1. Network Design for
Closed Loop Supply Chain Systems
---Energy Consumption and Time Delay
• Tutor :
Nachiappan Subramanian
Associate Professor
University Of Nottingham, Ningbo
• Students
Dinesh kumar
Industrial and Systems Engineering
Indian Institute of Technology,Kharagpur
Ying Jun(PhD)
Business School
University of Nottingham, Ningbo.
2. Outline大纲
• Motivations研究的动机
• Introduction to Close Loop Supply Chain环闭式供应链……………………………
• Introduction to remanufacture再制造………………………..
• Remanufacture in China再制造在中国……………………………………………………….
– Network of Reverse Logistics in China 反向物流网络
– Policy for remanufacture in China 政策
– Customer demand of remanufactured product in China 顾客需求
• Contributions 研究的贡献
• Mathematics Model 数学模型
manufacture
remanufacture
disassemble
3. Motivation
研究的动机
Large Gap to Fill
• In 2009,remanufactured engine was about 110
thousand in amount,60 thousand of gearbox, 1
million of generator and starting motor in total. Value
of them was less than 2.5 billion RMB, while this
number in the USA reached 50 billion dollars few
years before.
• Car holding number in china is 40% of America, but
the value that remanufacture create is only 1% of that
in the USA
• 中国汽车工业s协会统计的数据显示:2009年,再制造发动机约
11万台,再制造变速器约6万台,再制造发电机、起动机100万
台左右,产值不到25亿元。几年前美国汽车零部件再制造年产
值已经达到500亿美元。
• 国汽车保有量已经达到美国的40%,但发动机再制造的比例和
汽车再制造的总产值仅相当于美国的接近1/100,发展明显滞后
0
2000
4000
6000
8000
10000
12000
14000
16000
Number of
Cars 汽车
拥有量
(万量)
Counted
Scrapped
number计
算报废量
(万量)
In 2009, over 2 million scraped cars were
disassembled. By forecasting, the number will
be 10 million every year after 2020.
2009年,全国回收拆解报废汽车超过200万辆,
预计2020年以后,每年回收拆解报废汽车将
在1000万辆左右
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
0.6
0
50
100
150
200
250
Car Production
rate of change
Benefits: 再制造的益处
• Remanufacturing is more desirable than recycling
• Saving mechanism:
Raw material saving & Energy saving
6. Remanufacture再制造
Disassemble center
拆解中心
•Inspection for their ability to be remanufacture检验
•Disassembling拆解
•Cleaning 清洁
•And then distributed to remanufacture plant for retreat OR to
material recycler 分配去再制造或者原料回收处
Remanufacture plant
再制造中心
• Repair (+ upgrade) 修理(+功能升级)
• Reassemble在组装
Manufacture plant
生产基地
•Save 50% of the cost than the new product 比新品
节省一半花费
• Substitute new products 代替新品用在售后修理中
remanufacture should be done by OEM(original
equipment manufacture) can retain more asset
value of return products
Than 3rd parties
Prevent from reducing sale of new productions,
产品原有生产者应该负责物品回收和再制造,因为他们会比第三
方更能够 恢复产品价值,而且再制造比新品节省费用,而且避
免了和自己产品的竞争
Not all products prefer
remanufacture environmentally.
• new products with a high
diffusion rate
不是所有的产品都适合再制造
• 更新换代快的产品不适合
In Close loop Supply
Chain, all materials
in products need to
be reused at their
end of life.
环闭供应链中,产品中所
有材料都需要再利用
•Direct reuse直接再用
• Repair修理
• Refurbishing 修整
•
• Cannibalization 同型装配
Recover (End of Life) products
Back to their original phase
恢复到产品原始状态
Upgrade products
in function
功能上升级
7. Network
回收系统
• The RL network in china is very complex 中国回收系统很复杂
Customer
顾客
Repairing-store/
Retailer/wholesaler
经销商
Remanufacture
再制造者
Dismantler
(to deregister)
拆解者(注销)
original manufacturer or
authorized remanufacture
由原生产厂家或授权再制造厂家提
供支持
Second hand
market
二手市场
注销/以旧换新车辆不可进入
Sold to
repairing
companies/i
ndividual
卖给修理厂
家/个人
Import old parts
进口不良旧件
Repairable可修理
Non-Repairable
不可修理
8. Policy政策
Established step by step
the Technical Policy for Automotive Products Recovery was released, detailed supporting
polices come out gradually.
start
to
menti
on,
but
forbid
den a
lot
约束
作用
。拆解的
“五大总
成”应当
作为废金
属,交售
给钢铁企
业作为冶
炼原料
Free
add-
value
tax 报
废汽车回
收企业
免缴
增值
税
Design with
recyclable materials.
Rate of
Recovery设计
道路车辆时,考虑车
辆的再利用性。
新车在投放市
场前,制造商要
计算出其可再利用
率和可回收利用
率,用占车辆质量
的百分比。
计算包括可再
使用或可再利
用的零部件的
质量
国家逐步将汽车回收利用率指
标纳入汽车产品市场准入许可管
理体系。
节约资源和有效利用能源
2010年起汽车生产企业或进口
汽车总代理商要负责回收处理其销售
的汽车产品及其包装物品,也可委托相
关机构、企业负责
Import 允许进口车用发电机、
起动机及微电机进行再制造用于
汽车维修
14个龙头企业选定去做再制造
NDRC published 14 enterprises as
pilot automotive components
remanufacturers and released the
administrative method for pilot automotive
components remanufacturing. Five
assemblies, such as engine,
transmission, steering gear,
starter and generator, will be
remanufactured.
汽车以旧换新实施办法
帮助企业得到回收资源。
开始着重淘汰“黄标车”
提高了部分车型老旧汽车报废更新的补贴
标准。加快了更新换代。
Resource conservation has became the main
criteria in circular economy promotion law
adopted in 2009.
强制报
废标准
实施。
提高汽
车使用
效率
零部件制造
商也要考虑
再制造率
2001 2003 2004 2006 2008
2009 2013
地方政府不了解再制造,而
且中央没有强制,所以推行
的很慢the Local Vehicle
Administration Station of
Public Security Authorities are
not familiar with the
remanufactured engines, they
prohibited the legal change of
engine number. But Only
Time problem!
9. Remanufacture companies in China
中国的再制造企业• 14 selected in 2008 & Other remanufactured companies recently
中国第一汽车集团公司
JiLin, ChangChun
安徽江淮汽车集团有限公司
Anhui, HeFei
奇瑞汽车有限公司
Anhui, Wuhu
上海大众联合发展有限公司
(上海大众汽车有限公司授权)
Shanghai
浙江万里扬变速器有限公司
浙江省金华市
Zhejiang,JinHua
潍柴动力(潍坊)再制造有
限公司(潍柴动力股份有限
公司授权)
山东潍坊 中外合资
ShanDong
济南复强动力有限公司(中
国重型汽车集团有限公司授
权)
中英合资企业
ShanDong, JiNan
柏科(常熟)电机有限公司
江苏常熟 香港公司
JiangSu, ChangShu
广州市花都全球自动变速箱
有限公司(东风悦达起亚汽
车有限公司等授权)
民营
GuangZhou
广西玉柴机器股份有限公司
广西玉林 中外合资
GuangXi, YuLin
中国人民解放军第六四五六
工厂
国有企业
Chinese Liberation
Army factory
东风康明斯发动机有限公司
湖北襄阳 中美合资
HuBei, XiangYang
武汉东风鸿泰控股集团有限
公司(东风汽车公司授权)
国有控股企业
HuBei, WuHan
陕西法士特汽车传动集团有
限责任公司
陕西西安 外商独资
ShanXi
2011
天奇股份(002009.SZ)公告,
已与德国ALBA签署框架协议
2012
日本 在北京设立了汽车废品回
收系统的研发及实践部门。
The New Energy and Industrial
2013.03
长城汽车
获得了汽车发动机再制造国
家试点资质
张家港富瑞特种装备
股份有限公司
10. Market/Customer Demand
市场/顾客需求
Customer conscious 顾客的购买意识
higher income people with lower willingness to buy.
高收入的人反而不想要买再制造品
Reasons 原因:
• They don’t believe the quality of remanufactured products----let them try
顾客不相信再制造品的质量------无偿/有偿的让他们去尝试
• Someone bought “remanufactured” labeled product which is far worse than the original,
they promote this information and never come back again------strengthen supervision in
remanufactured market (Quality inspection departments are building 泰安国家再制造机械产品质检中心正在筹
建 2014.07.02 News)
有的顾客买了所谓的劣质“再制造”零部件,他们散布消息并且再也不会来买再制造品------加厂质检部们的监督力
度(事实上,国家正在各地积极建设再制造产品的质检中心building 泰安国家再制造机械产品质检中心正在筹建
2014.07.02 News
• Other industries 其它产业的再制造
Electronic, Old clothes, 电子,旧衣服的再制造在中国已经被慢慢接受。
remanufactured has been accepted by Chinese customers gradually. Time needed!
remanufactured
automotive
components
再制造汽车零部件
secondhand products
of poor quality
劣质的二手商品
11. Literature Review
文献
Year
Published
Objective(s)
Pharmaceutical sector.
Amaro et al.
2008 Profit
收益
agro-industrial sector: The case of the palm oil
Lizarazo et al.
2013 Profit (energy cost,)
收益(能源花费)
General model
Alumur et al.
2012 Profit
收益
Computer industries
Kusumastuti et al. Lee et al.
2007,
2006
Cost 花费
Cost 花费
Electronic field in Portuguese
Gomes et al. [26].
2009 Cost花费
automotive battery industry
Schultmann [4]
2005 Distance距离
Paksoy et al 2010 Gas Emission 污染
气体排放
John W.S. et.al 2008 Energy consumption
能源消耗
Timothy G.G Gutowski et. al 2011 Energy
能源
King et al. 2007 Environment &
Energy 环境和能源
Case Studies & Their model objectives
Very few papers mentioned
energy consumption
非常少的文章中用到能源
消耗
12. Contribution
本文的贡献
• Comprehensive model considering the economic, environmental and social aspects. 更加丰
富完整的模型,包涵经济,环境和社会三方面的信息。
• Minimizing of operating cost最小化操作花费
• Minimizing production costs最小化生产花费
• Maximizing the revenue最大化回报
Economic
经济
• Energy conservation 节约能源
• Material conservation 节约材料
• Reduction of waste materials 减少材料浪费
Environment
环境
• Customer satisfaction 顾客满意度
• Producer satisfaction. 生产中满意度
Social
社会
Emphasizes asset recovery process in
addition to operating costs. 重点强调物
品恢复过程中的操作花费
• Manufacture and remanufacture
energy 制作和再制造所用能量
• Use phase energy 物品使用中所
消耗能量
13. Time value in CLSC
在环闭供应链中时间的价值
But It is early product differentiation that determines profitability in reverse
logistics. 在反向物流中物品随时间的变化程度决定了它的可得利益大小。
Reverse facilities
各个再利用操作地
Collection
centers回收中心
Minimum Possible Time Delays
最小化时间延迟
Distance距离
Creates
Inventory
产生库存
Creates time delay in
the process
在过程中造成延后
Cost efficient reverse
networks
成本效益的反向物流
Time delays
时间延迟
Inventories
库存
Results in loss of return
product value due to
depreciation
导致返回物品价值的流失
So we proposed our model to 因此我们得出以下模型
14. Asset Loss Due To Time Delays
由于时间延迟而导致的物品价值流失
• Source来源: Blackburn J.D., Daniel V., Souza G.C., Van L.N. (2006) Reverse Supply Chain for commercial
returns 即刻返回物品的反向供应链
回收物品的价值
时间
产品回收
操作过程延迟
花费和
延迟
再制造
再制造后的
价值
库存
开始邮寄
15. Responsive Supply Value Chain Model
及时响应型供应链模型
Supplier
供应商
OEM
设备原有
制造商
Distributors
分配者
Retailers
零售商
Customers
顾客
Collection
centres回
收中心
Repair
修理
Remanufacture
再制造
Disassembly
Centre拆解中
心
Disposal回
收或掩埋处
理
Flow in forward chain正向物流
Flow in reverse chain反向物流
Recovery facilities
产品恢复地点
Design of proposed Network is derived from 模型设计缘由
1) Observing the return practices in china中国物品回流现状
2) The research on design strategies for Closed-loop supply chain 环闭型供应链设计策略的研究
16. OBJECTIVES
模型的目标函数
OBJECTIVE 1
目标函数 1:
Terms considered in profit
calculation: 利润计算中需要考虑的项目
1) Sales of new and reused products
2) Cost of production
3) Cost of virgin material
4) Cost of remanufacturing a core
5) Acquisition of core
6) Transportation cost
1) 新产品和再利用产品的销量
2) 生产花费
3) 原料花费
4) 再制造产品花费
5) 核心探测
6) 交通花费
福利 = 利润 + 顾客盈余
想要花费的钱数
再利用物品的平均价格
新品的平均价格
To consider the lost value
of the core
17. Objective 2
目标函数 2
Energy consumed
during production of
raw materials原料生产
中能量消耗
Energy consumed
during manufacture
or remanufacture
生产或再制造中能量消耗
Energy consumed while
the product is in use
产品使用中能量消耗
Energy consumed for
virgin components in
remanufacturing
再制造中元部件能量消耗
总的能量消耗 = 生产中能量消耗 + 再制造中能量消耗
18. Outcome and Next Stage Plans
目前的得到的结论和下一步的计划
• By solving the model in matlab we observe that 通过MATLAB,得到的一些结论
At remanufacturability of 60% it saves a energy of saves 54% of energy.
At remanufacturability of 90% it saves an energy of 58% of energy.
再制造能力为60%时,再制造能够节省69%的能量
再制造能力为10%时,再制造能够节省40%的能量
• Next Stage Plans: 下一步的计划
• Analyze the loss of profits due to time delays.分析由于时间延迟而流失的利润
• To analyze the energy consumptions for more than one use cycle. 分析多于一个生
命周期的能量消耗
• Extend the model to a multi- period closed-loop network. 扩展模型,使其成为多
时期的环闭供应链系统