In an ideal Just-in-Time (JIT) production environment, parts should be delivered to the workstationsat the exact time they are needed and in the exact quantity required. In reality, formost components/subassemblies this is neither practical nor economical. In this study, thematerial flow of the crossdocking operation at the Toyota Motor Manufacturing plant inGeorgetown, KY (TMMK) is simulated and analyzed.At the Georgetown plant between 80 and 120 trucks are unloaded every day, with approximately1300 different parts being handled in the crossdocking area. The crossdocking areaconsists of 12 lanes, each lane corresponding to one section of the assembly line. Whereassome pallets contain parts designated for only one lane, other parts are delivered in such smallquantities that they arrive as mixed pallets. These pallets have to be sorted/crossdocked intothe proper lanes before they can be delivered to the workstations at the assembly line. Thisprocedure is both time consuming and costly.In this study, the present layout of the crossdocking area at Toyota and a layout proposed byToyota are compared via simulation with three newly designed layouts. The simulation modelswill test the influence of two different volumes of incoming quantities, the actual volumeas it is now and one of 50% reduced volume. The models will also examine the effects ofcrossdocking on the performance of the system, simulating three different percentage levelsof pallets that have to be crossdocked.The objectives of the initial study are twofold. First, simulations of the current system,based on data provided by Toyota, will give insight into the dynamic behavior and the materialflow of the existing arrangement. These simulations will simultaneously serve to validateour modeling techniques. The second objective is to reduce the travel distances in the crossdockingarea; this will reduce the workload of the team members and decrease the lead timefrom unloading of the truck to delivery to the assembly line. In the second phase of theproject, the design will be further optimized. Starting with the best layouts from the simulationresults, the lanes will be rearranged using a genetic algorithm to allow the lanes withthe most crossdocking traffic to be closest together.The different crossdocking quantities and percentages of crossdocking pallets in the simulationsallow a generalization of the study and the development of guidelines for layouts ofother types of crossdocking operations. The simulation and optimization can be used as abasis for further studies of material flow in JIT and/or crossdocking environments.

[pt] O aumento da população em toda a parte evidencia a necessidade de uma geração de mais demandas em todos os segmentos empresariais. Para que essa mesma demanda possa chegar no cliente, um número de veículos significativo precisa crescer, numa grande problemática que são os centros urbanos cada dia mais concorridos para a circulação, estacionamento e distribuição de mercadorias. O problema ainda se eleva em regiões como a Cidade do Rio de Janeiro que possui em seu plano diretor proibições de carga e descarga de mercadorias em certos horários considerados críticos de pico. Neste contexto, este trabalho realiza um estudo de caso em uma empresa de distribuição de bebidas do Rio de Janeiro, descrevendo uma proposta de solução para a implantação de um ponto móvel (crossdocking) através da localização de um ponto móvel na região sul da cidade utilizando a p-mediana e a roteirização de desse ponto com todos os clientes da empresa. A solução proposta pelo estudo promove adequações nos processos da distribuidora, além de identificar os fatores críticos e as etapas do processo de implantação do ponto de crossdocking móvel. / [en] The population increase everywhere evidences the need for a generation of more demands in all business segments. For this same demand to arrive at the customer, a significant number of vehicles needs to grow, in a big problem that the urban centers are increasingly busy for the circulation, parking and distribution of goods. The problem still arises in regions such as the City of Rio de Janeiro that has in its master plan prohibitions of loading and unloading of merchandise at certain times considered critical of peak. In this context, this paper carries out a case study in a beverage distribution company in Rio de Janeiro, describing a proposal for a solution for the implantation of a mobile point (crossdocking) by locating a mobile point in the southern region of the city using The p-median and the routing of this point with all the clients of the company. The solution proposed by the study promotes adjustments in the distributor s processes, as well as identifying the critical factors and the stages of the mobile crossdocking point deployment process.

Afin d’accélérer les flux de produits, de réduire les niveaux de stocks et de faire des économies de transport, les entreprises de presque toutes les industries ont mis en place des centres de crossdock. Ces centres sont un point intermédiaire de consolidation dans une chaîne logistique. Les constructeurs automobiles Renault et Nissan s’appuient sur un réseau international de plateformes crossdock pour lier des fournisseurs de pièces de première monte avec des usines de production lointaines, généralement en outre-mer. Dans un cadre d’un partenariat académique-industriel entre le laboratoire LIMOS et Renault, cette thèse est focalisée sur la planification et l’ordonnancement des activités dans ces centres de crossdock. Des études de terrain menées chez Renault et Nissan nous ont permis d’identifier les caractéristiques, les contraintes et les inducteurs de coûts des plateformes de crossdock, ainsi que de cibler notre revue de la littérature. Sur ces bases, nous proposons une approche d’optimisation séquentielle, comprenant deux modèles en programmation linéaire en nombres entiers, implémentés dans CPLEX et testés sur des données industrielles de deux plateformes Renault. Les résultats des expérimentations obtenus sur le premier modèle (planification) ont montré une nette amélioration en termes de coûts, par rapport à la méthode Renault. Fort de ce constat, une implémentation industrielle a été faite, avec des résultats aussi probants. Le deuxième modèle (ordonnancement) s’avère pertinent pour des instances de moyenne taille. L’approche proposée permet de répondre à la configuration actuelle des AILN Renault et nous considérons qu’elle est adaptable à d’autres industries. / In order to accelerate product flow, reduce inventory levels and make economies in transportation, companies in almost all industries have set up cross-dock centres. These centres are an intermediate point of consolidation in a supply chain. Car manufacturers Renault and Nissan rely on an international network of crossdock platforms to link suppliers of OEM parts with overseas production plants. In a framework of an academic-industrial partnership between the LIMOS laboratory and Renault, this thesis focuses on the activity planning and scheduling at these crossdock centres.Field studies conducted at Renault and Nissan allowed us to identify the characteristics, constraints and cost drivers of crossdock platforms, as well as to target our review of the literature. Based on this, we propose a sequential optimization approach, comprising two integer linear programming models, implemented in CPLEX and tested on industrial data of two Renault platforms. Numerical experiments’ results obtained on the first model (planning) showed a significant improvement in cost, compared to the Renault method. In light of this results, an industrial implementation was made, with such convincing results. The second model (scheduling) proved to be relevant for medium-sized instances. The proposed approach fits to the current configuration of AILN Renault and we consider that it is adaptable to other industries.

Syftet med studien var att utreda hur den temporära lagringen av gods i en crossdockingterminal kan förbättras med hjälp av optimerad slotting. Den tillämpade metoden var av abduktiv natur med kvalitativ och kvantitativ empiri, samt en optimeringsbaserad analysmetod med hjälp av programvara. Det erhållna resultatet bestod av tre olika varianter på optimeringsmodellen, där varje variant löstes med fem olika viktningar på internt avstånd mellan baklagringsytorna. Varje lösning resulterade i den mest optimala placeringen av gods som modellen tog fram efter två timmars körning. Resultatet gav främst insikter kring vikten av informationssystem och informationsflöden, jämförelser av praktiskt tillämpade lagringsstrategier gentemot teorietiskt optimerade strategier gällande effektivitet, genomförbarhet och lämplighet. Slutsatserna av studien är bland annat att ju färre restriktioner och ju lägre krav på placeringen av gods desto färre slöserier skapade modellen. Det talar dessutom för värdet av lättillgänglig information för att kunna hantera en blandad baklagring. Utöver det framkom även att en låsning av vissa parametrar kan resultera i ett bättre resultat då problemet är för komplicerat för att köras till optimum. De kortsiktiga rekommendationerna bestod i en föreslagen layout som är realiserbar i dagsläget, vilken kommer frigöra 27,2 m2 i baklagringsyta. De långsiktiga rekommendationerna behandlade behovet av ett förbättrat informationssystem för att möjliggöra bättre framtida layouts genom nuvarande klassindelade lagring, samt även möjligheter till klassindelning baserad på lastbärare. Vidare föreslogs även förändringar för den övergripande terminallayouten för att ge bättre förutsättningar för tillämpning av redan existerande optimeringsmodeller. / The purpose with this thesis was to explore how temporary storage within a cross docking terminal can be improved by optimized slotting. An abductive method was used and the empirical data collected was both qualitative and quantitative in nature. The analysis consisted mainly of the development of an optimization model. The obtained result consisted of three different variants of the optimization model, where each one was solved with five different weights for the internal distance of storage slots. Each run resulted in the most optimal placement of goods that the model could produce in twohours. The results mainly provided insights of the importance of information systems and information flows, comparisons of practical applied storage strategies against theoretically optimized strategies regarding efficiency, feasibility and suitability. The conclusions of the study are, among other things, that fewer restrictions and lower requirements for the placement of goods, the less waste remained. It also emphasise the value of easily accessible information in order to handle a mixed storage. In addition, it was also found that locking certain parameters can result in a better result as the problem is too complicated to be executed to optimum. Long-term recommendations addressed the need for an improved information system to enable better future layouts through current class-based storage, as well as opportunities for class-based load carriers. Furthermore, changes were also proposed for the overall terminal layout to provide better conditions for the application of pre-existing optimization models.

Freight distribution systems are under stress. With the world population growing, the migration of people to urban areas and technologies that allow purchases from virtually anywhere, efficient freight distribution can be challenging. An inefficient movement of goods may lead to business not being economically viable and also has social and environmental negative effects. An important strategy to be incorporated in freight distribution systems is the consolidation of goods, i.e., group goods by their destination. This strategy increases vehicles utilisation, reducing the number of vehicles and the number of trips required for the distribution and, consequently, costs, traffic, noise and air pollution. In this thesis, we explore consolidation in three different contexts (or cases) from an optimisation point of view. Each context is related to optimisation problems for which we developed mathematical programming models and solution methods. The first case in which we explore consolidation is in container loading problems (CLPs). CLPs are a class of packing problems which aims at positioning three-dimensional boxes inside a container efficiently. The literature has incorporated many practical aspects into container loading solution method (e.g. restricting orientation of boxes, stability and weight distribution). However, to the best of our knowledge, the case considering more dynamic systems (e.g. cross-docking) in which goods might have a schedule of arrival were yet to be contemplated by the literature. We define an extension of CLP which we call Container Loading Problem with Time Availability Constraints (CLPTAC), which considers boxes are not always available for loading. We propose an extension of a CLP model that is suitable for CLPTAC and solution methods which can also handle cases with uncertainty in the schedule of the arrival of the boxes. The second case is a more broad view of the network, considering an open vehicle routing problem with cross-dock selection. The traditional vehicle routing problem has been fairly studied. Its open version (i.e. with routes that start and end at different points) has not received the same attention. We propose a version of the open vehicle routing problem in which some nodes of the network are consolidation centres. Instead of shippers sending goods directly to their consumers, they must send to one of the available consolidation centres, then, goods are resorted and forwarded to their destination. For this problem, we propose a mixed integer linear programming model for cost minimisation and a solution method based on the Benders decomposition framework. A third case in which we explored consolidation is in collaborative logistics. Particularly, we focus on the shared use of the currently available infrastructure. We defined a hub selection problem in which one of the suppliers is selected as a hub. In a hub facility, other suppliers might meet to exchange their goods allowing one supplier to satisfy the demand from others. For this problem, we propose a mixed integer linear programming model and a heuristic based on the model. Moreover, we compared a traditional distribution strategy, with each supplier handling its demand, against the collaborative one. In this thesis, we explore these three cases which are related to consolidation for improving the efficiency in freight distribution systems. We extend some problems (e.g. versions of CLP) to apply them to a more dynamic setting and we also define optimisation problems for networks with consolidation centres. Furthermore, we propose solution methods for each of the defined problems and evaluate them using randomly generated instances, benchmarks from the literature and some cases based on real-world characteristics. / Sistemas de distribuição de carga possuem uma demanda muito alta. Com a população mundial crescendo, a migração em direção às áreas urbanas e as tecnologias que permitem compras de virtualmente qualquer lugar, a distribuição eficiente de mercadorias pode ser um desafio. Uma movimentação ineficiente de mercadorias pode tornar negócios economicamente inviáveis além de ter um impacto social e ambiental negativos. Uma estratégia importante para se incorporar em sistemas de distribuição é a consolidação de cargas, isto é, agrupar cargas de acordo com seus destinos. Essa estratégia aumenta a utilização dos veículos, reduzindo o número de veículos e viagens necessários para a distribuição e, consequentemente, custos, tráfego, poluição sonora e do ar. Nesta tese, é explorada a técnica de consolidação em três casos diferentes de um ponto de vista de otimização. Cada caso é relacionado a problemas de otimização para os quais são propostos modelos de programação matemática e métodos de solução. O primeiro caso em que é explorada a consolidação é em Problemas de Carregamento de Contêineres (PCCs). PCCs pertencem a uma classe de problemas de empacotamento que visa posicionar caixas tridimensionais dentro de contêineres eficientemente. A literatura tem incorporado diversos aspectos práticos em procedimentos de solução dos PCCs (por exemplo, restringir a orientação das caixas, estabilidade e distribuição de peso). No entanto, o caso que considera sistemas logísticos mais dinâmicos (como cross-docking), nos quais mercadorias podem ter uma agenda de chegada ainda não havia sido contemplados. É definida uma extensão de PCC chamada de Problema de Carregamento de Contêieneres com Restrições de Disponibilidade Temporal (PCCRDT). Também, propõem-se modelos e métodos de solução para o PCCRDT que são capazes de lidar com incerteza na chegada das mercadorias. O segundo caso utiliza uma visão mais abrangente da rede de distribuição, considerando um problema de roteamento de veículos em rede aberta com seleção de cross-dock. O problema tradicional de roteamento de veículos é bastante estudado. A sua versão aberta (com rotas que começam e terminam em pontos diferentes) não tem recebido tanta atenção. É proposta uma versão do roteamento de veículos em rede aberta em que alguns nós da rede são centros de consolidação. Os fornecedores, ao invés de enviar as mercadorias diretamente para os consumidores, enviam-nas para um dos centros de consolidação disponíveis, então, as mercadorias são reorganizadas (em diferentes veículos) e encaminhadas para o seus destinos. Para esse problema, é proposto um modelo de programação linear inteira mista para a minimização de custo e um método de solução baseado no arcabouço de decomposição de Benders. Um terceiro caso em que foi explorada a consolidação de mercadorias é o de logística colaborativa. Particularmente, se concentrou no uso compartilhado de infra-estrutura já disponível na rede de distribuição. É definido um problema de seleção de seleção de um dos fornecedores como hub. No hub, outros fornecedores podem se encontrar para trocar suas mercadorias, permitindo que um fornecedor satisfaça a demanda de outro. Para esse problema, é proposto um modelo de programação linear inteira mista e uma heurística baseada no modelo. Ainda, é comparada uma estratégia de distribuição convencional (com cada fornecedor responsável pela sua própria demanda) com uma estratégia colaborativa. Nesta tese, são explorados esses três casos que se relacionam com consolidação para melhorar a eficiência de sistemas de distribuição de carga. São estendidos alguns problemas (como o PCC) para que se possa aplicá-los em cenários mais dinâmicos e também são definidos problemas de otimização em redes com centros de consolidação. Além disso, são propostos métodos de solução para cada um dos casos. Os métodos são avaliados em instâncias geradas aleatoriamente, instâncias da literatura e, em alguns casos, instâncias baseadas em cenários reais.