An enhanced solution approach for multi-period discrete manufacturing product assembly inventory routing problem with supply failure risks and customer demand uncertainty

Purpose This study primarily aims to develop and solve an enhanced optimisation model for an assembly product multi-period inbound inventory routing problem (IRP). The many-to-one (inbound) model considers the bill of materials (BOM), supply failure risks (SFR) and customer demand uncertainty. The secondary objective is to study the influence of potential time-dependent model variables on the overall supply network costs based on a full factorial design of experiments (DOE). Design/methodology/approach A five-step solution approach is proposed to derive the optimal inventory levels, best sourcing strategy and vehicle route plans for a multi-period discrete manufacturing product assembly IRP. The proposed approach considers an optimal risk mitigation strategy by considering less risk-prone suppliers to deliver the required components in a specific period. A mixed-integer linear programming formulation was solved to derive the optimal supply network costs. Findings The simulation results indicate that lower demand variation, lower component price and higher supply capacity can provide superior cost performance for an inbound supply network. The results also demonstrate that increasing supply capacity does not necessarily decrease product shortages. However, when demand variation is high, product shortages are reduced at the expense of the supply network cost. Research limitations/implications A two-echelon supply network for a single assembled discrete product with homogeneous vehicle fleet availability was considered in this study. Originality/value The proposed multi-period inbound IRP model considers realistic SFR, customer demand uncertainties and product assembly requirements based on a specific BOM. The mathematical model includes various practical aspects, such as supply capacity constraints, supplier management costs and target service-level requirements. A sensitivity analysis based on a full factorial DOE provides new insights that can aid practitioners in real-life decision-making.