Skip to main content
Springer Nature Link
Log in

Integrated production scheduling and distribution planning in dairy supply chain by hybrid modelling

  • Published:
Annals of Operations Research Aims and scope Submit manuscript

Abstract

In this paper we address the production scheduling and distribution planning problem in a yoghurt production line of the multi-product dairy plants. A mixed integer linear programming model is developed for the considered problem. The objective function aims to maximize the benefit by considering the shelf life dependent pricing component and costs such as processing, setup, storage, overtime, backlogging, and transportation costs. Key features of the model include sequence dependent setup times, minimum and maximum lot sizes, overtime, shelf life requirements, machine speeds, dedicated production lines, typically arising in the dairy industry. The model obtains the optimal production plan for each product type, on each production line, in each period together with the delivery plan.

The hybrid modelling approach is adopted to explore the dynamic behavior of the real world system. In the hybrid approach, operation time is considered as a dynamic factor and it is adjusted by the results of the simulation and optimization model iteratively. Thus, more realistic solutions are obtained for the scheduling problem in yoghurt industry by using the iterative hybrid optimization-simulation procedure. The efficiency and applicability of the proposed model and approach are demonstrated in a case study for a leading dairy manufacturing company in Turkey.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  • Acar, Y., Kadipasaoglu, S. N., & Schipperijn, P. (2010). A decision support framework for global supply chain modelling: an assessment of the impact of demand, supply and lead-time uncertainties on performance. International Journal of Production Research, 48(11), 3245–3268.

    Article  Google Scholar 

  • Ahumada, O., & Villalobos, J. R. (2011). A tactical model for planning the production and distribution of fresh produce. Annals of Operations Research, 190(1), 339–358.

    Article  Google Scholar 

  • Almeder, C., Preusser, M., & Hartl, R. F. (2009). Simulation and optimization of supply chains: alternative or complementary approaches? OR Spektrum, 31, 95–119.

    Article  Google Scholar 

  • Amorim, P., Antunes, C. H., & Almada-Lobo, B. (2011). Multi-objective lot-sizing and scheduling dealing with perishability issues. Industrial & Engineering Chemistry Research, 50(6), 3371–3381.

    Article  Google Scholar 

  • Amorim, P., Günther, H. O., & Almada-Lobo, B. (2012). Multi-objective integrated production and distribution planning of perishable products. International Journal of Production Economics, 138(1), 89–101.

    Article  Google Scholar 

  • Basnet, C., Foulds, L. R., & Wilson, J. M. (1999). An exact algorithm for a milk tanker scheduling and sequencing problem. Annals of Operations Research, 86, 559–568.

    Article  Google Scholar 

  • Berlin, J., Sonesson, U., & Tillman, A. M. (2007). A life cycle based method to minimise enviromental impact of dairy production through product sequencing. Journal of Cleaner Production, 15, 347.

    Article  Google Scholar 

  • Byrne, M. D., & Bakir, M. A. (1999). Production planning using a hybrid simulation-analytical approach. International Journal of Production Economics, 59, 305–311.

    Article  Google Scholar 

  • Byrne, M. D., & Hossain, M. M. (2005). Production planning an improved hybrid approach. International Journal of Production Economics, 59, 305–311.

    Article  Google Scholar 

  • Claassen, G. D. H., & van Beek, P. (1993). Planning and scheduling packaging lines in food industry. European Journal of Operational Research, 70, 150–158.

    Article  Google Scholar 

  • Doganis, P., & Sarimveis, H. (2007). Optimal scheduling in a yogurt production line based on mixed integer linear programming. Journal of Food Engineering, 80, 445–453.

    Article  Google Scholar 

  • Doganis, P., & Sarimveis, H. (2008a). Optimal production scheduling for the dairy industry. Annals of Operations Research, 159, 315–331.

    Article  Google Scholar 

  • Doganis, P., & Sarimveis, H. (2008b). Mixed integer linear programming scheduling in the food industry. In Optimization in food engineering (pp. 305–328). London: CRC Press.

    Google Scholar 

  • Foulds, L. R., & Wilson, J. M. (1997). A variation of the generalized assignment problem arising in the New Zealand dairy industry. Annals of Operations Research, 69, 105–114.

    Article  Google Scholar 

  • Gellert, T., Höhn, W., & Moehring, R. H. (2011). Sequencing and scheduling for filling lines in dairy production. Optimization Letters, 5(3), 491–504.

    Article  Google Scholar 

  • Gnoni, M. G., Iavagnilio, R., Mossa, G., Mummolo, G., & Di Leva, A. (2003). Production planning of a multi-site manufacturing system by hybrid modeling: a case study from the automotive industry. International Journal of Production Economics, 85, 251–262.

    Article  Google Scholar 

  • Gunther, H.-O., & Neuhaus, U. (2004). Advanced planning and scheduling in the consumer goods industry: realizing block planning concepts for make-and-pack production using MILP modelling and SAP’s APO software. In L. N. Van Wassenhove, A. de Meyer, E. Yucesan, E. D. Gunes, & L. Muyldermans (Eds.), Operations management as a change agent (Vol. 2, pp. 757–766). Fontainebleau: INSEAD.

    Google Scholar 

  • Hsieh, S. J. (2002). Hybrid analytic and simulation models for assembly line design and production planning. Simulation Modelling Practice and Theory, 10, 87–108.

    Article  Google Scholar 

  • Kim, B., & Kim, S. (2001). Extended model for a hybrid production planning approach. International Journal of Production Economics, 73(2), 165–173.

    Article  Google Scholar 

  • Kopanos, G. M., Puigjaner, L., & Georgiadis, M. C. (2010). Optimal production scheduling and lot-sizing in dairy plants: the yogurt production line. Industrial & Engineering Chemistry Research, 49, 701–718.

    Article  Google Scholar 

  • Kopanos, G. M., Puigjaner, L., & Georgiadis, M. C. (2011a). Resource-constrained production planning in semicontinuous food industries. Computers & Chemical Engineering, 35(12), 2929–2944.

    Article  Google Scholar 

  • Kopanos, G. M., Puigjaner, L., & Georgiadis, M. C. (2011b). Production scheduling in multiproduct multistage semicontinuous food processes. Industrial & Engineering Chemistry Research, 50(10), 6316–6324.

    Article  Google Scholar 

  • Kopanos, G. M., Puigjaner, L., & Georgiadis, M. C. (2012a). Efficient mathematical frameworks for detailed production scheduling in food processing industries. Computers & Chemical Engineering, 42, 206–216.

    Article  Google Scholar 

  • Kopanos, G. M., Puigjaner, L., & Georgiadis, M. C. (2012b). Simultaneous production and logistics operation planning in semicontinuous food industries. Omega, 40, 634–650.

    Article  Google Scholar 

  • Lee, Y. H., & Kim, S. H. (2002). Production-distribution planning in supply chain considering capacity constraints. Computers & Industrial Engineering, 43, 169–190.

    Article  Google Scholar 

  • Lee, Y. H., Kim, S. H., & Moon, Ch. (2002). Production-distribution planning in supply chain by using a hybrid approach. Production Planning & Control, 13(1), 35–46.

    Article  Google Scholar 

  • Lütke Entrup, M. (2005). Advanced planning in fresh food industries: integrating shelf life into production planning. Heidelberg: Physica.

    Google Scholar 

  • Lütke Entrup, M., Günther, H.-O., Van Beek, P., Grunow, M., & Seiler, T. (2005). Mixed-integer linear programming approaches to shelf-life-integrated planning and scheduling in yoghurt production. International Journal of Production Research, 43(23), 5071–5100.

    Article  Google Scholar 

  • Marinelli, F., Nenni, M. E., & Sforza, A. (2007). Capacitated lot sizing and scheduling with paralel machines and shared buffers: a case study in a packaging company. Annals of Operations Research, 150, 177–192.

    Article  Google Scholar 

  • Nakhla, M. (1995). Production control in the food processing industry. International Journal of Operations & Production Management, 15, 73–88.

    Article  Google Scholar 

  • Nikolopoulou, A., & Ierapetritou, M. G. (2012). Hybrid simulation based optimization approach for supply chain management. Computers & Chemical Engineering, 47, 183–193.

    Article  Google Scholar 

  • Safaei, A. S., Husseini, M., Farahani, R. Z., Jolai, F., & Ghodsypour, S. H. (2010). Integrated multi-site production distribution planning in supply chain by hybrid modelling. International Journal of Production Research, 48(14), 4043–4069.

    Article  Google Scholar 

  • Shanthikumar, J. G., & Sargent, R. G. (1983). A unifying view of hybrid simulation/analytic models and modeling. Operations Research, 31(6), 1030–1052.

    Article  Google Scholar 

  • Smith-Daniels, V. L., & Ritzman, L. P. (1988). A model for lot sizing and sequencing in process industries. International Journal of Production Research, 26, 647–674.

    Article  Google Scholar 

  • van Dam, P., Gaalman, G., & Sierksma, G. (1993). Scheduling of packaging lines in the process industry: an empirical investigation. International Journal of Production Economics, 30, 579–589.

    Google Scholar 

  • Yoo, T., Cho, H., & Yücesan, E. (2010). Hybrid algorithm for discrete event simulation based supply chain optimization. Expert Systems with Applications, 37(3), 2354–2361.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Industrial Engineering, Dokuz Eylul University, Buca, Izmir, Turkey

    Bilge Bilgen & Yelda Çelebi

Authors
  1. Bilge Bilgen
    View author publications

    You can also search for this author inPubMed Google Scholar

  2. Yelda Çelebi
    View author publications

    You can also search for this author inPubMed Google Scholar

Corresponding author

Correspondence to Bilge Bilgen.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Bilgen, B., Çelebi, Y. Integrated production scheduling and distribution planning in dairy supply chain by hybrid modelling. Ann Oper Res 211, 55–82 (2013). https://doi.org/10.1007/s10479-013-1415-3

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10479-013-1415-3

Keywords