Reverse Material Flows Research Articles

Green logistics solutions

Today, climate change is the greatest challenge for future generations. In particular, logistics is perceived as a key sector to contribute to sustainable development meeting the future generations’ needs in terms of low greenhouse gas emissions in a socially and economically responsible way. Green logistics involves all attempts to reduce the ecological impact of peoples’ mobility, traffic systems and of transport in regional and global supply chains including the reverse flow of products and materials. The primary objective of this special issue is to reflect the sustainable development of logistics from various perspectives preferably in an integrated and holistic approach and to examine research issues concerned with quantitative analysis and decision support for supply network design, freight transport and logistics infrastructure. For this special issue eight papers from 36 submissions have been selected for publication after a thorough peer-review according to the standards of the FSM journal.

A Logística Reversa de Pós-Consumo: Um Estudo de Caso na Cooperativa Cootre de Esteio-RS

A global increase in customized products manufacturing has been noticed over the years and it has generated a high level of disposed material, which may cause damages to the environment. In this context, the present study aimed to identify the post-consumption reverse logistics practices in a recycling cooperative located at Esteio, in the State of Rio Grande do Sul, Brazil. To do so, a qualitative research with an exploratory approach and operationalized through a case study was carried out. Data about the cooperative activities and the way it performs its processes were collected through interviews and observations. The results show that the studied recycling cooperatives perform several reverse logistics practices, which are essential for the reverse flow of materials.

The Design of Integrated Logistics Management System of an Industrial Company

In the contemporary global business markets environment, when the business markets are getting more and more commercial, there are growing demand for effective management of material flows. The effectivity and effectiveness of planning, management and control the material flows across an industrial company and its distribution networks, represents one of the main pillar regarding the high level of competitive advantage within the frame of supply chains. Thus, the company information management system design should have also included a module of integrated logistics management system to ensure required level of material flow management effectivity and effectiveness. The article deals with brief description of the issues on company management, company information management systems and logistics management. Further it’s stated the methodology to created integrated logistics management system, which is containing the methodics to design logistics management sub-systems of purchasing, manufacturing, distribution and reverse material flows. The essential methodics of the stated methodology is the methodics to create independent demand forecasting sub-system.

A closed-loop supply chain network design for automotive industry in Turkey

Increasing worldwide environmental and social concerns are motivating manufacturers and consumers to implement recycling strategies such as product recovery, waste management or usage of recycled materials. Besides environmental and social concerns, in some countries legislations also force recycling of products such as end-of-life vehicles (ELVs). Automotive manufactures in Turkey are responsible for free take-back of ELVs from consumers to reintegrate used parts into industry according to ELVs regulation by Republic of Turkey Ministry of Environment and Urbanization. Regarding mentioned motivation, in this study a closed-loop supply chain (CLSC) is presented, based on a case study considering the ELVs treatment in Turkey. A linear programming (LP) model is developed to handle the reverse material flows with regard to reintegrate them into forward supply chains. Several CLSC scenarios are discussed to show the performance of the proposed model and its applicability in the automotive industry.

Closed-loop supply chains: What reverse logistics factors influence performance?

This paper analyses the inventory and order flow dynamics in closed-loop supply chains (CLSCs). In this kind of supply chains the reverse flow of materials entering the system for recycling purposes complicates the way in which inventories should be managed and replenishment policies should be designed. Specifically, we analyse the relationships between some reverse logistics’ factors (remanufacturing lead-time, return rate of recycled products, reverse order policy, and number of supply chain tiers) on the order and inventory variance amplification. We firstly perform a systematic literature review of the related studies. Secondly, by adopting a difference equation math approach and design of experiment we perform a robust what-if analysis of a CLSC under a variety of operational and market conditions. Results show that, ceteris paribus, CLSC outperforms a forward supply chain, both in mono-echelon and multi-echelon structures and under both stationary and turbulent market demands. Furthermore, reducing remanufacturing lead-time and promoting information transparency may be crucial to improve CLSC dynamics. Finally, we use the research findings to provide interesting managerial consideration about how to reduce unnecessary operational members’ costs.

A New Extended MILP MRP Approach to Production Planning and Its Application in the Jewelry Industry

It is important to manage reverse material flows such as recycling, reusing, and remanufacturing in a production environment. This paper addresses a production planning problem which involves reusing of scrap and recycling of waste that occur in the various stages of the production process and remanufacturing/recycling of returns in a closed-loop supply chain environment. An extended material requirement planning (MRP) is proposed as a mixed integer linear programming (MILP) model which includes—beside forward—these reverse material flows. The proposed model is developed for the jewelry industry in Turkey, which uses gold as the primary resource of production. The aim is to manage these reverse material flows as a part of production planning to utilize resources. Considering the mostly unpredictable nature of reverse material flows, the proposed model is likewise transformed into a fuzzy model to provide a better review of production plan for the decision maker. The suggested model is examined through a case study to test the applicability and efficiency.

Reverse Material Flow of Worn-Out Conveyor Belts

Options for further use of worn-out conveyor belts were analysed and examined within the frame of research about options of reverse logistics. Reverse logistics has importance because one of the most important elements of reverse logistics is presented by wastes. By the research it is examined the reverse logistics network system for wastes. The article presents partial results of the aforesaid research in the field of reverse material flow of rubber wastes, especially results of theoretical knowledge of the current state of reverse material flow of rubber wastes in Slovak republic and re-processing of rubber wastes.

Numerical analysis of heat generation and temperature field in reverse dual-rotation friction stir welding

A 3D model is developed for numerical analysis for heat generation, temperature field, and material flow in reverse dual-rotation friction stir welding (RDR-FSW) process. The reverse rotation of the assisted shoulder and the tool pin is considered to determine the heat generation rate. Friction heat, plastic deformation heat, and their partition coefficients are analyzed. Due to the tool pin and assisted shoulder being separated and reversely rotated independently, the temperature difference between the advancing and retreating sides is weakened. The reverse material flow is beneficial to the uniformity of both the temperature and microstructure at the advancing and retreating sides. The calculated temperature profiles agree well with the corresponding experimentally measured values.

An emergy-based evaluation of a reverse logistics network for steel recycling

Abstract Efficient implementation of recycling networks requires appropriate logistical structures for managing the reverse flow of materials from users to producers. The steel sheet distributor studied had established a protocol for scrap recovery with the steel plant and its customers. The company invested in producing containers, hiring a specialized labor force and in purchasing trucks for container transportation to implement the logistics network for recycling. That network interconnected the company with two kinds of customers: the ones returning scrap and the ones who preferred to continue business-as-usual. The logistical network was analyzed using emergy synthesis, and the data obtained were used to evaluate and compare the system's environmental costs and benefits from the perspective of the distributor and the steel plant operator. The use of emergy ternary diagrams provided a way to assess recycle strategies to compare the relative economic and environmental benefits of the logistical network implemented. The minimum quantity of scrap that the distributor must recover to improve environmental benefits was determined allowing decision on whether it is worth keeping the system running. The new assessment method proposed also may help policy-makers to create strategies to reward or incentive users of reverse logistics, and help to establish regulations, by decreasing taxes or stimulating innovation, for effectively implement the National Policy on Solid Waste.

Remanufacturing in automotive industry: Challenges and limitations

Purpose: The aim of this paper is to provide the framework for management of reverse flow of materials in automotive industry. The emphasis is placed on the remanufacturing activities. Materials management in such conditions is a real challenge. The cause for this is parallel use of raw materials and reused materials. Such hybrid flows of materials are characterized by increased level of uncertainty connected with amount, quality and timing. Design/methodology/approach: This paper presents a comprehensive review of remanufacturing and traditional manufacturing. The stabilization of reverse flows is crucial for continuity of remanufacturing operations. The simulation model and results are discussed regarding stabilization of the reverse flows. Findings: Authors identify main problems that appear in the area of combining at the production system forward and reverse flows of materials. The agent-based technology is applied for configuration and stabilization of reverse network.

Remanufacturing in automotive industry: Challenges and limitations

Purpose: The aim of this paper is to provide the framework for management of reverse flow of materials in automotive industry. The emphasis is placed on the remanufacturing activities. Materials management in such conditions is a real challenge. The cause for this is parallel use of raw materials and reused materials. Such hybrid flows of materials are characterized by increased level of uncertainty connected with amount, quality and timing. Design/methodology/approach: This paper presents a comprehensive review of remanufacturing and traditional manufacturing. The stabilization of reverse flows is crucial for continuity of remanufacturing operations. The simulation model and results are discussed regarding stabilization of the reverse flows. Findings: Authors identify main problems that appear in the area of combining at the production system forward and reverse flows of materials. The agent-based technology is applied for configuration and stabilization of reverse network. Research limitations/implications: Paper is case – oriented. Practical implications: Both logistician and IT researchers might benefit from authors approach. Originality/value: Authors provide an interdisciplinary approach combining operations management, logistics and information technology.

A structural framework for closed‐loop supply chains

PurposeThe concept of the customer order decoupling point (CODP) has been used in many different contexts as an important structural concept for the traditional forward supply chain. The CODP is rarely explicitly applied in reverse supply chain management and the purpose of this paper is to show that the CODP can be an important corner stone of a framework for analysis of the closed‐loop supply chain containing both forward and reverse material flows.Design/methodology/approachConceptual similarities are identified using analogies between forward and reverse supply chains. First, the concepts are discussed in their original context of forward flows and thereafter the concepts are applied on reverse flows. Finally, a holistic closed‐loop model is established.FindingsThe conventional CODP framework for forward flow supply chains can be extended to cover also reverse material flows and therefore providing a foundation for a more comprehensive discussion of closed‐loop supply chains useful in both education, research, and industrial applications. Using the suggested extended framework it is possible to identify nine fundamental supply chain configurations.Practical implicationsDifferentiating between demand driven and forecast driven activities plays a critical role in practical supply chain management and this paper highlights that this approach also can be applied to closed‐loop supply chains and therefore extending the reach of the toolbox previously developed for the forward supply chain.Originality/valueThe concept CODP has not previously been comprehensively treated for the closed‐loop supply chain and this paper provides a foundation for establishing a strategic structural framework for discussing issues such as lean vs agile and balancing efficiency and responsiveness in a more comprehensive context involving also reverse material flows.

Optimal policy for a closed-loop supply chain inventory system with remanufacturing

Previous researchers have developed ways of managing forward-oriented supply chains, and gave insight to solve single-stage inventory systems. In this study, we analyze an inventory system with traditional forward-oriented material flow as well as a reverse material flow supply chain. In the reverse material flow, the used products are returned, remanufactured and shipped to the retailer for resale. A multi-echelon inventory system with remanufacturing capability is proposed. We then develop a closed-loop supply chain inventory model and maximize the joint profits of the supplier, the manufacturer, the third-party recycle dealer and the retailer under contractual design. The analytical results of this study show a significant increase in the joint profit when the integrated policy is adopted.

Modeling reverse logistic tasks within closed-loop supply chains: An example from the automotive industry

In this contribution, the peculiarities of establishing a closed-loop supply chain (CLSC) are presented, based on an example considering the end-of-life vehicle (ELV) treatment in Germany. Different design options for a CLSC are put up, concentrating on how reverse material flows can be handled with regard to reintegrate them into their genuine supply chains. Reverse logistics aspects are modeled with vehicle routing planning. Introducing a problem-tailored algorithm, results of several CLSC scenarios are discussed which are based on real case data, depicting measures from German ELV stakeholders.

Accounting for reverse logistics activities

Traditional logistics systems aim at minimising total (logistics) costs. At the same time, these systems focus on forward material flows in the supply chain. Concerns for the environment, and warranty related product returns have led to both end-of-life and commercial product take-backs, introducing the question of reverse material flows in these systems. These are backward moving inventories that have to be (re-)processed and show several coupling points to the forward materials flows in the logistics system. We argue that modern accounting systems are challenged with the phases of remanufacturing and refurbishment in the reverse supply chain. Many reverse logistics and reprocessing activities are integrated in other corporate processes, and their costs are difficult to separate from other cost objects, hindering the correct costing of reverse flows. By an analogy to safety management accounting, this paper proposes an activity-based method to account for the costs of reverse material flows. Accounting for these costs will help to take a more holistic view on total logistics costs and improve management control of logistical flows