1. Introduction
Instead of a traditional business system, supply chain management (SCM) provides different kinds of business policies in terms of inventory management. The vendor managed inventory (VMI) is one of these in which the manufacturer takes full responsibility of the existing inventory at the buyer’s position. Dong and Xu [
1] found opportunities where buyers received more profit than the manufacturer. The manufacturer’s profit may vary according to the business policy, where the short-term and long-term VMI affects the SCM, which were decided by them. They concluded that the short-term VMI can be a competitor for coordination business policy. In any business, the forecasting uncertainty is a major issue and Guo et al. [
2] developed a method to reduce the supply chain forecasting uncertainty through information sharing via macro prediction which can reduce the system robustness. However, it is possible that not all information is shared by both parties. Then, unreliability occurs in the business system due to information asymmetry (Mukhopadhyay et al. [
3]; Yan and Pei [
4]; Xiao and Xu [
5]). An information basically flows in the upward direction of SCM. The lack of information of the manufacturer may cause insufficient supply of products which can affect the inventory and production process. The situation is even more complicated when an imperfect production process takes place (Sarkar [
6]). The rework of defective products was considered by Cárdenas-Barrón et al. [
7] for an imperfect production process. They developed an improved algorithm to find the optimum lot size and replenish the defective production system. Cleaner production can be formed by discarding defective products, which was established by Tayyab and Sarkar [
8]. Those defective products were reworked up to good quality through additional investment. This work was extended by multi-stage cleaner production by Kim and Sarkar [
9] using budget constraints. There are several researchers who worked on imperfect products, reworking, and deterioration (Guchhait et al. [
10], Majumder et al. [
11], Tiwari et al. [
12]). Finally, Sarkar [
13] introduced an exact duration for reworking within a multi-stage multi-cycle production system. However, there is a lack of literature regarding RFID, i.e., RFID was not used to maintain the inventory pooling effect. Reworking was considered by Sarkar et al. [
14] in a material requirement planning (MRP) system.
Production quantity mainly depends upon the market demand. In reality, it cannot always be the case that data related with demand are available. If no known distribution function is followed by the demand or no data are available, then instead of taking any arbitrary probability distribution, the distribution-free (DF) approach is used (Gallego and Moon [
15], Sarkar et al. [
16], Guchhait et al. [
17]). This method was invented by Scarf [
18]. Due to the complex calculations, it was not understandable to people in the industry at that time. Later, this approach was simplified by Gallego and Moon [
15]. This method is used by Sarkar et al. [
19] for a consignment stock-based newsvendor model. They allowed a fixed-fee payment technique to prevent loss from any participant. There are multiple manufacturers and retailers available for a single-type of products. Based on advertisements given by the manufacturer, retailers opted to choose their manufacturers. For the random demand, the variable production rate is useful (Sarkar et al. [
20]) for modeling uncertain demand. A service level can help avoid shortages (Moon et al. [
21]) and backorder (Sarkar [
22]) due to the uncertain random demand. Partial trade credit for deteriorating items in the inventory model was discussed by Tiwari et al. [
23]. For any industry, it may be that they need to analyze their previous data. Tiwari et al. [
24] provided a big data analysis of SCM from 2010 to 2016.
Competitive markets in the business industry becoming more intense everyday. To handle this situation, companies prefer to adopt smart technologies within the SCM. The fast movement of products for the electronic industry is a key feature since competition is very high in the electronics sector. The implementation of technology instead of labor-based production is helpful not only for fast production, but also to profit gain. The use of RFID technology in SCM for managing inventory has been studied by several researchers. A wireless sensing problem for coverage was first studied by Meguerdichian et al. [
25]. Zhang and Hou [
26] investigated how many readers need to be implemented to provide a complete coverage of a search area. The coverage area sensing radius and transmitting radius were discussed by Hefeeda and Ahmadi [
27]. They established that probabilistic sensing coverage can function as deterministic coverage. Dias [
28] implemented RFID for a multi-agent system. Sarac et al. [
29] surveyed the literature and found several implementation and usages of RFID in different sectors of SCM. They found that inventory loss can be reduced with increased efficiency of the system and real-time information of the inventory. Kim and Glock [
30] investigated the effectiveness of an RFID tracking system for container management and found that the return rate of container was increased after using RFID. A four-echelon SCM was studied by Sari [
31] to examine the effects of collaboration. They found through simulation that the integrated RFID technology is more beneficial for good collaboration between participants. Besides SCM, warehouse efficiency can be improved using RFID technology (Biswal et al. [
32]). In the production sector, RFID improves the efficiency and maintenance, as investigated by Chen et al. [
33]. They established that operation time can be increased by up to 89% and that the labor cost is reduced significantly by using RFID. Even, remanufacturing companies can get benefit from RFID via just-in-time (JIT) features or transiting towards a closed-loop SCM (Tsao et al. [
34]).
From literature, it is found in most of the studies that RFID is used in SCM to prevent inventory shrinkage as well as minimize the operation time of the system, reduction of lead time, and labor consumption (Ustundag and Tanyas [
35]; Jaggi et al. [
36]) and improve the efficiency. However, the reason behind this efficiency improvement by RFID is not discussed in the literature. This study introduces for the first time the RFID distance function
based on the sensing and transmitting radii. The distance between two readers can be optimized and thus, the number of RFID readers can be found to increase the efficiency. Based on the transmitting and sensing radii, two types of readers are used by the manufacturer, namely Type 1 and Type 2. To understand the complete search capacity of a Type 1 reader, the area is divided into sub-areas that are under the coverage of Type 2 readers. This combined system may enhances the system accuracy and provides strong coverage of the sensing and transmitting areas.
Table 1 gives the contribution of different authors in the literature. This study shows benefits for the buyer in the optimum order quantity, optimizes distance the between two readers, and optimizes the service given by the buyers. The rest of the study is designed as
Section 2 gives the details about the mathematical model.
Section 3 gives the results of the numerical experiment and
Section 4 provides a discussion of results.
Section 5 concludes this study. Associated references are attached in the References section.
3. Mathematical Modelling
A VMI contract policy for the electronic industry is discussed for a single-manufacturer and multi-buyer newsvendor model. The optimum number of RFID readers, which can cover the optimized distance, can provide maximum profit to the supply chain for a long time. As implementation of RFID requires a huge investment, a reasonable demand rate is expected for the manufacturer. However, the market demand
for buyer
i is uncertain, it cannot be predicted. The demand
for buyer
i can be represented by a random variable where the mean is
and
is the standard deviation which both are known. As
does not follow any specific distribution function, this problem can be solved using the DF approach. The surplus and shortage amount can be calculated by the lemma of Gallego and Moon [
15]. The required surplus amount is
and the shortage amount is
3.1. Structure of the Proposed RFID System
The total search area is covered by the RFID tracking system. The cost regarding RFID depends on the number of readers. The concept of VMI is that the manufacturer will manage the whole inventory of the retailer as some unreliable issues are coming from retailer’s side. To overcome these issues, the manufacturer introduces RFID technology with the minimum investment for it. Therefore, within the total area of the retailer, how much inventory are these, that should be verified by RFID readers. Therefore, it is not essential to use always powerful RFID readers like as Type 1 or similarly it is not recommended also that always low powerful Type 2 reader should be used. Hence, an optimization is needed to optimize the optimum number of Type 1 and Type 2 reader within the whole area. That is why, this model recommended two types of RFID reader for the sensing and coverage model: the disk sensing model and the exponential coverage model. The entire search area is divided into subareas which are covered by the Type 1 reader. This Type 1 reader has a higher sensing power for coverage, which uses the disk sensing model. Each subarea is divided into subareas those are covered by two Type 2 readers. Type 2 readers have low sensing power and use an exponential coverage protocol system. The connectivity between the sensing radius and transmitting radius is given by the condition
(for instance, see Zhang and Hou [
26]).
If
is the length and
is the breadth of each subdivided area, then from the properties of right-angled triangle (
Figure 1), it is follows that
For each square foot area,
, which implies that
Therefore, if the length and the breadth of the total search area are l and b, respectively, the total number of Type 1 reader is .
Now, each subdivided area of sensing radius
is divided into two areas with sensing radius
. The maximum distance between two Type 2 readers is
d, i.e.,
. Now, from the exponential coverage protocol (Hefeeda and Ahmadi [
27]), the maximum distance
d between two Type 2 readers is smaller than
, i.e.,
The area of the circle for sensing radius
is
. The area of circle of sensing radius
is
. Therefore, the number of Type 2 readers for each subdivided area of Type 1 reader is
. Hence, the total number of Type 2 readers for all Type 1 readers is
3.2. Manufacturer’s Model
In reality, it is not always the case that all buyers are reliable enough to share all information to the manufacturer. To prevent the piracy on the inventory inaccuracy, the manufacturer invests in RFID technology even though this may reduce the profit margins. However, there may be long-term benefits compensate the shrinkage of inventory. Still, there may be some ambiguity regarding information due to information asymmetry.
3.2.1. RFID Cost
The total area is covered by
Type 1 readers. This area is again subdivided and is covered by Type 2 readers. If
is the cost of each Type 1 reader and
is for each Type 2. A fixed cost is included within
and
which the manufacturer pays as an investment. Then the required RFID cost is given by
subject to the conditions
Therefore, the RFID cost per cycle is , where and .
3.2.2. Production Cost and Wholesale Price
If the manufacturer produces a lot size Q per cycle then the production cost of those products is given by . When the manufacturer sells products as a wholesale price w per unit, then the wholesale price is given by .
3.2.3. Holding Cost
The situation of holding products is created when the demand is less than the ordered quantity . If is the unit holding cost of buyer i, the holding cost is . As the manufacturer pays both the holding cost of the buyers and the manufacturer , the total holding cost of the manufacturer is given by .
3.2.4. Goodwill Lost Cost
A goodwill lost cost is allowed since the manufacturer takes the responsibility for the products for the whole supply chain, where shortage affects the goodwill of manufacturer. The cost expression for goodwill loss is given by .
Including the RFID cost, the expected total profit of the manufacturer is given by the following expression
subject to the conditions
3.3. Buyer’s Model
Buyers are unreliable resulting in information asymmetry. As this is a dependent business policy and the manufacturer is responsible for both inventory supervision and holding inventory for buyers, all information should be known to the manufacturer. However, today’s business systems are very complex and buyers are unreliable at sharing information their own business strategy. Buyer i buys the electronic products from the manufacturer and sells them in the market. To increase market demand, the buyers provide facilities to the customers without telling the manufacturer meaning that an unreliable supply chain system is formulated.
3.3.1. Revenue
is the unit selling price of the electronic products. Now, two types of situation may arise, where the demand
is more than the ordered quantity
or vice-versa. Then the selling price can be found as
3.3.2. Purchasing Cost and Goodwill Lost Cost
If w is the unit purchasing cost for the ordered quantity , then the purchasing cost is given by . When the reverse situation arises i.e., the demand is more than the ordered quantity, backordering occurs, meaning that some goodwill for buyer i is lost. The goodwill lost cost is given by where is the unit goodwill lost cost of buyer i.
3.3.3. Service Cost
The buyer provides extra services
to attract customers, which requires extra money to invests
. Customer satisfaction is involved in this situation. If the service is appropriate and satisfactory to the customers, the purpose of giving service is fulfilled. On the other hand, if some customers are not happy with the given service or buyer is incapable to give the standard service, customers may not want to buy products from that buyer as customers have multiple choices to buy the same product. This is the opposite situation of the service, i.e.,
. Thus, it creates some monetary loss to the buyer, which is indicated as customer satisfaction cost. It has the inverse relation with the provided service. Whenever the service increases, the customer satisfaction increases and thus the cost
, related to the customer satisfaction decreases. If
is the service cost and
is the customer satisfaction cost, the relative cost is given by
. Therefore, the expected total profit of buyer
i is
The total profit of buyer is given by
Therefore, the expected total profit of SCM is given by
subject to the conditions
3.4. Solution Methodology
The solution is found for both the coordination and non-coordination cases. The model is solved by using classical optimization techniques. The necessary conditions give the optimum results for the corresponding decision variables and the sufficient conditions give the stability of the solutions. The constraint function of the manufacturer is modified and transferred into an unconstrained function using the Kuhn-Tucker (KT) method. The modified function is given by
Then, the total profit of the entire SCM is
3.4.1. Non-Coordination Case
The necessary conditions of optimization provide the optimum values of the decision variable for the manufacturer. The value of the decision variable
is computed by
where
Therefore,
(from Equation (
10)) gives the optimum order quantity for the manufacturer. The optimum distance is given by the following value of
d.
Equation (
11) provides the optimum distance between readers. The sufficient conditions prove that the above results represent global solutions.
All criterion for the sufficient conditions of a Hessian matrix are satisfied proving the stability of the optimum solution. Therefore, the values of the decision variables are the optimum for the manufacturer.
The optimum values of the decision variables for the buyer are given by the following necessary conditions for optimization.
where
The optimum order quantity for the buyer
i is given by Equation (
12). Equation (
13) gives the optimum service provided by the buyer
i to customers.
This sufficient condition proves the global nature of the solution.
The Algorithm 1 is developed to find the numerical results from theory. The following steps help to solve the model numerically.
Algorithm 1: |
Step 1 | Input all values of all relevant parameters. Set the value of i. |
Step 2 | Set the initial values of for manufacturer and buyers. |
Step 3 | Write down the values of from the Equation (10) and d from the Equation (11) for manufacturer. |
| For buyers, the values of and are given by Equation (12) and (13), respectively. |
Step 4 | Find the value of , , and d using the values from Step 1 and Step 2. |
Step 4.a | If and , then terminate the process. The optimum values are obtained as , , and . |
Step 4.b | Else if and , go to Step 4. |
Step 4.c | Increment of i as . |
Step 5 | Stop. |
3.4.2. Coordination Case
The results for the joint profit of the entire SCM are given by the following necessary conditions.
where
The optimum order quantity is given by Equation (
14) and service is given by Equation (
15). Using the necessary conditions, one has
Equation (
16) gives the optimum distance between two RFID readers. From the sufficient conditions, it can be concluded that since the second order derivatives are negative definite and the values of the Hessian matrix alternate, the required values of the decision variables are global.
Now, the calculation of the principal minors gives
Lemma 1. The values of the coordinated case are optimum if the Hessian matrix of third order () has a value less than zero, i.e., . The required criteria is given by This Algorithm 2 helps to find the numerical results. The following steps are required as follows.
Algorithm 2: |
Step 1 | Input all parametric values. Set the value of i. |
Step 2 | Set the initial values of . |
Step 3 | Write down the values of from the Equation (14), from Equation (15), and d from the |
| Equation (16). |
Step 4 | Find the value of , , and d using the values from Step 1 and Step 2. |
Step 4.a | If and , then terminate the process. The optimum values are obtained as , , and . |
Step 4.b | Else and , go to Step 4. |
Step 4.c | i as . |
Step 5 | Stop. |
3.5. Revenue Sharing (RS)
Instead of a traditional policy, the manufacturer and multiple buyers are involved in a VMI contract. It is the manufacturer’s role to support buyer such that the buyers so that they do not face losses due to the contract. Thus, a revenue sharing policy for coordinated supply chain is incurred by the manufacturer. If is the sharable revenue by the manufacturer from the total profit, then the sharing mechanism for the coordinated case is . The rest of the profit is accounted for by the manufacturer as he invests more in the business.
4. Numerical Experiment
Numerical experiments are used to validate this study numerically. Supportive data are taken from Sarkar et al. [
19] and Xiao and Xu [
5]. Some data are taken from an industry visit in West Bengal, India, which justifies the industry using this policy for their business. Two examples are provided here.
Example 1. Table 3 gives all input values of the related parameters and Table 4 provides the optimum results for Example 1. Therefore,
$19,783.46 is the total profit of the entire supply chain. After gaining profit from the business, the manufacturer shares the revenue
(Xiao and Xu [
5]) of the total profit with the buyers, i.e., the manufacturer shares
$8902.56 with the two buyers. Thus, a (
$19,783.46 −
$8902.56) =
$10,880.90 profit is earned by the manufacturer from the VMI contract policy. The required number of Type 1 readers is 4 and the number of Type 2 readers is 8, which cover the total search area.
Example 2. Table 5 gives all input values of the related parameters and Table 6 provides the optimum results for Example 2. $17,122.01 is the total profit of the entire supply chain for Example 2. The manufacturer shares the revenue
(Xiao and Xu [
5]) of the total profit with the buyers, i.e., the manufacturer shares
$7704.90 with the two buyers for the coordination business policy. Thus, a (
$17,122.01 −
$7704.90) =
$9417.11 profit is earned by manufacturer from the VMI contract policy. The total search area is covered by 4 number of Type 1 readers and 12 number of Type 2 readers.
Comparative Study of the Coordination and Non-Coordination Cases
From
Table 7, it is seen that, manufacturer and buyer’s profit in the coordination case are higher than the non-coordination case for both of the examples. The results conclude that the coordination VMI is more beneficial for both business participants. It is seen that the coordination policy is beneficial for both the manufacturer and the total supply chain profit, whereas buyers get more profit in the non-coordination policy than then coordination case. The shared revenue to the buyers in the coordinated case is less than the profit earned from the non-coordination case. As in the non-coordination policy, buyers can move freely according to their surrounding phenomenon, but in the coordination policy, the joint profit for the entire supply chain is more important for a long-term business rather than an individual one. Even though the profit of buyers is less in the coordination case, they do not face any loss from the business. In both cases of coordination and non-coordination policy, the manufacturer needs same number of readers as the area of the manufacturer is fixed for both of the cases.
5. Discussion
Service is provided to the customers by buyers. This extra service makes an effect to the customers of satisfaction that they are happy and satisfied after buying products from that buyer. Whenever the service level increases, the satisfaction increases.
The sensitivities of the cost parameters of Example 1 over the total profit are depicted in
Table 8. It is found that the manufacturing cost
c is the most profit sensitive parameter relative to the others. Positive percentage changes of the parameter are more sensitive than negative changes, i.e., profit loss will be more whenever the cost increases. For the holding cost of the manufacturer
, whenever
decreases and increases, the total profit decreases and increases, respectively. Negative percentage changes of
result in a smaller
, which leads to an increased RFID cost, i.e., decreasing
increases the radio frequency cost per cycle. The holding cost of the buyers and the shortage costs of the manufacturer and buyers have the same type of positive and negative changes. The service investment of the buyers has the usual impact on total profit, where increasing the investment causes less profit and vice-versa.