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An Integrated Outbound Logistics Model for Frito-Lay: Coordinating Aggregate-Level Production and Distribution Decisions

Author

Listed:
  • Sıla Çetinkaya

    (Department of Industrial and Systems Engineering, Texas A&M University, College Station, Texas 77843)

  • Halit Üster

    (Department of Industrial and Systems Engineering, Texas A&M University, College Station, Texas 77843)

  • Gopalakrishnan Easwaran

    (Department of Engineering, School of Science, Engineering and Technology, St. Mary's University, San Antonio, Texas 78228)

  • Burcu Baris Keskin

    (Department of Information Systems, Statistics, and Management Science, University of Alabama, Tuscaloosa, Alabama 35487)

Abstract
In this paper, we describe research to improve Frito-Lay's outbound supply chain activities by simultaneously optimizing its inventory and transportation decisions. Motivated by Frito-Lay's practice, we first develop a mixed-integer programming formulation from which we develop a large-scale, integrated multiproduct inventory lot-sizing and vehicle-routing model with explicit (1) inventory holding costs, truck loading and dispatch costs, and mileage costs; (2) production, storage, and truck capacity limitations; and (3) direct (plant-to-store) and interplant (plant-to-plant) delivery considerations. Second, we present an iterative solution approach in which we decompose the problem into inventory and routing components. The results demonstrate the impact of direct deliveries on distribution costs and show that direct deliveries and efficient inventory and routing decisions can provide significant savings opportunities over two benchmark models, one of which represents the existing Frito-Lay system. We implemented our models using an application that allows strategy evaluation, analysis of output files, and technology transfer. This application was particularly useful in evaluating potential direct-delivery locations and inventory reductions throughout the supply chain.

Suggested Citation

  • Sıla Çetinkaya & Halit Üster & Gopalakrishnan Easwaran & Burcu Baris Keskin, 2009. "An Integrated Outbound Logistics Model for Frito-Lay: Coordinating Aggregate-Level Production and Distribution Decisions," Interfaces, INFORMS, vol. 39(5), pages 460-475, October.
    • Handle: RePEc:inm:orinte:v:39:y:2009:i:5:p:460-475
    DOI: 10.1287/inte.1090.0450
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    References listed on IDEAS

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    2. Diana Sánchez-Partida & Rodolfo Rodríguez-Méndez & José Luis Martínez-Flores & Santiago-Omar Caballero-Morales, 2018. "Implementation of Continuous Flow in the Cabinet Process at the Schneider Electric Plant in Tlaxcala, Mexico," Interfaces, INFORMS, vol. 48(6), pages 566-577, November.
    3. Habibi, Muhammad Khakim & Hammami, Ramzi & Battaia, Olga & Dolgui, Alexandre, 2024. "Simultaneous Pickup-and-Delivery Production-Routing Problem in closed-loop supply chain with remanufacturing and disassembly consideration," International Journal of Production Economics, Elsevier, vol. 273(C).
    4. Manousakis, Eleftherios G. & Kasapidis, Grigoris A. & Kiranoudis, Chris T. & Zachariadis, Emmanouil E., 2022. "An infeasible space exploring matheuristic for the Production Routing Problem," European Journal of Operational Research, Elsevier, vol. 298(2), pages 478-495.
    5. Liqing Zhang & Sıla Çetinkaya, 2017. "Stochastic Dynamic Inventory Problem Under Explicit Inbound Transportation Cost and Capacity," Operations Research, INFORMS, vol. 65(5), pages 1267-1274, October.
    6. Yossiri Adulyasak & Jean-François Cordeau & Raf Jans, 2014. "Optimization-Based Adaptive Large Neighborhood Search for the Production Routing Problem," Transportation Science, INFORMS, vol. 48(1), pages 20-45, February.
    7. Zakaria Chekoubi & Wajdi Trabelsi & Nathalie Sauer & Ilias Majdouline, 2022. "The Integrated Production-Inventory-Routing Problem with Reverse Logistics and Remanufacturing: A Two-Phase Decomposition Heuristic," Sustainability, MDPI, vol. 14(20), pages 1-30, October.
    8. Neves-Moreira, Fábio & Almada-Lobo, Bernardo & Cordeau, Jean-François & Guimarães, Luís & Jans, Raf, 2019. "Solving a large multi-product production-routing problem with delivery time windows," Omega, Elsevier, vol. 86(C), pages 154-172.
    9. Cheng, Bayi & Leung, Joseph Y.-T. & Li, Kai & Yang, Shanlin, 2019. "Integrated optimization of material supplying, manufacturing, and product distribution: Models and fast algorithms," European Journal of Operational Research, Elsevier, vol. 277(1), pages 100-111.
    10. Amin Abbasi-Pooya & Michael T. Lash, 2024. "The third party logistics provider freight management problem: a framework and deep reinforcement learning approach," Annals of Operations Research, Springer, vol. 339(1), pages 965-1024, August.
    11. Mutlu, Fatih & Çetinkaya, Sıla, 2020. "Supplier–carrier–buyer channels: Contractual pricing for a carrier serving a supplier–buyer partnership," International Journal of Production Economics, Elsevier, vol. 230(C).

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