Window (Input)
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformer-Type-Period-Product Edit Window (Output)
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformer-Type-Period-Resource Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transformer-Type-Period-Product-Resource Edit Window
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
Importance of Transportation
Smaller, faster, more frequently, more on time shipments50 % of total logistics cost and rising
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transportation Performance Measures
AccessibilityCapacityCostSpeedDependabilityTradeoff with inventory for shipperTradeoff with flow volume for carrier
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transportation Modes
PipelineRailRoadWaterOceanAirSpace
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transportation Channel Edit Window (Input)
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
Transportation Channel Edit Window (Output)
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Channel-Period Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Channel-Period-Product Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Channel-Period-ResourceEdit Window
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·25
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Channel-Period-Product-Resource Edit Window
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Strategies:Evaluation Criteria
Total Logistics CostsEconomies of scaleEconomies of scopeInventory and transportation costs
Simplicity of ControlResponsiveness to changesFlexibility and robustness
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Systems Strategies: Suppliers
CentralizationRegionalizationConsolidationDispersion
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Systems Strategies: Transformation
Manufacturing facilities strategyRegionalizationConsolidationProduct FocusProcess FocusDispersion
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·26
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Systems Strategies: Transformation
Distribution network strategyConsolidationCustomer FocusCo-Location
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Design Software Requirements
User FriendlyGeneration of Reports, Maps, & VisualsHigh Fidelity Economic RepresentationHigh Degree of Optimization of the Results
Ballou & Masters, “Commercial Software for Locating Warehouses and Other Facilities,” Journal of Business Logistics, Vol. 35, No. 2, 1993.
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Design Decision Support System Components
System data and data baseDesign modelsSolution algorithmsReports, displays and interactive executive
7-Mar-03 Logistics Systems Design Marc Goetschalckx
CIMPEL
Cost Minimization St. Service ConstraintsNeutral Data BaseComprehensive Integrated ModelAlgorithm ToolkitStandard Interactive Color Graphics Interface
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
CIMPEL Illustration
7-Mar-03 Strategic Modeling of Logistics Systems Marc Goetschalckx
CIMPEL Structure
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Enterprise Resource Planning (ERP) Software
Logistics Systems Status“Bookkeeping”
TransactionalData Warehouse
AdvantagesEnterprise StandardizationData IntegrationUp-To-Date DataMultinational
7-Mar-03 Logistics Systems Design Marc Goetschalckx
ERP Vendors
Growing ImportanceMajor Vendors
SAP (Financial), Baan (Manufacturing),PeopleSoft (Human Resources)...
Logistics Systems Design: Supply Chain Systems March 7, 2003
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 6·28
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Management (SCM) Software
Logistics Systems Configuration and Planning“Optimizing”
Operations ResearchConstraint Based Logic
Interface with ERP
7-Mar-03 Logistics Systems Design Marc Goetschalckx
SCM Vendors
Strong ConsolidationMajor Vendors
I2 - InterTransManugisticsChesapeake - SupplyChain
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Logistics Software Reference
Andersen Consulting, “Logistics Software,” jointly with Council of Logistics Management, Oak Brook, IL, 1992 and yearly updates.
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Logistics Planning Software Catalogue
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Design Challenges
Integrated models are large and complex
More tactical effects (seasonal, inventory)Multi-objective performance measures
Cost/profit, flexibility, and responsiveness tradeoffs
Strategic design as a continuous effortModels, data, algorithms
7-Mar-03 Logistics Systems Design Marc Goetschalckx
Supply Chain Design Challenges Continued
Technology transfer to logistics professionals and students
Toy cases and black-box software
7-Mar-03 Logistics Systems Design Marc Goetschalckx
From a Multicommodity Case...
7-Mar-03 Logistics Systems Design Marc Goetschalckx
...and Configurationby a Current Design Tool
Logistics Systems Design: Supply Chain Systems March 7, 2003
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7-Mar-03 Logistics Systems Design Marc Goetschalckx
To Design Toolsfor the Next Century