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Coordinating a three-level supply chain with learning-based continuous improvement

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  • Jaber, Mohamad Y.
  • Bonney, Maurice
  • Guiffrida, Alfred L.

Abstract

Learning curve theory has been widely used as a managerial tool to describe and model product and process improvement. This paper investigates a three-level supply chain (supplier-manufacturer-retailer) where the manufacturing operations undergo a learning-based continuous improvement process. Improvements in the manufacturer's operation are characterized by enhanced capacity utilization, reductions in set-ups times, and improved product quality through the elimination of rework. As a result of these continuous improvements, the manufacturer can justify a production policy that is based on more frequent, smaller lot size production. For this production policy to be practical and not sub-optimal to the supply chain, the manufacturer must integrate its lot-sizing models with the replenishment policies of its upstream raw material suppliers and the demand requirements of its downstream customers (retailers). Mathematical models that achieve chain-wide lot-sizing integration are developed and solution procedures for the models are illustrated by numerical examples. The results demonstrate that learning-based improvements in set-up time and rework allow retailers to order in progressively smaller lot sizes as the manufacturer offers larger discounts and profits and that the entire supply chain benefits from implementing learning-based continuous quality improvements. The results also demonstrate that forgetting effects lead to increases in supply chain costs.

Suggested Citation

  • Jaber, Mohamad Y. & Bonney, Maurice & Guiffrida, Alfred L., 2010. "Coordinating a three-level supply chain with learning-based continuous improvement," International Journal of Production Economics, Elsevier, vol. 127(1), pages 27-38, September.
  • Handle: RePEc:eee:proeco:v:127:y:2010:i:1:p:27-38
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    1. Hoque, M.A., 2011. "Generalized single-vendor multi-buyer integrated inventory supply chain models with a better synchronization," International Journal of Production Economics, Elsevier, vol. 131(2), pages 463-472, June.
    2. Zhang, Shichen & Zhang, Jianxiong, 2018. "Contract preference with stochastic cost learning in a two-period supply chain under asymmetric information," International Journal of Production Economics, Elsevier, vol. 196(C), pages 226-247.
    3. Nasr, Walid W. & Jaber, Mohamad Y., 2019. "Supplier development in a two-level lot sizing problem with non-conforming items and learning," International Journal of Production Economics, Elsevier, vol. 216(C), pages 349-363.
    4. Kumar, Patanjal & Baraiya, Rajendra & Das, Debashree & Jakhar, Suresh Kumar & Xu, Lei & Mangla, Sachin Kumar, 2021. "Social responsibility and cost-learning in dyadic supply chain coordination," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 156(C).
    5. Bazan, Ehab & Jaber, Mohamad Y. & Zanoni, Simone & Zavanella, Lucio E., 2014. "Vendor Managed Inventory (VMI) with Consignment Stock (CS) agreement for a two-level supply chain with an imperfect production process with/without restoration interruptions," International Journal of Production Economics, Elsevier, vol. 157(C), pages 289-301.
    6. Yamane, Yasuo & Takahashi, Katsuhiko & Hamada, Kunihiro & Morikawa, Katsumi & Nur Bahagia, Senator & Diawati, Lucia & Cakravastia, Andi, 2015. "Developing a plant system prediction model for technology transfer," International Journal of Production Economics, Elsevier, vol. 166(C), pages 119-128.
    7. Zanoni, Simone & Jaber, Mohamad Y. & Zavanella, Lucio E., 2012. "Vendor managed inventory (VMI) with consignment considering learning and forgetting effects," International Journal of Production Economics, Elsevier, vol. 140(2), pages 721-730.
    8. Hosseini-Motlagh, Seyyed-Mahdi & Govindan, Kannan & Nematollahi, Mohammadreza & Jokar, Abbas, 2019. "An adjustable bi-level wholesale price contract for coordinating a supply chain under scenario-based stochastic demand," International Journal of Production Economics, Elsevier, vol. 214(C), pages 175-195.
    9. Heuser, Patricia & Tauer, Björn, 2023. "Single-machine scheduling with product category-based learning and forgetting effects," Omega, Elsevier, vol. 115(C).
    10. Panda, S. & Modak, N.M. & Basu, M. & Goyal, S.K., 2015. "Channel coordination and profit distribution in a social responsible three-layer supply chain," International Journal of Production Economics, Elsevier, vol. 168(C), pages 224-233.
    11. Utama, Dana Marsetiya & Santoso, Imam & Hendrawan, Yusuf & Dania, Wike Agustin Prima, 2022. "Integrated procurement-production inventory model in supply chain: A systematic review," Operations Research Perspectives, Elsevier, vol. 9(C).
    12. Dai, Zhuo & Aqlan, Faisal & Gao, Kuo, 2017. "Optimizing multi-echelon inventory with three types of demand in supply chain," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 107(C), pages 141-177.
    13. Bonney, Maurice & Jaber, Mohamad Y., 2013. "Developing an input–output activity matrix (IOAM) for environmental and economic analysis of manufacturing systems and logistics chains," International Journal of Production Economics, Elsevier, vol. 143(2), pages 589-597.
    14. Araneda-Fuentes, Cristina & Lustosa, Leonardo Junqueira & Minner, Stefan, 2015. "A contract for coordinating capacity decisions in a business-to-business (B2B) supply chain," International Journal of Production Economics, Elsevier, vol. 165(C), pages 158-171.
    15. Glock, Christoph H., 2012. "The joint economic lot size problem: A review," International Journal of Production Economics, Elsevier, vol. 135(2), pages 671-686.
    16. Meng, Qingfeng & Li, Zhen & Liu, Huimin & Chen, Jingxian, 2017. "Agent-based simulation of competitive performance for supply chains based on combined contracts," International Journal of Production Economics, Elsevier, vol. 193(C), pages 663-676.
    17. Chen, Jingxian & Liang, Liang & Yao, Dong-qing, 2019. "Factory encroachment and channel selection in an outsourced supply chain," International Journal of Production Economics, Elsevier, vol. 215(C), pages 73-83.

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