Increasing legislative and societal pressures are forcing manufacturers to become environmentally-conscious and take responsibility for the fate of their goods after they have been used by consumers. As a result, some manufacturers operate hybrid systems which produce new goods and recover used goods. Product recovery describes the process by which used products are returned to their manufacturers or sent to a specialised facility for recovery, before being sold on the original or a secondary market. The quality of the returned goods is a significant issue in product recovery systems as it can affect both the type of recovery and costs associated with it. Quality in product recovery systems has not been adequately studied, with many authors either ignoring the possibility of receiving lower quality returns, or assuming they are disposed of rather than recovered. However, such assumptions ignore the possibility that the firm might be able to salvage value from lower quality returns by using them for parts or materials. This thesis presents four models that investigate the importance of considering the quality of returns in the management of inventory in a product recovery system, by examining the cost-effectiveness of recovering both high quality and low quality returns. The first model is a deterministic lot-sizing model of a product recovery system. It was found that performing both high and low quality recovery reduced the sensitivity of the optimal cost to operational restrictions on the choice of decision variables. The second model is a discrete-time, periodic-review model formulated as a Markov decision process (MDP) and introduces uncertainty in demand, returns, and the quality of the returns. It was found that performing both types of recovery can lead to cost savings and better customer service for firms through an increased fill rate. The third model addresses those industries where produced and recovered goods cannot be sold on the same market due to customers’ perceptions and environmental legalisation. Using an MDP formulation, the model examines a product recovery system in which produced and recovered goods are sold on separate markets. The profitability of offering two-way substitution between these markets was investigated. It was found that offering substitution can allow firms to increase both their profits and fill rates. The fourth model examines the issue of separate markets and substitution in the continuous time domain using a semi-Markov decision process. The continuous nature of the model allows more detailed examination of the substitution decision. It was found that offering substitution can allow firms to increase their profit and in some cases also increase their fill rate. In some cases, production is performed less frequently when downward substitution can be offered, and recovery is performed less often when upward substitution can be offered. The findings of this thesis could be used to help a firm that is currently recovering high quality returns assess the cost-effectiveness of also recovering lower quality returns. Recovering low-quality items, rather than disposing of them, may allow a firm to increase the amount it recycles. The findings highlight the importance of considering the quality of returns when managing a product recovery system as they show that economic gains can be achieved by reusing rather than refusing low quality returns.

[pt] Elevado custo com estoques é um problema enfrentado por muitas empresas brasileiras. Reduzir esse custo mostra-se como uma oportunidade, mas essa redução deve ser acompanhada de uma análise criteriosa, de maneira a não trazer consequências indesejáveis como parada de unidades ou perda de mercado. A presente dissertação teve como objetivos a proposição de um framework de gestão de estoques intermediários baseado em revisão sistemática de literatura seguida de um estudo de caso com entrevistas e observação participante, resultando na análise da gestão de estoques intermediários de uma empresa de óleo e gás. Uma comparação entre as práticas atuais da companhia e o framework foi realizada e recomendações para implantação listadas, através da proposição de um roadmap para implementação do framework. Apontamento de ganho de agilidade e foco na gestão dos estoques intermediários, e redução do inventário são elencados como contribuição desse estudo. As principais recomendações levantadas são referentes à realização da classificação ABC dos estoques, utilização de princípios e ferramentas da filosofia lean, realização de simulações, modelagem e mapeamento de fluxo de valor. Recomendações para estudos futuros incluem técnicas quantitativas de modelagem matemática de estoques e simulações. / [en] High inventory costs is a problem faced by many Brazilian companies. Reducing these costs can be very beneficial. This reduction needs a careful analysis so as not to bring undesirable consequences, including unit downtime or reduced market share. The goal of this dissertation is to propose an intermediate stock management framework. The proposal is based on a systematic literature review followed by a case study with interviews and participant observation. An analysis of the intermediate stocks management in an oil and gas company is produced. A comparison between the current practices of the company and the proposed framework was carried out. Recommendations and a roadmap on how to implement this framework are offered. Agility in managing intermediate stocks and inventory reduction are pointed as contribution of this study. The main recommendations of this study for the company are related to ABC inventory classification, lean principles and tools, simulation, modelling and value stream mapping. Recommendations for future studies include quantitative techniques for mathematical modeling of inventories and simulations.

nÃo hà / A Lubnor à uma refinaria de pequeno porte da Petrobras instalada dentro da cidade de Fortaleza-CE, que processa petrÃleos do tipo naftÃnico, pouco disponÃveis na natureza. A refinaria dispÃe hoje de trÃs opÃÃes desses Ãleos para processamento e produz basicamente asfaltos e lubrificantes naftÃnicos, sendo a Ãnica produtora nacional destes Ãltimos. O planejamento de processamento de matÃria-prima e produÃÃo dessa unidade industrial à realizado de forma centralizada pela sede da organizaÃÃo, que busca os melhores resultados para o todo, mesmo que isso penalize uma unidade especÃfica. Este trabalho temcomo objetivos planejar as operaÃÃes logÃsticas em uma refinaria de petrÃleo para maximizar seus resultados e mostrar que sincronizando a demanda por produtos acabados e a chegada de matÃria-prima, a refinaria pode aumentar a capacidade de processamento reduzindo os estoques em processo. Para esse fim, foi adotada a estratÃgia de pesquisa bibliogrÃfica e exploratÃria aplicada a um estudo de caso. Os referenciais teÃricos estÃo suportados na previsÃo de demanda, gestÃo de estoques e nos sistemas de apoio à decisÃo. Os resultados apontam que entre seis configuraÃÃes possÃveis de processamento pela refinaria, duas apresentam melhor rentabilidade, duas apresentam um resultado um pouco inferior e as duas outras sÃo inviÃveis. A demonstraÃÃo de que à possÃvel aumentar a produÃÃo com a reduÃÃo dos estoques em processo à realizada atravÃs de uma planilha do Microsoft Excel, que tem como variÃvel a carga da unidade. Aumentando-se a carga em 50% e 100%, os estoques em processo caem a nÃveis inferiores aos existentes hoje na refinaria. Ao final deste trabalho sÃo apontadas recomendaÃÃes para a soluÃÃo de problemas especÃficos que reduzem a rentabilidade da refinaria e o nÃvel de serviÃo desejado / Lubnor is a small tonnage Petrobrasâ refinery located in Fortaleza, CearÃ, Brazil. It refines naphtenic crude oils, which are not easy to find in nature. There are three kinds of Brazilian naphtenics oils currently available to be processed in Lubnor. The refinery produces basically asphalts and naphtenic lubricants, and it is the only Brazilian producer of these kinds of lubricants. The kinds of petroleum to process and the production planning of the refinery are made by the headquarters of the organization, which looks for the best results for the whole Company, although it means losses for one of the refineries. This work has the following objectives: to plan the logistic operations of a petroleum refinery in order to maximize its profits and to show that the refinery can improve its processing capacity reducing its in process inventory by synchronizing or balancing the output of final products and the input of crude oils. To reach these objectives, it was adopted the strategy of a literature research applicable to a case study. The theoretical references concern demand forecasting, inventory management and decision support systems. The results show that among the six possible configurations of oil refining, two are profitable, other two have a little gain and the last two are unfeasible. The demonstration that it is possible to increase the production reducing the in process inventory is made by using a Microsoft Excel spreadsheet with one variable: the diary flow of crude oil in the distillation unit. Increasing the flow in 50% and 100%, the in process inventory decreases to a lower level when compared with the current inventory at the refinery. At the end of this work, there are recommendations to solve specific problems which are reducing the refinery profitability and the service level

The purpose of this thesis is to develop a model that will guide a company towards a decision of whether to change the current due date of work orders or not. The model will help the company to reveal the technical and financial factors that will be affected and how these factors can be assessed. After accomplishing a thorough literature review, we found no existing practical models in this specific area. We developed a model to cover this gap in the existing theories. A case study approach was used to test the developed model on our case company Elitfönster in Lenhovda who manufactures windows. We applied our model at the processing department and the change concerned going from a weekly to a daily due date of work orders. The technical factors that would be affected by the change of the due date are; setup times, lead time and output of components. The financial factors that will be affected are the tied-up capital and the manning. We found that a change could not be carried through without a purchase of an extra plane. The model also showed that the financial benefits that the change generated could not surpass the costs that an extra plane would cause. Thereby, our recommendations to the case company are to keep the current due date of work orders until the rest of the company can handle the extra components that can be produced after the change. / Syftet med denna uppsats är att utveckla en modell som ska vägleda ett företag mot ett beslut om man ska ändra den nuvarande tidpunkt när en arbetsorder ska vara färdigställd, eller inte. Modellen kommer att hjälpa företaget att påvisa de tekniska och finansiella faktorer som kommer att påverkas och hur dessa kan bedömas. Efter att ha gjort en grundlig litteraturstudie kunde vi inte hitta några existerande modeller inom detta specifika område. Vi utvecklade en modell för att täcka denna brist i den existerande teorin. Vi använde oss av en fallstudie för att testa vår utvecklade modell på Elitfönster i Lenhovda som tillverkar fönster. Vi applicerade vår modell på maskinverkstaden och förändringen handlade om att gå från att färdigställa arbetsorder på en vecka till att färdigställa dem på en dag. De tekniska faktorer som skulle påverkas av en förändring är; ställtiderna, ledtiden och mängden producerade komponenter. De finansiella faktorerna som kommer att påverkas är mängden bundet kapital samt bemanningen. Vi kom fram till att en förändring inte kunde genomföras utan att köpa in en extra hyvel. Modellen visade också att de finansiella fördelarna som en förändring skulle generera inte skulle motsvara de kostnader som den extra hyveln skulle orsaka. Våra rekommendationer till företaget är således att fortsätta med den nuvarande tidpunkt när en arbetsorder ska vara färdigställd tills resten av företaget kan hantera de extra komponenter som skulle kunna bli producerade efter förändringen.

<p>The purpose of this thesis is to develop a model that will guide a company towards a decision of whether to</p><p>change the current due date of work orders or not. The model will help the company to reveal the technical and</p><p>financial factors that will be affected and how these factors can be assessed. After accomplishing a thorough</p><p>literature review, we found no existing practical models in this specific area. We developed a model to cover this</p><p>gap in the existing theories. A case study approach was used to test the developed model on our case company</p><p>Elitfönster in Lenhovda who manufactures windows. We applied our model at the processing department and the</p><p>change concerned going from a weekly to a daily due date of work orders. The technical factors that would be</p><p>affected by the change of the due date are; setup times, lead time and output of components. The financial</p><p>factors that will be affected are the tied-up capital and the manning. We found that a change could not be carried</p><p>through without a purchase of an extra plane. The model also showed that the financial benefits that the change</p><p>generated could not surpass the costs that an extra plane would cause. Thereby, our recommendations to the</p><p>case company are to keep the current due date of work orders until the rest of the company can handle the extra</p><p>components that can be produced after the change.</p> / <p>Syftet med denna uppsats är att utveckla en modell som ska vägleda ett företag mot ett beslut om man ska</p><p>ändra den nuvarande tidpunkt när en arbetsorder ska vara färdigställd, eller inte. Modellen kommer att hjälpa</p><p>företaget att påvisa de tekniska och finansiella faktorer som kommer att påverkas och hur dessa kan bedömas.</p><p>Efter att ha gjort en grundlig litteraturstudie kunde vi inte hitta några existerande modeller inom detta specifika</p><p>område. Vi utvecklade en modell för att täcka denna brist i den existerande teorin. Vi använde oss av en</p><p>fallstudie för att testa vår utvecklade modell på Elitfönster i Lenhovda som tillverkar fönster. Vi applicerade vår</p><p>modell på maskinverkstaden och förändringen handlade om att gå från att färdigställa arbetsorder på en vecka</p><p>till att färdigställa dem på en dag. De tekniska faktorer som skulle påverkas av en förändring är; ställtiderna,</p><p>ledtiden och mängden producerade komponenter. De finansiella faktorerna som kommer att påverkas är</p><p>mängden bundet kapital samt bemanningen. Vi kom fram till att en förändring inte kunde genomföras utan att</p><p>köpa in en extra hyvel. Modellen visade också att de finansiella fördelarna som en förändring skulle generera</p><p>inte skulle motsvara de kostnader som den extra hyveln skulle orsaka. Våra rekommendationer till företaget är</p><p>således att fortsätta med den nuvarande tidpunkt när en arbetsorder ska vara färdigställd tills resten av företaget</p><p>kan hantera de extra komponenter som skulle kunna bli producerade efter förändringen.</p>