<p>This study models a hybrid manufacturer that replenishes semi-finished inventory, decides how much work to complete before demand realization, and selects the inbound transportation mode used for each product family. The decision variables are product-family order quantities, pre-completion levels, and transportation modes; reorder points are computed from the cycle-service requirement once lead time and demand variability are known. The objective combines annual ordering, supplier processing, manufacturer finishing, transportation, holding, and shortage-related costs under warehouse, budget, and finishing-labor constraints. In the base instance, the optimal policy assigns different completion regimes across product families, showing that a uniform postponement or pre-completion rule can be either infeasible or unnecessarily costly. Pure postponement fails when finishing capacity is tight, while expedited inbound transportation is economical only when its reduction in inventory and shortage exposure exceeds the freight premium. Robustness tests with stochastic lead times and dynamic demand pressure show that completion timing mainly reallocates labor between supplier and finishing stages, whereas transportation choice substitutes freight cost for lead-time-driven service exposure. A resilience assessment based on absorption, adaptation, and residual recovery gap further shows how semi-finished inventory form and inbound-mode flexibility affect disruption response.</p>

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Coordinating inbound logistics, inventory control, and order decoupling point in hybrid manufacturing systems

  • Iman Ghalehkhondabi

摘要

This study models a hybrid manufacturer that replenishes semi-finished inventory, decides how much work to complete before demand realization, and selects the inbound transportation mode used for each product family. The decision variables are product-family order quantities, pre-completion levels, and transportation modes; reorder points are computed from the cycle-service requirement once lead time and demand variability are known. The objective combines annual ordering, supplier processing, manufacturer finishing, transportation, holding, and shortage-related costs under warehouse, budget, and finishing-labor constraints. In the base instance, the optimal policy assigns different completion regimes across product families, showing that a uniform postponement or pre-completion rule can be either infeasible or unnecessarily costly. Pure postponement fails when finishing capacity is tight, while expedited inbound transportation is economical only when its reduction in inventory and shortage exposure exceeds the freight premium. Robustness tests with stochastic lead times and dynamic demand pressure show that completion timing mainly reallocates labor between supplier and finishing stages, whereas transportation choice substitutes freight cost for lead-time-driven service exposure. A resilience assessment based on absorption, adaptation, and residual recovery gap further shows how semi-finished inventory form and inbound-mode flexibility affect disruption response.