IDEAS home Printed from https://ideas.repec.org/a/gam/jlogis/v6y2022i2p34-d825690.html
   My bibliography  Save this article

Improving Replenishment Flows Using Simulation Results: A Case Study

Author

Listed:
  • Othmane Benmoussa

    (Euromed Research Center, Euromed Polytechnic School, Euro-Mediterranean University of Fes, Rond-Point Bensouda, Fès 30030, Morocco)

Abstract

Background : Replenishment process is one of the success factors for a more efficient management of operations and a regained profitability. The application of the principles of lean manufacturing in the field of industrial logistics, where substantial improvements in the replenishment process are necessary, is relevant with the objective of optimising the replenishment flow of raw materials from assembly lines in order to propose and implement robust solutions capable of mitigating or even eliminating all types of waste and maximising the productivity of value-added activities. Methods : To achieve this goal, the paper follows the spirit of the DMAIC (Define, Measure, Analyse, Improve and Control) and 5-Why methods that allow the mapping of internal processes of factory logistics in the particular case of a Wire Harness Automotive Plant. Results : Based on the data collected, as well as on specific analysis methods, simulations are launched to challenge and validate the improvements made to the replenishment process. Conclusions : Several generalisable lessons are learnt regarding replenishment flow management, covering topics such as inventory traceability, in addition to logistics costs and process flow optimisation.

Suggested Citation

  • Othmane Benmoussa, 2022. "Improving Replenishment Flows Using Simulation Results: A Case Study," Logistics, MDPI, vol. 6(2), pages 1-26, May.
    • Handle: RePEc:gam:jlogis:v:6:y:2022:i:2:p:34-:d:825690
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/2305-6290/6/2/34/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/2305-6290/6/2/34/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Geraghty, John & Heavey, Cathal, 2004. "A comparison of Hybrid Push/Pull and CONWIP/Pull production inventory control policies," International Journal of Production Economics, Elsevier, vol. 91(1), pages 75-90, September.
    2. Masae, Makusee & Glock, Christoph H. & Grosse, Eric H., 2020. "Order picker routing in warehouses: A systematic literature review," International Journal of Production Economics, Elsevier, vol. 224(C).
    3. Alexander Tsigkas, 2022. "The Modern Lean Enterprise," Management for Professionals, in: The Modern Lean Enterprise, edition 2, chapter 1, pages 1-10, Springer.
    4. Alexander Tsigkas, 2022. "Principles of Lean Production," Management for Professionals, in: The Modern Lean Enterprise, edition 2, chapter 4, pages 43-51, Springer.
    5. Kleijnen, J.P.C. & van Beers, W.C.M. & van Nieuwenhuyse, I., 2008. "Constrained Optimization in Simulation : A Novel Approach," Other publications TiSEM e49ba0fc-853c-4a13-b564-d, Tilburg University, School of Economics and Management.
    6. Marc Helmold, 2022. "Strategic Performance Management," Management for Professionals, Springer, number 978-3-030-98725-1, December.
    7. Hammer, Michael & Champy, James, 1993. "Reengineering the corporation: A manifesto for business revolution," Business Horizons, Elsevier, vol. 36(5), pages 90-91.
    8. Glock, C. H. & Grosse, E. H., 2012. "Storage policies and order picking strategies in U-shaped order-picking systems with a movable base," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 57442, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    9. Franzke, T. & Grosse, E. H. & Glock, C. H. & Elbert, R., 2017. "An investigation of the effects of storage assignment and picker routing on the occurrence of picker blocking in manual picker-to-parts warehouses," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 82572, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    10. Alexander Tsigkas, 2022. "The Modern Lean Enterprise," Management for Professionals, Springer, edition 2, number 978-3-662-64476-8, December.
    11. Hamed Jalali & Inneke Van Nieuwenhuyse, 2015. "Simulation optimization in inventory replenishment: a classification," IISE Transactions, Taylor & Francis Journals, vol. 47(11), pages 1217-1235, November.
    12. Matusiak, Marek & de Koster, René & Kroon, Leo & Saarinen, Jari, 2014. "A fast simulated annealing method for batching precedence-constrained customer orders in a warehouse," European Journal of Operational Research, Elsevier, vol. 236(3), pages 968-977.
    13. Marc Helmold & Ayşe Küçük Yılmaz & Tracy Dathe & Triant G. Flouris, 2022. "Introduction to Supply Chain Risk Management (SCRM)," Management for Professionals, in: Supply Chain Risk Management, chapter 1, pages 1-12, Springer.
    14. Kleijnen, Jack P.C. & Beers, Wim van & Nieuwenhuyse, Inneke van, 2010. "Constrained optimization in expensive simulation: Novel approach," European Journal of Operational Research, Elsevier, vol. 202(1), pages 164-174, April.
    15. Matusiak, Marek & de Koster, René & Saarinen, Jari, 2017. "Utilizing individual picker skills to improve order batching in a warehouse," European Journal of Operational Research, Elsevier, vol. 263(3), pages 888-899.
    16. Marc Helmold, 2022. "Performance Management as Part of the Corporate Strategy," Management for Professionals, in: Strategic Performance Management, chapter 1, pages 1-23, Springer.
    17. Marc Helmold & Ayşe Küçük Yılmaz & Tracy Dathe & Triant G. Flouris, 2022. "Supply Chain Risk Management," Management for Professionals, Springer, number 978-3-030-90800-3, December.
    18. Amdework Gochel & Sisay G. Gebeyehu & Muluken Abebe, 2022. "Production lead time improvement through lean manufacturing," International Journal of Industrial and Systems Engineering, Inderscience Enterprises Ltd, vol. 40(2), pages 147-156.
    19. Mark L. Spearman & Michael A. Zazanis, 1992. "Push and Pull Production Systems: Issues and Comparisons," Operations Research, INFORMS, vol. 40(3), pages 521-532, June.
    20. Marc Helmold, 2022. "Performance Management in Operations Management," Management for Professionals, in: Strategic Performance Management, chapter 3, pages 57-70, Springer.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Yahel Giat, 2024. "Stock Levels and Repair Sourcing in a Periodic Review Exchangeable Item Repair System," Logistics, MDPI, vol. 8(2), pages 1-19, March.
    2. Benjamin Gazeau & Atiq Zaman & Roberto Minunno & Faiz Shaikh, 2024. "Developing Traceability Systems for Effective Circular Economy of Plastic: A Systematic Review and Meta-Analysis," Sustainability, MDPI, vol. 16(22), pages 1-28, November.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Masae, Makusee & Glock, Christoph H. & Vichitkunakorn, Panupong, 2021. "A method for efficiently routing order pickers in the leaf warehouse," International Journal of Production Economics, Elsevier, vol. 234(C).
    2. Maria A. M. Trindade & Paulo S. A. Sousa & Maria R. A. Moreira, 2022. "Ramping up a heuristic procedure for storage location assignment problem with precedence constraints," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 646-669, September.
    3. Kleijnen, Jack P.C., 2017. "Regression and Kriging metamodels with their experimental designs in simulation: A review," European Journal of Operational Research, Elsevier, vol. 256(1), pages 1-16.
    4. Glock, Christoph H. & Grosse, Eric H. & Abedinnia, Hamid & Emde, Simon, 2019. "An integrated model to improve ergonomic and economic performance in order picking by rotating pallets," European Journal of Operational Research, Elsevier, vol. 273(2), pages 516-534.
    5. Osorio, Carolina, 2019. "High-dimensional offline origin-destination (OD) demand calibration for stochastic traffic simulators of large-scale road networks," Transportation Research Part B: Methodological, Elsevier, vol. 124(C), pages 18-43.
    6. Strang, Kenneth David, 2012. "Importance of verifying queue model assumptions before planning with simulation software," European Journal of Operational Research, Elsevier, vol. 218(2), pages 493-504.
    7. Kleijnen, Jack P.C. & van Beers, W.C.M. & van Nieuwenhuyse, I., 2011. "Expected Improvement in Efficient Global Optimization Through Bootstrapped Kriging - Replaces CentER DP 2010-62," Discussion Paper 2011-015, Tilburg University, Center for Economic Research.
    8. Dhahri, Akrem & Gharbi, Ali & Ouhimmou, Mustapha, 2022. "Integrated production-delivery control policy for an unreliable manufacturing system and multiple retailers," International Journal of Production Economics, Elsevier, vol. 245(C).
    9. Park, Chan-Woo & Lee, Hyo-Seong, 2013. "Performance evaluation of a multi-product CONWIP assembly system with correlated external demands," International Journal of Production Economics, Elsevier, vol. 144(1), pages 334-344.
    10. Carolina Osorio & Michel Bierlaire, 2013. "A Simulation-Based Optimization Framework for Urban Transportation Problems," Operations Research, INFORMS, vol. 61(6), pages 1333-1345, December.
    11. Yang, Taho & Fu, Hsin-Pin & Yang, Kuang-Yi, 2007. "An evolutionary-simulation approach for the optimization of multi-constant work-in-process strategy--A case study," International Journal of Production Economics, Elsevier, vol. 107(1), pages 104-114, May.
    12. van Gils, Teun & Caris, An & Ramaekers, Katrien & Braekers, Kris, 2019. "Formulating and solving the integrated batching, routing, and picker scheduling problem in a real-life spare parts warehouse," European Journal of Operational Research, Elsevier, vol. 277(3), pages 814-830.
    13. Carolina Osorio & Linsen Chong, 2015. "A Computationally Efficient Simulation-Based Optimization Algorithm for Large-Scale Urban Transportation Problems," Transportation Science, INFORMS, vol. 49(3), pages 623-636, August.
    14. Miranda, Rafael de Carvalho & Montevechi, José Arnaldo Barra & da Silva, Aneirson Francisco & Marins, Fernando Augusto Silva, 2017. "Increasing the efficiency in integer simulation optimization: Reducing the search space through data envelopment analysis and orthogonal arrays," European Journal of Operational Research, Elsevier, vol. 262(2), pages 673-681.
    15. Arbex Valle, Cristiano & Beasley, John E, 2020. "Order batching using an approximation for the distance travelled by pickers," European Journal of Operational Research, Elsevier, vol. 284(2), pages 460-484.
    16. Nikolaos Chondromatidis & Anastasios Gialos & Vasileios Zeimpekis, 2022. "Investigating the Performance of the Order-Picking Process by Using Smart Glasses: A Laboratory Experimental Approach," Logistics, MDPI, vol. 6(4), pages 1-26, December.
    17. Hernandez, Andres F. & Grover, Martha A., 2013. "Error estimation properties of Gaussian process models in stochastic simulations," European Journal of Operational Research, Elsevier, vol. 228(1), pages 131-140.
    18. Zhongshun Shi & Siyang Gao & Hui Xiao & Weiwei Chen, 2019. "A worst‐case formulation for constrained ranking and selection with input uncertainty," Naval Research Logistics (NRL), John Wiley & Sons, vol. 66(8), pages 648-662, December.
    19. Hainan Guo & Haobin Gu & Yu Zhou & Jiaxuan Peng, 2022. "A data-driven multi-fidelity simulation optimization for medical staff configuration at an emergency department in Hong Kong," Flexible Services and Manufacturing Journal, Springer, vol. 34(2), pages 238-262, June.
    20. Rajabighamchi, Farzaneh & van Hoesel, Stan & Defryn, Christof, 2023. "The order picking problem under a scattered storage policy," Research Memorandum 006, Maastricht University, Graduate School of Business and Economics (GSBE).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jlogis:v:6:y:2022:i:2:p:34-:d:825690. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.