G Improving sustainability of agriculture supplies distribution - A case study of Foria AB Master of Science Thesis in the Master Degree Programme Supply Chain Management Adrian Ruiz de la Llata & Oscar Kjellberg Department of Technology Management and Economics Division of Logistics and Transportation Technical report no E2012:065 CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden, 2012 Improving sustainability of agriculture supplies distribution - A case study of Foria AB ADRIAN RUIZ DE LA LLATA & OSCAR KJELLBERG © ADRIAN RUIZ DE LA LLATA & OSCAR KJELLBERG, 2012. Technical report no E2012:065 Department of Technology Management and Economics Chalmers University of Technology SE-412 96 Göteborg Sweden Telephone + 46 (0)31-772 1000 Cover: A collage of some of the equipment used and cargo delivered in the analyzed transports. See pages 28-32. Department of Technology Management and Economics Gothenburg, Sweden 2012 i ABSTRACT This master thesis analyzes the distribution of general cargo from a centralized warehouse to a large number of widespread drop-off points. The research approach is practical and by analyzing a real-world case through both a financial analysis and by mimicking their operations in a proprietary simulation program, the authors were able to analyze how transport efficiency is affected by changes to the distribution setup. The case used for the study is the distribution of agriculture supplies performed by Foria from Lantmännen’s central warehouse in Västerås to farmers in the counties of Östergötland, Södermanland, Närke, northern Småland, Västmanland and Uppland. This distribution could be thought of as the distribution of general cargo, from a central warehouse to a large number of widespread drop-off points. The aim of the thesis is twofold: (1) propose efficiency improvements for the focal company Foria so that their operations could improve both financially and from an environmental point of view. (2) Generalize the case specific results and draw general conclusions on which distribution efficiency improvements renders the best sustainability outcomes from both a financial perspective as well as an environmental perspective. After an introduction, method description and literature review, the thesis describes the studied operations in detail and the algorithm describing their work operations which are the base for the simulation program are presented. The analysis part starts with an in-depth problem analysis of focal company´s current way of working. Possible solutions to the identified problems are presented and two methods for attacking the issues, vehicle differentiation of the trucks and routing differentiation, are quantified in a financial analysis and through using the simulation program to analyze it both from a hauler´s perspective and an environmental perspective. The results from this thesis confirm previous research assumptions and indications that there exist many inefficient and unprofitable transports due to poor choice of distribution strategy. Furthermore, the simulation analyses indicate a discrepancy in incentives for improving transport efficiency from a financial perspective and the incentives for improving from an environmental perspective. Keywords: Transportation, Distribution Network Design, Simulation, Scenario Analysis. ii ACKNOWLEDGEMENTS This Master of Science thesis was conducted between September of 2011 and April of 2012 as part of the Master Degree Program in Supply Chain Management at Chalmers University of Technology in Gothenburg, Sweden. The thesis was carried out as a case study and a project for Foria AB’s office in Nyköping. We would first of all like to send our gratitude to all the people working at Foria AB. This thesis would not have been possible without their help and cooperation. Thanks to the management team for their insights on the problem, thanks to the transport planners for helping us understand their work process, and thanks to the drivers for their guiding in an inspirational field study. We would especially like to thank Mr. Stefan Palmgren, our supervisor and tutor at Foria AB. Thank you for your support, guidance and feedback through the entire work process of this thesis. We also want to thank our Chalmers supervisor Dr. Henrik Sternberg for his constant encouragement to pursuit excellence. We also want to acknowledge the staff at the division of Logistics and Transport at Chalmers University of Technology who has contributed to our learning along the two year master programme. Last but not least, we want to recognize our computer systems engineering friends, Manuel Espinoza, Salvador Melendez and Guillermo Leon. Their help and support during the work of coding our algorithm into a functioning simulation program saved us a great deal of time. Gothenburg, April 2012. Adrian Ruiz de la Llata and Oscar Kjellberg iii TABLE OF CONTENTS ABSTRACT ................................................................................................................................................... I ACKNOWLEDGEMENTS ........................................................................................................................ II TABLE OF CONTENTS ........................................................................................................................... III ABBREVIATIONS .................................................................................................................................. VII LIST OF FIGURES ................................................................................................................................ VIII LIST OF TABLES ..................................................................................................................................... IX 1 INTRODUCTION ................................................................................................................................ 1 1.1 Background and motivation .......................................................................................................... 1 1.2 Problem Area .................................................................................................................................... 2 1.3 Purpose .............................................................................................................................................. 3 1.4 Research questions .......................................................................................................................... 4 1.5 Delimitations .................................................................................................................................... 4 1.6 Outline of the thesis ......................................................................................................................... 4 1.7 The focal company - Foria AB ........................................................................................................ 6 2 RESEARCH APPROACH ................................................................................................................ 7 2.1 Research strategy for the thesis ........................................................................................................ 7 2.2 Methodology ....................................................................................................................................... 8 2.2.1 Literature review ........................................................................................................................ 8 2.3 The problem analysis models .......................................................................................................... 12 2.3.1 Qualitative analysis methods .................................................................................................... 12 2.3.2 How was the financial analysis tool created and analyzed? ..................................................... 13 2.3.3 How was the simulation model created and analyzed? ............................................................ 13 2.4 Validation ......................................................................................................................................... 13 2.4.1 Financial analysis ..................................................................................................................... 13 2.4.2 Simulation model ..................................................................................................................... 13 2.5 Reliability .......................................................................................................................................... 14 3 LITERATURE REVIEW ................................................................................................................ 15 3.1 Logistic performance ....................................................................................................................... 15 3.1.1 Logistics Efficiency and Effectiveness ..................................................................................... 15 3.2 Distribution and Transportation Network Design ........................................................................ 18 3.2.1 Distribution network design (DND) ......................................................................................... 18 3.2.2 Transportation network design (TND) ..................................................................................... 20 3.3 Distribution and Transportation Optimization ............................................................................. 21 3.3.1 Traveler Sales Problem (TSP) .................................................................................................. 21 iv 3.3.2 Greedy Algorithm ..................................................................................................................... 22 3.4 Environmental implication of transportation ................................................................................ 23 3.4.1 Approaches to Reduce emissions ............................................................................................. 23 3.4.2 Environmental performance in transportation .......................................................................... 24 4 EMPIRICAL FINDINGS ................................................................................................................ 26 4.1 Operations of interest for this project ............................................................................................ 26 4.1.1 Historically ............................................................................................................................... 26 4.1.2 The new contract – a shift in responsibilities ........................................................................... 26 4.2 The involved actors .......................................................................................................................... 27 4.2.1 Transport planners at Foria ....................................................................................................... 27 4.2.2 Foria associated haulers ............................................................................................................ 28 4.2.3 The supplier of cargo - Lantmännen AB, Division Lantbruk ................................................... 29 4.2.4 The end customers - The farmers ............................................................................................. 29 4.3 What they are transporting and order information ...................................................................... 30 4.4 Case Fleet .......................................................................................................................................... 31 4.5 Transportations costs ....................................................................................................................... 32 4.5.1 Costs for Foria using their own drivers .................................................................................... 32 4.5.2 Costs to use and external network provider .............................................................................. 33 4.5.3 Freight calculation and volumetric weight ............................................................................... 33 4.5.4 Costs for the Foria associated haulers ...................................................................................... 33 5 THE SIMULATION MODEL ........................................................................................................ 34 5.1 How the program works .................................................................................................................. 34 5.1.1 Input to the program ................................................................................................................. 34 5.1.2 Output from the program .......................................................................................................... 35 5.1.3 Working conditions and assumptions for the simulation model ............................................... 35 5.2 The algorithm and its parts ............................................................................................................. 36 5.2.1 The start of the simulation ........................................................................................................ 36 5.2.2 Choosing one of two different LTL-building processes ........................................................... 37 5.2.3 Calculation of the distance traveled by the truck ...................................................................... 40 5.2.4 How alpha was estimated ......................................................................................................... 41 5.2.5 Validation of model .................................................................................................................. 43 5.2.6 Delimitations to the simulation model ...................................................................................... 45 6 ANALYSES ...................................................................................................................................... 46 6.1 Root cause problem analysis of the agriculture supplies distribution ......................................... 47 6.1.1 Physical distribution activities restraining profitability ............................................................ 49 6.1.2 Planning activities are restraining profitability ......................................................................... 50 6.1.3 External activities and factors are limiting profitability ........................................................... 51 6.2 Visualization framework ................................................................................................................. 51 6.3 How to address the case company´s problems ............................................................................... 53 6.3.1 Proposals of different distributions models .............................................................................. 53 6.3.2 How would the focal company be able to implement these solutions? .................................... 54 6.4 Financial analysis ............................................................................................................................. 56 6.4.1 Foria Price Structure ................................................................................................................. 56 v 6.4.2 EDN price Structure ................................................................................................................. 56 6.4.3 Comparison between Foria prices and EDN prices .................................................................. 56 6.4.4 The breaking Point ................................................................................................................... 57 6.4.5 The Breaking point with volumetric weight adjustment ........................................................... 58 6.5 Simulation analysis – Hauler’s perspective ................................................................................... 64 6.5.1 Outsource to an EDN all orders up to 450 kg ........................................................................... 64 6.5.2 Outsource to an EDN all orders up to 780 kg ........................................................................... 65 6.5.3 Outsource to an EDN all orders up to 1000 kg ......................................................................... 65 6.5.4 Outsource to an EDN all orders up to 1500 kg ......................................................................... 66 6.5.5 Outsource to an EDN all orders up to 2000 kg ......................................................................... 66 6.5.6 Outsource to an EDN all orders up to 3000 kg ......................................................................... 66 6.6 Environmental analysis ................................................................................................................... 68 6.6.1 Assumptions and Specifications ............................................................................................... 68 6.6.2 Pollutant Emission in different transportation setups scenarios ............................................... 68 6.6.3 Environmental Qualitative Analysis ......................................................................................... 75 7 RESULTS ......................................................................................................................................... 76 7.1 Results from the analyses ................................................................................................................ 76 7.1.1 Results from the case study analysis ........................................................................................ 76 7.1.2 Results From the financial analysis .......................................................................................... 77 7.1.3 Results From the simulation analysis – Hauler´s perspective .................................................. 77 7.1.4 Results From the environmental analysis ................................................................................. 78 7.1.5 Combined results from the analyses ......................................................................................... 78 7.2 Answers to research questions ........................................................................................................ 79 7.2.1 RQ1 .......................................................................................................................................... 79 7.2.2 RQ2 .......................................................................................................................................... 80 8 RECOMMENDATIONS TO FORIA ............................................................................................ 81 8.1 Short term ......................................................................................................................................... 81 8.2 Long term ......................................................................................................................................... 82 9 CONCLUSIONS .............................................................................................................................. 83 10 REFERENCE LIST ......................................................................................................................... 84 APPENDIX A – THE SIMULATION ALGORITHM .............................................................................. I APPENDIX B – IMAGES AND TABLES ............................................................................................... IV APPENDIX C – INITIAL TOPICS FOR THE OPEN INTERVIEWS ............................................. VIII APPENDIX D – SIMULATION RESULTS HAULERS PERSPECTIVE ............................................. X APPENDIX E – ENVIRONMENTAL TABLES AND FIGURES ..................................................... XVI APPENDIX F – FINANCIAL ANALYSIS (QLIKVIEW) .................................................................. XXI APPENDIX G - SCALED MAP OF SWEDEN ................................................................................. XXVI vi APPENDIX H –SUMMARIES OF INTERVIEWS, MEETINGS AND FIELD STUDIES ......... XXVII APPENDIX I – FINANCIAL ANALYSIS OF VEHICLE DIFFERENTIATION SCENARIOS .. XLII APPENDIX J – ESTIMATION OF COST FOR UNREIMBURSED WORK ............................... XLIII APPENDIX K – VISUAL VALIDATION OF SIMULATION MODEL AND DISTANCES .......XLIV APPENDIX L – ALPHA SENSITIVITY ANALYSIS ......................................................................... LIV vii ABBREVIATIONS API Application Programming Interface BI Business Intelligence CCU Cargo Capacity Utilization DND Distribution Network Design EDN External Distribution Network EU European Union GHG Greenhouse Gas GPS Geographical Positioning System HDV Heavy Duty Vehicle ICT Information and Communication Technology IS Information Systems IT Information and Technology LCV Light Cargo Vehicle LTL Less Than Truckload MDV Medium Duty Vehicle NTM Network for Transport and Environment SCM Supply Chain Management SCP Shipping Consolidation Problem SEK Swedish Kronor TND Transportation Network Design TT Transit Time TSP Traveler Sales Problem T&D Transportation and Distribution US United States VSM Value Stream Mapping WMS Warehouse Management Inventory viii LIST OF FIGURES Figure 1 Region where Foria is responsible for Lantmännen´s agriculture supplies distribution ........................... 3 Figure 2 Organizational chart of Foria AB ............................................................................................................. 6 Figure 3 Visualization model (Allenström and Linger, 2010) .............................................................................. 12 Figure 4 Logistics Performance Model (Fugate et al., 2010) ................................................................................ 15 Figure 5. Designing the Optimal Distribution Network (Sharma et al., 2008) .................................................... 19 Figure 6 Foliated transportation network (Persson and Lumsden, 2006) .............................................................. 21 Figure 7 The four greedy principles with implications (Curtis, 2003) .................................................................. 22 Figure 8 Value stream mapping of current operations .......................................................................................... 26 Figure 9 Service Area and sub regions with actual customer visits during 2010-2011 ......................................... 29 Figure 10 1: The truck, 2: The trailer, 3-4: The crane, 5-6: The portable forklift ................................................. 32 Figure 11 Interface of the simulation model ......................................................................................................... 34 Figure 12 Start of simulation algorithm ................................................................................................................ 36 Figure 13 Simulation algorithm, one or several "Prio1" orders ............................................................................ 37 Figure 14 Simulation model available orders........................................................................................................ 37 Figure 15 Simulation algorithm, LTL-shipment building process 1 ..................................................................... 39 Figure 16 Simulation algorithm, LTL-shipment building process 2 ..................................................................... 40 Figure 17 Simulation Algorithm, distance calculation .......................................................................................... 41 Figure 18 Simulation Algorithm, alpha calculation .............................................................................................. 41 Figure 19 Top 20 sub-regions with unique visits .................................................................................................. 42 Figure 20 Relationship of the three numerical analyses ........................................................................................ 46 Figure 21 Root cause analysis of problems for the case studied ........................................................................... 48 Figure 23 Vehicle differentiation .......................................................................................................................... 53 Figure 23 Distribution setup with a transshipment terminal ................................................................................. 54 Figure 24. Outline of the volumetric weight analysis ........................................................................................... 59 Figure 25 Errors in weight column in the historic order lines data ....................................................................... IV Figure 26 Typical order, pallets with animal feed ................................................................................................. IV Figure 27 Foria associated haulers trucks .............................................................................................................. V Figure 28 Screenshot from the transport planners IS interface. ............................................................................. V Figure 29 Screenshot from a few of the original raw orderliness from the year of shipping data......................... VI Figure 30 Price matrix combined below 1000 kg (part of) ................................................................................... VI Figure 31 Price matrix combined above 1000 kg (part of) .................................................................................. VII Figure 32. Qlikview overview: Regions by Volume (Weight and Order) ......................................................... XXI Figure 33 Qlikview overview: Weight Range occurrence ................................................................................. XXI Figure 34. County and Sub-region prices comparison between Foria and EDN ............................................... XXII Figure 35. The Breaking Point (Foria vs. EDN) ............................................................................................... XXII Figure 36. Breaking point overview with the different sensitive volumetric weight adjustments ................... XXIII Figure 37. The Breaking Point volumetric adjustment (Conservative Scenario) ............................................ XXIV Figure 38. The Breaking Point volumetric adjustment (Max Profit Scenario) ................................................ XXIV Figure 39. Conservative Scenario price comparison by county (0 kg – 299 kg) ............................................... XXV Figure 40. Conservative Scenario price comparison by county (350 kg – 449 kg) ........................................... XXV Figure 41. Max Profit Scenario price comparison by county (0 kg – 299 kg) .................................................. XXV Figure 42. Max Profit Scenario price comparison by county (350 kg – 449 kg) .............................................. XXV file:///C:/Users/Oscar/Dropbox/Master%20Thesis%20-%20fall%202011/0%20-%20Master%20File/2012-06-09/Theses%20new%20with%20references%20Adrian_02.docx%23_Toc328950896 file:///C:/Users/Oscar/Dropbox/Master%20Thesis%20-%20fall%202011/0%20-%20Master%20File/2012-06-09/Theses%20new%20with%20references%20Adrian_02.docx%23_Toc328950901 file:///C:/Users/Oscar/Dropbox/Master%20Thesis%20-%20fall%202011/0%20-%20Master%20File/2012-06-09/Theses%20new%20with%20references%20Adrian_02.docx%23_Toc328950902 file:///C:/Users/Oscar/Dropbox/Master%20Thesis%20-%20fall%202011/0%20-%20Master%20File/2012-06-09/Theses%20new%20with%20references%20Adrian_02.docx%23_Toc328950903 file:///C:/Users/Oscar/Dropbox/Master%20Thesis%20-%20fall%202011/0%20-%20Master%20File/2012-06-09/Theses%20new%20with%20references%20Adrian_02.docx%23_Toc328950905 file:///C:/Users/Oscar/Dropbox/Master%20Thesis%20-%20fall%202011/0%20-%20Master%20File/2012-06-09/Theses%20new%20with%20references%20Adrian_02.docx%23_Toc328950916 ix LIST OF TABLES Table 1 Summary of meetings and interviews ...................................................................................................... 10 Table 2 Summary of field studies and orientation visits ....................................................................................... 11 Table 3 Summary of quantitative data collection .................................................................................................. 11 Table 4 Summary of articles relating to logistic efficiency and effectiveness ...................................................... 16 Table 5 Proposed Distribution Networks Designs (Chopra, 2003) ....................................................................... 18 Table 6 Proposed Transportation Networks Designs (Chopra and Meindl, 2007) ................................................ 20 Table 7 Greedy Algorithms Classification (Curtis, 2003) ..................................................................................... 22 Table 8. Link between emissions from transport and environmental impact (Thomas and Harrison, 2004) ........ 23 Table 9. Vehicle concepts/types and cargo capacity (NTM-Road, 2008) ............................................................. 25 Table 10 Calculation of alpha value ...................................................................................................................... 42 Table 11 Simulation distances and real world distances ....................................................................................... 44 Table 12 Confidence interval calculation of simulation distances ........................................................................ 44 Table 13 Visualization framework adapted from Allenström & Linger (2010) .................................................... 52 Table 14 Solutions to the issues identified in the root cause analysis presented through Allenström & Linger (2010) visualization framework ...................................................................................................... 55 Table 15. Foria price structure obtained in Qlikview. ........................................................................................... 56 Table 16. EDN price structure obtained in Qlikview. ........................................................................................... 56 Table 17. Difference between Foria prices and EDN prices ................................................................................. 57 Table 18. Breakpoint 450 kg (EDN 0-449 kg and Foria 450 kg– up) ................................................................... 57 Table 19. Safety factor 1,5X (Breakpoint 299kg) ................................................................................................. 59 Table 20. Safety factor 2X (Breakpoint 249kg) .................................................................................................... 60 Table 21. Safety factor 3X (Breakpoint 149kg) .................................................................................................... 60 Table 22. Safety factor 5X (Breakpoint 79kg) ...................................................................................................... 60 Table 23. Conservative Scenario results overview ............................................................................................... 61 Table 24. Order weight adjustment for Max Profit Scenario ................................................................................ 62 Table 25. Max Profit Scenario overview .............................................................................................................. 63 Table 26. Pre-defined data for the environmental performance calculations in scenario 1 (Simulation) .............. 68 Table 27. Summary of the fuel consumption for scenario 1 ................................................................................. 69 Table 28. Total pollutant emissions (Scenario 1 simulation with 574 trucks). ..................................................... 69 Table 29. Pre-defined data for the environmental performance calculations in scenario 2 (Simulation) .............. 70 Table 30. Summary of the fuel consumption for scenario 2 ................................................................................. 70 Table 31. Total pollutant emissions (Scenario 2 simulation with 340 MDV Lorry trucks and 515 HDV + trailer). ........................................................................................................................................................ 71 Table 32. Total pollutant emissions (Scenario 2 simulation with 855 trucks). ..................................................... 71 Table 33. Pre-defined data for the environmental performance calculations in scenario 3 (Simulation) .............. 72 Table 34. Summary of the fuel consumption for scenario 3 ................................................................................. 72 Table 35. Total pollutant emissions (Scenario 3 simulation with 429 MDV Lorry trucks and 478 HDV + trailer). ........................................................................................................................................................ 73 Table 36. Total pollutant emissions (Scenario 3 simulation with 907 trucks). ..................................................... 73 Table 37. Total pollutant emissions Scenario 1 versus Scenario 2 ....................................................................... 74 Table 38. Total pollutant emissions Scenario 1 versus Scenario 3 ....................................................................... 74 Table 39 Comparison of simulation results, outsourcing all orders up to 450 kg .................................................. X Table 40 Comparison of simulation results, outsourcing all orders up to 780 kg ................................................. XI Table 41 Comparison of simulation results, outsourcing all orders up to 1000 kg .............................................. XII Table 42 Comparison of simulation results, outsourcing all orders up to 1500 kg ............................................ XIII Table 43 Comparison of simulation results, outsourcing all orders up to 2000 kg ............................................ XIV Table 44 Comparison of simulation results, outsourcing all orders up to 3000 kg .............................................. XV Table 45. Fuel consumption for the vehicles concepts/types (NTM, 2008) ....................................................... XVI Table 46. Data used to calculate fuel consumption based on Cargo Capacity and type of road (Scenario 1) .... XVI x Table 47. Data used to calculate fuel consumption based on Cargo Capacity and type of road (Scenario 2) ... XVII Table 48. Data used to calculate fuel consumption based on Cargo Capacity and type of road (Scenario 3) ... XVII Table 49. Emissions for HVD + trailer truck in urban road type (NTM-Road, 2008) ..................................... XVIII Table 50. Emissions for HVD + trailer truck in rural road type (NTM-Road, 2008) ....................................... XVIII Table 51. Emissions for HVD + trailer truck in motorway road type (NTM-Road, 2008) ................................ XIX Table 52. Emission for MVD Lorry truck in urban road type (NTM-Road, 2008) ............................................ XIX Table 53. Emission for MVD Lorry truck in rural road type (NTM-Road, 2008) ............................................... XX Table 54. Emission for MVD Lorry truck in motorway road type (NTM-Road, 2008) ...................................... XX 1 1 INTRODUCTION This chapter starts with a brief background description and the underlying reasons for this thesis. Following this the purpose, the research questions, and the delimitations for this research are presented. 1.1 BACKGROUND AND MOTIVATION The demand for transportation is increasing on a yearly basis (Piecyk and McKinnon, 2011) and it is not only the shipped weight that is increasing. Supply chain efficiency measures such as reducing local warehouse levels increase the demand for more frequent, timely and small deliveries. Most industries, as well as the public, depend heavily on trucking companies to solve their demand for cargo transportation and motor hauler transportation is the predominantly used mode of inland transportation. In Sweden this compose around 60% of the total inland freight transported weight (International Transportation Forum, 2010). Truck hauling ventures is normally a low margin business with fierce competition, usually margins lie within the range of 2-4% (SIKA Statistik, 2009). The transportation execution is often easy to copy which means that most of the actors mainly compete on price and relationships have often been at arm’s length (Belman et al., 2005). An example of this is the recent market penetration of low-cost eastern European haulers on the Nordic market (Sternberg, 2011a), they are pushing an already low price down further and putting pressure on local haulers to increase their operation efficiency. However, many of actors the actors involved in distribution have realized the potential with closer relationships and logistic alliances have formed where one actor are providing a larger package of a value adding services (Lumsden, 2006b) and not only the actual transportation, e.g. planning processes or outsourcing the entire distribution process and handing over control and responsibility to an external expert (Esper and Williams, 2003). Another important reason is to improve transportation efficiency is to reduce the environmental impact of transportation. Thomas and Harrison (2004) agree on major impacts such as human health implications, dilution of the ozone layer, greenhouse effect, hyper fertilization, acidification and destruction of landscapes. The transportation sector in general stands for 19% of the greenhouse gases (GHG) emitted in the European Union (EU-27) and out of this, road transportation share is up to 90% (Huggins, 2009). Reducing air pollution is already a priority for policymakers and through the establishment of regulations and environmental policies (Thomas and Harrison, 2004), policymakers are increasing pressure on Transportation and Distribution (T&D) companies to improve operating efficiency to reduce their environmental impact. Moreover, society is also pressuring companies towards being “green” and becoming environmental friendly has increased its importance as an order qualifier in the market (Jonsson, 2008, McKinnon, 2003). The above-mentioned developments are the underlying motives for this thesis. A lot of research has previously been done in the field of transportation efficiency. E.g. Samuelsson 2 and Tilanus (1997) described a general framework for measuring the physical efficiency of Less-than-truckload (LTL) transports, Crainic and Roy (1988) developed a mathematical model for the tactical planning of freight transportation, Chapman et al. (2003) discussed how innovation on logistics firms can help to re-design their structures and enhance relationships through information sharing and coordination, and Kalantari and Sternberg (2009) described the conceptual model of foliated transportation networks, which aims at increasing the efficiency of transportation networks by increasing resource utilization. However, an identified gap in previous research is the study and numerical analysis of real world problem based on actual transportation and not an optimization of an ideal situation or research limited to qualitative analysis and suggestions. Sternberg (2011b) states that there exist a lot of wasteful transport operations due to inefficient strategies and lack of knowledge about what drives the revenues and what drives the costs. This leads road transport operators to carry many unprofitable assignments. The close relationship and correlation between transport efficiency, profitability and environmental sustainability makes addressing unprofitable an interesting area of research since it will also likely improve environmental sustainability. This thesis has its base in a case study of the Swedish logistics firm Foria AB. More specifically, the part of their operations which is responsible for distributing agriculture supplies to farmers in mid-eastern Sweden from Lantmännen´s central warehouse in Västerås. To analyze improvements to their operations a financial sustainability analysis is made comparing the impact of using an External Distribution Network (EDN) for part of this distribution. Secondly, a simulation model that analyzes the financial impact to local haulage companies and impact to transportation efficiency and environmental impact from different distribution design scenarios are developed. From this case study general conclusions are drawn. 1.2 PROBLEM AREA The distribution of agricultural supplies is essentially the distribution of general cargo on pallets in a LTL setup. Our focal company shares the above described need for efficiency improvements, as most T&D companies have in order to stay competitive. Furthermore, Foria as the sponsors of this thesis has a request to receive suggestions that would improve the financial and environmental performance for their agriculture supplies distribution, which is an important aspect of this thesis. This means that the general research area for this thesis is methods for improving financial and environmental performance in the distribution of general cargo. More specifically, it examines how distribution of general cargo from a central warehouse could be made more financially and environmentally sustainable through the use of fleet optimization techniques and/or the use transshipment terminals. The basis for suggestions and conclusions is the case study done at Foria’s operations for Lantmännen in mid-eastern Sweden. This thesis investigates the economic and environmental impact of modifying, in terms 3 of fleet selection and adding transshipment terminals, Foria´s distribution model for agriculture products from Lantmännen´s central warehouse in Västerås to farmers in mid- eastern Sweden. The changes are then compared to the current distribution model and one year of shipment data for these shipments will be used as input to the analysis models and as reference for comparison. From this case study a recommendation to focal company along with general conclusions on transport efficiency improvements regarding LTL-shipments of general cargo will be presented. 1.3 PURPOSE This thesis analyzes the current distribution setup, in terms of fleet performance and delivery routes, the distribution of agriculture supplies from Lantmännen terminals in Västerås to the end user in the counties of Östergötland, Södermanland, Närke, northern Småland, Västmanland and Uppland as is shown in Figure 1. With this analysis as a reference, the purpose is to propose distribution efficiency improvements so Foria will gain a better financial performance along with a reduced environmental impact from these shipments, without having a negative effect on the current service level. Moreover, these results are then to be analyzed to form general recommendations on how the distribution of general cargo from a central warehouse could be made more efficient and sustainable. Figure 1 Region where Foria is responsible for Lantmännen´s agriculture supplies distribution 4 1.4 RESEARCH QUESTIONS Derived from the problem identification and the purpose two sets of research questions were formulated. These research questions are the starting point from where the literature review, empirical data collection and analysis were carried out. RQ1 are derived from the focal company´s need and the specific problem identification from the analyzed transport operations. RQ1 is split into four parts and presented below. RQ1-1. What transport efficiency improvements should be implemented at Foria to increase the financial sustainability for the agriculture supplies distribution? RQ1-2. How high are the possible financial gains for Foria? RQ1-3. What environmental effects will the proposed transport efficiency improvements render? RQ1-4. How will proposed changes affect the local hauler companies that today perform these transports? Derived from the RQ1, which is targeted directly towards the focal company´s situation, RQ2 generalizes the results from the case study and puts them into a broader context. RQ2. Given the conclusions from RQ1: How can distribution of general cargo from a central warehouse to a wide array of drop-of points become more sustainable? 1.5 DELIMITATIONS This thesis focuses on improvements on the T&D activities that the focal company will perform in the new arrangement. All other activities performed by other external actors are out of the scope for potential improvements. Therefore, Lantmännen’s distribution warehouse in Västerås, the customers (farmers) location, and the products are fixed external factors that are not feasible to change and they set the boundaries for any realistic improvement. 1.6 OUTLINE OF THE THESIS This section presents how the thesis is structured and under what headings different segments will be found. 1 Introduction This chapter starts with a brief background description and the underlying reasons for this thesis. Following this the purpose, the research questions, and the delimitations for this research are presented. 2 Research approach In this chapter the research method this thesis is presented. It starts with a description of 5 the general strategy for solving Foria’s problems, following this is a description of how data collection, problem analysis, and data analysis was done. Finally the reliability and validity of the results are discussed. 3 Literature review This chapter describes and explains the academic literature that supports and function as reference in the analysis part of the master thesis. Three main areas will be presented and broken down into different subareas: Efficiency in LTL Transportation, DND and Fleet/Vehicle Differentiation. 4 Empirical findings In this chapter the empirical findings are presented. This includes the roles, responsibilities and activities of the involved actors. Furthermore, the nature of the goods that is being transported as well as the properties of the vehicles being used for these transports today. 5 The simulation model This chapter starts with describing the reasons for the constructed simulation model; following this, a through description of how the simulation model works in detail in the most important parts is presented. How it tries to mimic the behavior of a transport planner, how it creates shipments and simulates a year of transportation. Finally the limitations to the model and how it was validated is presented. 6 Analyses In this chapter theory and empirical findings form the base for analysis. An initial problem analysis of the focal company´s situation within the agriculture supplies distribution identifies thirteen problems. Possible solutions to the identified problems are examined with three analyses from three perspectives; financial perspective, haulers perspective, and environmental perspective. These analyses will then acts as a reference from which general efficiency improvements can be sought in the research area of improving transport efficiency of general cargo from a central warehouse. 7 Results This chapter presents the results from the different analyses made. First the qualitative general results from the case study analysis are presented; following this the quantitative results from the financial analysis as well as the two simulation analyses are presented. Finally the last subchapter answers research question 1 and research question 2. 6 8 Recommendations to Foria In this chapter we provide our recommendations to the company based on the analysis and conclusions drawn. Recommendations are given on both a short-term and long-term perspective. 9 Conclusions In this chapter the results of the research are discussed from a managerial and theoretical perspective. Lastly possibilities for future research and improvements are highlighted. 1.7 THE FOCAL COMPANY - FORIA AB Foria is one of the biggest transport- and heavy equipment service companies in Sweden. They are mainly active in the middle of Sweden on the east coast; however, through partnerships with other actors they are able to offer services all over Sweden. During 2010, they had a turnover of 1.237 billion SEK, and made a profit of 9 million SEK. They have approximately 1000 units in their fleet of vehicles that are operating in their four different business areas, “Civil engineering services”, “Logistic services”, “Industry services” and “Environmental services”. (See Figure 2) This master thesis project has collaborated with Foria´s Business Development & Traffic Control in their business area Logistics Services. Within Logistics Services, they work with distribution services, long-haul traffic services, terminal and warehouse services, courier services, moving, relocation services, and total logistics solutions with outsourcing. CEO Civil Engineering Services Logistcs Services Industry Services Environmental Services Finance Business Development & Traffic Control Quality and Environment Sales & Marketing Human Resources Properties Figure 2 Organizational chart of Foria AB 7 2 RESEARCH APPROACH In this chapter the research method this thesis is presented. It starts with a description of the general strategy for solving Foria’s problems, following this is a description of how data collection, problem analysis, and data analysis was done. Finally the reliability and validity of the results are discussed. 2.1 RESEARCH STRATEGY FOR THE THESIS The starting point for this thesis was Foria’s problem since it is written for, and in cooperation with Foria AB. A general way of describing the research methodology, different steps and parts of this thesis are:  PROBLEM FORMULATION The problem at the focal company is specific and practical in its nature. This practical problem was generalized and broken down to its core to formulate research questions and to define the purpose of the thesis. After an initial orientation of the focal company’s operations an overview of relevant literature were carried out to so a direction for the research could be formulated.  LITERATURE REVIEW After an initial orientation, a deeper search of articles relating to the field was conducted and connected to our problem. However, continuously through the work with the thesis, study and review of articles, books and other media that related to the field of research have been done as the problem evolved over time.  EMPIRICAL DATA COLLECTION The thesis aims at contributing to theory through solving a real world problem; therefore gathering of empirical data has been crucial to the thesis. Empirical data was collected both qualitatively and quantitatively.  SIMULATION AND BUSINESS INTELLIGENCE ANALYSES As the understanding of the problems developed, two separate solutions to Foria’s problems emerged. In order to answer Foria’s two main questions, what is the best distribution network alternative and how should they motivate associated hauler companies’ to change according to this? The first question was approached through a financial analysis through building an analysis tool in the Business Intelligence (BI) program Qlikview. The haulers’ perspective through analyzing the impact in a simulation analysis created for this purpose. Environmental analyses were finally made through assessing the pollutant emissions impact of different distribution scenarios.  VALIDATION OF RESULTS The results are validated both quantitatively through a statistical analysis and qualitatively through examination and scrutiny of the models and its results to identify possible errors.  THEORETICAL DICSUSSION OF RESULTS Finally the results from analysis were related to previous reviewed literature in a theoretical discussion of the results. 8  CONCLUSIONS AND RECOMMENDATIONS TO FORIA A visual and numerical financial analysis was done with Qlikview and a transport efficiency analysis through our simulation model. Conclusions were drawn based on these results and considering these results; recommendations to Foria were given both from a short-term perspective and a long-term perspective. 2.2 METHODOLOGY Both a literature review and an empirical data gathering were carried out. The following subchapter will describe in detail how these were performed. 2.2.1 LITERATURE REVIEW After an initial background orientation and problem description by Foria a deep literature review and general search within the fields of “Efficiency and Effectiveness in transportation” “Distribution and Transportation Network” and “Route and Fleet optimization” was done. A selection of different e-journals was made based on significance to the topics Transportation/Logistic/Supply Chain Management from the pool of e-journals available at the Chalmers library through their licensing agreements. The following e-journals were identified to be connected with these topics, available at Chalmers and initially searched:  Journal of Business Logistics (JBL) (ISSN: 0735-3766)  International Journal of Logistics (IJL) (ISSN: 1367-5567)  International Journal of Logistics Management (IJLM) (ISSN: 0957-4093)  International Journal of Retail and Distribution Management (IJRDM)(ISSN: 0959- 0522)  International Journal of Physical Distribution and Logistics Management (IJPDLM) (ISSN: 0960-0035)  Light and medium truck (LMT) (ISSN: 1091-9651)  Logistic and transportation review (LTR) (ISSN: 0047-4991)  Logistic Management (LM) (ISSN: 1540-3890)  Professional Distributor (PD) (ISSN: 1553-6211)  Transport Reviews (TR) (ISSN: 0144-1647)  Transportation Journal (TJ) (ISSN: 0041-1612)  Transportation Research Part B: Methodological (TRB) (ISSN: 0191-2615)  Transportation Research Part D: Transport and Environment (TRD) (ISSN: 1361- 9209)  Transportation Research Part E: Logistics and Transportation Review (TRE) (ISSN: 1366-5545)  International Journal of Integrated Supply Management (IJISM) (ISSN: 1477-5360) A complementary search at Google Scholar was also performed. When articles of interest were found the method of ancestry approach was implemented where searched through the reference lists of relevant articles narrowing the search net related to the topics of this thesis. Finally as the project progressed, information relevant to issues 9 that rose was searched for at Google and Google Scholar. To start with the literature review the following six search strings were used:  “Transportation efficiency + effectiveness”  “Fleet optimization”  “Route optimization”,  +Distribution +”milk-runs”  +Distribution +”direct deliveries”  +Distribution +”environmental impact” First, for each search term it was looked at the first 30 results for every journal and also the 50 first results at Google Scholar. Based on the title of the article it was decided whether to read the abstract or disregard the article directly. The second filter was based on the abstract. After the abstract had been read a decision was made whether further reading was of interest or if the article can be discarded at this stage. 2.2.1 Empirical data Empirical data was collected in both qualitative forms from interviews, meetings and field studies as well as through quantitative form from shipping data and pricelists. The gathering, understanding and analysis of the empirical data were one of the central parts of this thesis. Structuring the empirical data in a process map enabled the creation of an algorithm for representing the T&D activities. The historic shipping and sales data along with prices was the input for the cost calculations for the financial analysis that was performed to find the optimum mix of own drivers versus an EDN. The historic data was also the input to the simulation model emulating a year of shipments. Qualitative empirical data collection A two-day study visit to Foria´s office in Nyköping and Lantmännen´s warehouse in Västerås was held to broaden our understanding. The aim was to understand the perspectives of the different actors involved in case. Gather empirical data through interviews and also get an overview of the operations. During the two days several meetings and interviews were held with different actors involved in these shipments, see Table 1. The method of choice for conducting these meetings and interviews were in a semi- structured style. Questions and topics were prepared in advance (see Appendix C) however the flow of conversation was flexible and new questions were allowed to rise during the interview and meetings and the topics were mainly used as support and starting points. To not miss any information or hinder the flow of ideas and thoughts with intensive note taking the conversations were recorded and revised afterwards. 10 To further deepen the authors understanding of the day-to-day operations, how these transports are performed, and the difficulties the drivers encounter and gain insight to possible improvements, field studies and orientation visits were held, see Table 2. This gave the author’s valuable insights and understanding of the operations that would have been hard to learn otherwise. The extent of such problems as e.g. not contracted and unreimbursed work activities were experienced firsthand. When creating and validating the simulation model this enhanced understanding was of great value. Table 1 Summary of meetings and interviews Meetings and interviews With Type Objective 1 Foria´s management accompanied with a management representative from Lantmännen Meeting and a semi-structured group interview Get a better understanding of Foria, who they and their operations. Get a better understanding of Foria’s problem from a management perspective. Make sure that the authors and the management group was on the same page regarding the projects purpose and goals. 2 Foria´s transport planners Meeting and a semi-structured group interview Get an understanding of how the transport planners work with these shipments. Get a better understanding of Foria’s problem from a transport planner perspective. 3 A Foria associated hauler and driver Meeting and a semi-structured interview Get an understanding of how the drivers and local haulers perceive these shipments Get a better understanding of Foria’s problem from a driver perspective. 4 A farmer at the receiving end of these shipments. Meeting and a semi-structured interview Get an understanding of the receiver of these shipments perceive them. Get knowledge of any problems that the farmers might have regarding these shipments. 11 Table 2 Summary of field studies and orientation visits Field studies and orientation visits Where With Objective 1 Foria´s operation office at Nyköping Transport planners and Foria management Get an orientation of the day-to-day work with these shipments at Foria 2 Lantmännen’s warehouse in Västerås Foria management, transport planners and Lantmännen representatives Get an orientation of the day-to-day work with these shipments at Lantmännen and possible limitations at the starting end for these shipments. 3 Started with loading in Västerås and riding with a hauler during one day and unloading at various farms. A Foria associated driver for a local hauler. Experience how these shipments are performed and get a real world understanding of the problems facing the drivers on a day-to-day basis. 4 Started with loading in Västerås and riding with a hauler during one day and unloading at various farms. A Foria associated driver for a local hauler. Experience how these shipments are performed and get a real world understanding of the problems facing the drivers on a day-to-day basis. Quantitative empirical data collection The following quantitative data files describing the shipments and the restrictions for analysis were received from Foria, see Table 3. Table 3 Summary of quantitative data collection Quantitative data Received from Foria Type Description Excel file with one year of raw order data. Order data for these shipments from 2010-2011 containing over 25000 order lines. Excel file with distance and time data The distance and expected travel time from Västerås to 3128 different customers based on the customer number. Excel file with price matrix Pricelist and reimbursement matrix per order based on weight from Västerås for different distances for the Foria associated drivers. Excel file with price matrixes Pricelist and reimbursement matrix per order based on weight from Västerås for different distances for an external network provider. One based on postal code for order below 1000kg and one based purely on distance for order above 1000. Excel file with cost calculations. Costs calculations for the trucks currently used based on the Swedish transport industry standard cost calculation tool, SåCalc. 12 2.3 THE PROBLEM ANALYSIS MODELS To start the problem analysis a basic 5-Why’s analysis originating from the Lean principles developed for the Toyota Production System by Toyoda (Liker, 2004) was done. This enhanced the initial understanding of the problem. As the project advanced it became evident that Foria’s problems had several root causes, which generated a need for a deeper analysis. 2.3.1 QUALITATIVE ANALYSIS METHODS A so-called logic tree was created where a “tree” grows from the effect/problem with causes to the problem, which aims at finding the root causes to the overwhelming problem (Rasiel and Friga, 2002). The method is similar to the principle of an Ishikawa diagram first described by Kaoru Ishikawa (1968). The gain from this approach is a deeper understanding of the causes and effects of the problem compared to the simpler 5-why’s analysis. To find solutions to the identified problems the same tree is used, but instead of asking “why”, one asks “how”. Allenström and Linger visualization model A drawback from a logic tree analysis is that it is not easy to overview from a reader perspective. To improve the presentation of the problem analysis for the intended audience, results from the logic tree analysis where transferred to the visualization model presented by Allenström and Linger (2010). This model is based on the well-known 7M’s used in Ishikawa diagrams for production companies but adjusted to fit the specific environment for hauler firms. The visualization method is presented in Figure 3. It is a matrix with two axes; the horizontal axis corresponds to the main processes of a T&D company identified through the use of the lean tool Value Stream Mapping (VSM). The vertical axis, motivated by the 7 M’s used in Ishikawa diagrams, correspond to the possible categorizations of the problems identified (Allenström and Linger, 2010). Shipper Order Entry Planning & Traffic control Transport Execution Invoicing & Registration Routines Manpower & Management Equipment Environment Figure 3 Visualization model (Allenström and Linger, 2010) 13 2.3.2 HOW WAS THE FINANCIAL ANALYSIS TOOL CREATED AND ANALYZED? With the quantitative empirical data it is possible to calculate breaking points between the different pricelist on which is the best in different weight spans. The BI-program Qlikview was chosen as a method and a project specific interface was created in Qlikview. Before that was possible the raw data and pricelist needed to be analyzed and transformed into formats possible to load into the program. E.g. possible errors in the raw data were accounted for and scenarios were created to adjust for them. When the tool was built in Qlikview and the data was loaded the analysis was straightforward to perform in the visual interface of Qlikview. 2.3.3 HOW WAS THE SIMULATION MODEL CREATED AND ANALYZED? The aim of the simulation model is to emulate the work of a transport planner and thus empirical data regarding their way of working were the starting point. A process flow chart was created and approved. The optimization technique called Greedy Algorithm was used to in order to determine the routing of the trucks. The simulation results were then compared and analyzed against each other and conclusion of likely real world implications were drawn from a haulers point of view and an environmental point of view. 2.4 VALIDATION In order to ensure a high validity, i.e. making sure that we measure the right thing, the authors have interviewed people with good knowledge and insight to the operations as well as collecting several viewpoints by talking to all involved parties. Continuous contact with Foria and feedback on the proposed model has also made sure that the validity has been kept high. 2.4.1 FINANCIAL ANALYSIS Quantitative empirical data as input is considered to have a very high validity, it is consists of historical data shipping and sales data, and up-to-date pricelists from their information system (IS). Some errors in weights are identified but they are adjusted for in the financial analysis, so overall the validity of quantitative analysis should be high. Qlikview BI analysis software Qlikview is well-known software, it presents the loaded excel data in a visually and easy to understand way, it does not alter it. Therefor the use of Qlikview does not affect this research validity in any negative way. 2.4.2 SIMULATION MODEL The simulation model simulates a year of shipments, emulates the work of a transport planner and measures the distance driven and the number of stops. Empirical data was the input for the creation of the algorithm describing how the simulation program works. Traffic controllers and an internal process developer scrutinized and confirmed that the algorithm is a valid representation of how transport planners work when they plan shipments. To make sure that this program works as intended a visual validation of randomly selected shipments were made. Simulated shipments were loaded into to a driving 14 optimization software using Google Maps 1 . The real world distance from Google Maps was compared with the simulated distance and the map offered a visual representation that provided confirmation that the routes chosen by the simulation model were logical. The error between the randomly selected simulation shipments and real world distances from the optimization program was also statistically examined and the confidence interval from analysis is presented in the results. The coding of the program was done through pair programming. This reduces programing errors (Cockburn and Williams, 2000) and increases validity. Furthermore, when the program was finished it was scrutinized line by line simultaneously of three people to make sure that it followed the previously approved algorithm. Possible errors and their effects in the simulation model The program is a simulation and it is not as flexible as transport planner could be. E.g. the strict division into regions in the program would not be enforced as strictly in the real world and the transport planners would also take the possibilities of a return shipment into consideration when deciding whether to add the final orders or not. However, the effect of this is considered small since this is the same for all simulation runs. The simulation program is loaded with the historic shipping and sales data. After the simulation program was created the authors identified a few possible errors in the smallest orders. This means that a truck could be loaded with more orders than possible in the real world. However, the analysis is made over an average of a year of simulated shipments; the impact of this should not have a noteworthy effect on the conclusions from the analysis. 2.5 RELIABILITY Reliability, i.e. will that the results be repeatable and consistent, is thought to be very high. Both the financial analysis and the simulation analysis use the quantitative empirical data as input, which is consistent over time for the time period analyzed. Reliability of input from the qualitative empirical data and qualitative analysis are not as high as the quantitative data since it derives from a subjective appreciation of the operations. However, people interviewed have many years of experience and descriptions from different actors from all corners have overlapped and matched. The problems and difficulties with these shipments have been well known for many by actors involved. Therefor we conclude that other researchers would get the same answers and should reach the same results. 1 http://gebweb.net/optimap/ http://gebweb.net/optimap/ 15 3 LITERATURE REVIEW This chapter describes and explains the academic literature that supports and function as reference in the analysis part of the master thesis. Three main areas will be presented and broken down into different subareas: Efficiency in LTL Transportation, DND and Fleet/Vehicle Differentiation. 3.1 LOGISTIC PERFORMANCE Logistics has become one of the most important factors in business competitiveness. Smooth connections among the supply chain (the essential function of logistics) has become the grounding of competitiveness in the global market where innovation and operation technology are no longer enough as qualifiers since everyday they are more reachable for the different players (Kim, 2010). Logistic performance has been defined by the efficiency and effectiveness in the execution of the logistic related activities, e.g. T&D (Mentzer and Konrad, 1991). Within the recent years an increasing awareness of the importance of customers’ value has enhanced the need for excellence and differentiation in the performance of the logistic activities. Thus, logistic performance is recently defined as “the degree of efficiency, effectiveness and differentiation associated with the accomplishment of the logistic activities” (Smith, 2000, Bobbitt, 2004). Figure 4 Logistics Performance Model (Fugate et al., 2010) 3.1.1 LOGISTICS EFFICIENCY AND EFFECTIVENESS Efficiency is the measure of how the resources are utilized in order to achieve a goal and it is expressed as the percentage of the stated normal level of inputs supposed to be utilized, compared against the actual level of inputs utilized (Mentzer and Konrad, 1991). 16 Based on this general definition and applied in a logistic perspective, (see Figure 4) Fugate et al. (2010) defined efficiency of the logistic function as “the measure of how well the resources expended are utilized”. In a general management perspective, effectiveness is expressed as the percentage of the actual outputs compared to the expected or stated normal outputs. Consequently, being 100% effective denotes full accomplishing of a particular goal (Mentzer and Konrad, 1991). Extending the definition to the area of interest of this thesis, logistic, Mentzer and Konrad (1991) defined logistic effectiveness as “the extent to which the logistics function’s goals are accomplished”. Efficiency and effectiveness on transportation has been assessed by several researches within two main different perspectives: (a) Technical / Physical and (b) Strategic / Planning, and impacting mainly Environmentally, Economically and the Service level (See Table 4). Depending on the scope of the organizations, private companies may focus on a combination of them in order to secure profitability and good image while government may be strongly focus on reduce pollution (Samuelsson and Tilanus, 1997). Table 4 Summary of articles relating to logistic efficiency and effectiveness Perspective Impact Author (Researcher) Year Technical / Physical Strategic / Planning Environ- mentally Economic- ally Service Level Samuelsson & Tilanus 1997 X X X X Kim 2010 X X Crainic and Roy 1988 X X X van de Klundert and Otten 2010 X X X Vilkelis 2011 X X Aronsson and Brodin 2006 X X X Li et al. 2006 X X X Apte and Viswanathan 2002 X X X Wang and Regan 2008 X X X Chapman, Soosay and Kandampully 2003 X X X Harmatuck 1990 X X X Samuelsson and Tilanus (1997) described a general framework for measuring the physical efficiency of LTL based on four basic transportation dimensions: time, distance, speed and transportation, emphasizing the importance on not to overlook possible efficiency loss in the physical part of the transportation, often easier to measure, rather than going 17 straight for route optimization and other types of strategic approaches. In the same way, Kim (2010) evaluated various technical efficiency results in order to estimate logistics performance of trucks. Both Samuelsson and Tilanus (1997) and Kim (2010), consistently agreed on the importance of the identification and measure of physical and technical efficiencies in transportation as one important step for profit maximization. On the other hand, strategic or planning perspectives can also improve the efficiency of transportation. Crainic and Roy (1988) developed a mathematical model for the tactical planning of freight transportation. By approaching it as and optimization problem where economic efficiency as well as service level were of main interest, their model proposed a better operating planning and minimizing cost compared to a manually done one. Moreover, strategies aiming to increase capacity utilization of the transport, e.g. consolidation, better IS, etc. will result in cost reductions and mitigation of negative environmental impact, i.e. congestion and pollution (Vilkelis, 2011, van de Klundert and Otten, 2010, Aronsson and Brodin, 2006). Li et al. (2006) described and presented an example of a shipping consolidation problem (SCP), which main goal is to minimize the total cost (transportation and inventory) while satisfying service level constrains. Similarly, cross docking is another distribution strategy thoroughly described by Apte and Viswanathan (2000) which also aims to reduce transportation cost by efficiently maintain low inventory levels without compromising the deliveries. However, cross docking is just one innovative strategy that may be used together with other strategies, e.g. postponement, vendor managed inventory, mass customization, time-based scheduling and among others, in order to boost logistic and transportation efficiencies (Apte and Viswanathan, 2000, Wang and Regan, 2008). Chapman et al. (2003) discussed how innovation on logistics firms can help to re-design their structures and enhance relationships through information sharing and coordination, resulting on overall efficiency improvement, flexibility for upcoming market changes and increase customer service. Furthermore, Harmatuck (1990) described the United States (US) carriers’ strategies after the 1980 US Deregulation 2 . A large number of commodity carriers made strategic and operational strategies in order to cope with the competition. Terminal Expansions, Equipment, Discount pricing, Service Levels and Labor agreements were the most important and resulting on profit increase and efficiency on operations, however service quality did not increased as the others. Another interesting approach to improve transportation technical efficiency, i.e. increase fill rate without diminishing the service level, is a model called “Foliated transportation network” (see Figure 6). Presented by Persson and Lumsden (2006) and furthermore explained by Kalantari and Sternberg (2009), this model combines the advantages of the direct distribution strategy and the hub-and-spoke distribution strategy. 2 The 1980 US Deregulation, known as the Motor Carrier Act of 1980, opened free pricing and routes to be served by the truckers resulting in a significant growth of the competition and number of independent firms. 18 3.2 DISTRIBUTION AND TRANSPORTATION NETWORK DESIGN Distribution and transportation network design decisions concerning storage, location, markets, etc. will guide towards the determination of a proper supply chain structure (Chopra and Meindl, 2007). In the pursuit of this proper and profitable network structure, organizations are devoted to the optimization of their T&D networks through the use different strategies and consequently minimize inventory and reduce transportation costs (Li et al., 2006). 3.2.1 DISTRIBUTION NETWORK DESIGN (DND) As constantly customer needs change in any business, organizations must periodically evaluate their current distribution network and adapt it to match business requirements. In doing so, the most important goal is to find the balance between cost and service level (Tiede and Kay, 2005). Although most companies design their distribution networks based on cost and speed, these processes also have an influence on other factors, including carbon emissions. Optimizing a network design can reduce both costs and carbon emissions significantly (Vilkelis, 2011). There are two key decisions regarding DND: Whether deliver to the customer location or picked up from a predefined site and second, if the flow includes an intermediary or intermediate location. Based on the choices for the two decisions, six distinct DND´s are proposed as shown in Table 5 (Chopra, 2003, Chopra and Meindl, 2007). Table 5 Proposed Distribution Networks Designs (Chopra, 2003) Distribution Network Design Manufacturer storage with direct shipping Manufacturer storage with direct shipping and merge in transit Distributor storage with carrier delivery Distributor storage with last mile delivery Manufacturer/distributor storage with costumer pick-up Retail storage with customer pick-up There are two main criteria in order to select the most suitable DND: meeting the customer needs and the cost of meeting those needs. Then, the performance of the distribution network will depend on the satisfaction of the customer needs, directly impacting the revenues, and the supply chain costs of the network (Chopra, 2003). 19 Sharma, Moon and Bae (2008), adapted Chopra`s framework in order to outline the most important criteria and sub-criteria towards the design of an optimal distribution network (see Figure 5), where is necessary to prioritize the metrics both related to costs and customer service. For the cost factors, Chopra (2003) distinct: inventories, transportation, facilities and handling and information. Accordingly, in order to fulfill the customer needs, the factors to consider are: response time, product variety, product availability, etc. Figure 5. Designing the Optimal Distribution Network (Sharma et al., 2008) Crainic and Roy (1988) classified in three groups the problems and policies required when designing a transportation network: strategic (long-term), tactical (medium-term) and operational (short-term). The strategic group entails for large investments and the decisions connected with this level of planning are connected to physical network design, location, resource acquisition and service policy definition. The tactical planning, which is not as dynamic as the previous group looks after the performance of the whole system and the decisions are sensitive only to wide variations. The selection of routes, traffic distribution and service network design are examples of decisions regarding this group. The operational planning, characterized by a dynamic environment, consisting on decisions as: scheduling, maintenance, terminals and routes daily operations, allocating resources, etc. 20 3.2.2 TRANSPORTATION NETWORK DESIGN (TND) Regarding TND the decisions are mainly affected by the tradeoff between the service level (responsiveness) and the inventory and transportation costs. Different options proposed by Chopra and Meindl (2007) are shown in Table 6. Table 6 Proposed Transportation Networks Designs (Chopra and Meindl, 2007) Transportation Network Design Direct Shipping Milk-runs Central DC with storage Central DC with cross-docking Milk-runs via DC Tailored network Direct shipment transportation consists on the delivery of goods from one supplier to one buyer location, eliminating intermediaries and reducing complexity and coordination. Direct shipments are suitable if economy of scale can be found and if the demand is high enough, that optimal lot size is close to the size of a full truck. The effectiveness of direct shipping deteriorates as the economic lot sizes decrease (Gallego and Simchi-Levi, 1990, Persson and Lumsden, 2006, Chopra and Meindl, 2007). Milk Runs or Peddling is a distribution strategy where one truckload is delivered to more than one customer, i.e. two or more drop points. The use of milk runs enables consolidation of multiple deliveries, which may result in better utilization of a truck (Chopra and Meindl, 2007). Burns et al. (1985) presented the use of delivery regions and sub-regions for the analysis of the milk run transportation network. This region division of the different customers enables the definition of the truckloads and outlines the geographical area for the milk run routing. For TND involving the use of a central distribution center, organizations can increase the service level with bigger product assortment and quick responsiveness but the inventory cost will be higher. An alternative of this is the use of cross docking strategies, however it requires more coordination and synchronization through the use of information technologies (Chopra and Meindl, 2007). In the same way, Distribution Centers allow the use of milk runs, which will depend on the size and consolidations possibilities of the goods. According to Persson and Lumsden (2006), transportation companies today are hardly operating with a fix distribution strategy as pure direct shipments or completely hub-and- spoke networks. Thus, a tailored network design facilitates an appropriate combination of the previous described transportation network designs (Chopra and Meindl, 2007). Foliated transportation network, shown in Figure 6, is an example of a tailored network design. 21 Figure 6 Foliated transportation network (Persson and Lumsden, 2006) 3.3 DISTRIBUTION AND TRANSPORTATION OPTIMIZATION Optimization describes the process of finding an optimal solution among a large number of possibilities. Optimization problems involve decisions characterized by the three components: (1) resource constraints, e.g. time, money, etc. (2) variables, e.g. distance, cost, etc. and (3) objectives e.g. minimize cost. Optimization problems directly related to T&D include the Traveler Sales Problems (TSP) and greedy algorithms, which are further described below. 3.3.1 TRAVELER SALES PROBLEM (TSP) The TSP is a well-known optimization problem whose objective is to find the minimum total distance travelled by a salesman, from an origin location to a defined number of different cities, returning to the origin and visiting each city only once time (Gutin and Punnen, 2002). One of the first persons to study similar problems to TSP problems was Leonhard Euler back in 1759, however it is believed that the first person on reported in a mathematical formulation a comparable TSP problem was Karl Menger with his “messenger problem” (Gutin and Punnen, 2002, Klanšek, 2011). Optimization software had increase the reach of the TSP within the last years, e.g. it is possible to compare TSP studies before the 80’ with no more than 500 nodes to recent studies with almost one million of nodes or visits (Klanšek, 2011). Moreover, TSP optimization models have been used in numerous fields as manufacturing, logistics, and operational research among others (Klanšek, 2011, Gutin and Punnen, 2002). 22 3.3.2 GREEDY ALGORITHM A greedy algorithm is the kind of algorithm that makes a choice base on the best available option at that precisely moment, called “local optimal” and, once the choice is made; it never goes back on previous decisions. Every step is constructed towards the overall solution of the problem, called “global optimal” (Curtis, 2003). Curtis (2003) described the four greedy principles: Best global, better global, best local and better local (see Figure 7). While all greedy algorithms compile with the best global principle, the compliance with the other three principles defines how strong the algorithm in the pursuit for the optimal solution is. Following this, Curtis (2003) classified the greedy algorithms as shown in Table 7. Table 7 Greedy Algorithms Classification (Curtis, 2003) Greedy Algorithm Classification Strength Description 1. Best-global only Minimum Greedy Algorithm Best local choice can ultimately lead to a better solution 2. Better-Global and Best-Global only Stronger than 1 Better local choice can ultimately lead to a better solution 3. Best-Local and Best-Global only Stronger than 2 Repeatedly best local choice always results in a partial solution that is best so far. 4. Best-Local, Better-Global and Best-Global only Stronger than 3 Repeatedly better local choice always results in a partial solution that is best so far. 5. Better-Local, Best-Local, Better- Global and Best-Global The Strongest Better partial solution can lead to one that is still better after the next construction step The most emblematic and well-known greedy algorithms deal with minimum spanning tree theories, e.g. Dijkstra’s minimum spanning tree, Prim’s minimum spanning tree, Kruskal’s minimum spanning tree, etc. (Chang et al., 2008, Wu et al., 2004). These three examples are situated on the “best-local” classification because by choosing the least weight of paths at every step (local optimal), this will secure the best solution until completing the Figure 7 The four greedy principles with implications (Curtis, 2003) 23 solution to the problem. 3.4 ENVIRONMENTAL IMPLICATION OF TRANSPORTATION Thomas and Harrison (2004) explained that the major environmental impacts from the transport sector are: human health implications, dilution of the ozone layer, GHG effect, hyper fertilization, acidification and destruction of landscapes that creates barriers. Table 8 presents the links between main emissions from the freight transport and environmental impacts. Table 8. Link between emissions from transport and environmental impact (Thomas and Harrison, 2004) Environmental impacts CO NOx HC PM SOx CO2 Human health Nerves and Heart Lungs and breathing by forming ground level ozone Nerves and breathing, and may cause cancers Important effects on life expectancy Lungs and breathing X Dilution ozone layer X Through N2O only X X X Acidification Damages forests and fish through acid rain Damages forests and fish through acid rain Greenhouse effect Through N20 Through CH4 X Increase of the global temperature and sea levels Hyper fertilization Leads to a lack of oxygen and dead sea bed as the number of algae increases X X In order to develop a strategy concerning environmental performance targets and, at the same time securing the company’s long term economy success, it is necessary to identify the specific environmental impact on the transportation system and thus propose viable alternatives leading to a low environmental impact (Aronsson and Brodin, 2006). 3.4.1 APPROACHES TO REDUCE EMISSIONS There are different solutions or approaches to reduce transportation emissions and it is possible to classify them in three different categories: There are technological solutions such as alternatives fuels, greener engines or catalytic converters. There are also logistics solutions such as better vehicle utilization, route optimization or improving of route planning (Lumsden, 2006a). The last category concerns social or behavioral solutions for example 24 better planning of the way of driving by reducing speed or braking patterns. The International Energy Agency (1999) affirm that these solutions can reduce the environmental impacts on transport but none of these can stand alone as the ultimate solution. Holden and Høyer (2005) go even further, stating that these changes won’t be enough as road transport increase and therefore there is a need to change the means of transportation. 3.4.2 ENVIRONMENTAL PERFORMANCE IN TRANSPORTATION The Network for Transport and Environment (NTM) group developed a set of documents for transportation where it is provided the tools, instructions and pre-defined data in order to calculate and evaluate the environmental performance of a transport activities (NTM-Road, 2008). Even though NTM-Roads provided default data selected in order to be representative of a normal transport performed in European countries today, it is recommended to use situation specific data when available for more close to reality results. Vehicle types and Characteristics NTM-Road (2008) described ten different vehicles for road cargo transportation (see Table 8). From the smallest Light Cargo Vehicle (LCV) to the biggest Heavy Duty Vehicle (HDV), the descriptions and characteristics match all normal ranges of cargo trucks. Fuel Consumption When specific data is not available, NTM-Road (2008), suggest the use of fuel consumption figures contained in Table 45 (Appendix E). The fuel consumption data, given in liters per kilometer (l/km), is subject to different variants: the type of truck, the cargo capacity utilization (CCU) of the truck, the type of engine (Euro I – Euro V) and the type of road (motorway, rural or urban). Vehicles Emissions NTM-Road (2008) provide a compendium of tables where is possible to find pre-defined values for pollutant emissions in the road transport. These emissions are: HC, CO, NOx, PM, CO2, CH4 and SOx. Similarly than the fuel consumption data, the values are depending on the type of truck, the type of engine, the CCU, and the type of road. Calculation Strategy In order to calculate the environmental impact of a given transportation activity, NTM- Road (2008) defined the following strategy steps: First select the appropriate vehicle from Table 9. Secondly, set and calculate the fuel consumption from Table 45 (Appendix E) and with the parameters explained before. The next step is to select the appropriate emissions based on the tables and restrictions described before. And finally, find the distance for the transportation activity. 25 Table 9. Vehicle concepts/types and cargo capacity (NTM-Road, 2008) 26 4 EMPIRICAL FINDINGS In this chapter the empirical findings are presented. This includes the roles, responsibilities and activities of the involved actors. Furthermore, the nature of the goods that is being transported as well as the properties of the vehicles being used for these transports today. 4.1 OPERATIONS OF INTEREST FOR THIS PROJECT Figure 8 below describes how the studied shipments are performed from a historical perspective as well as how they performed as of December 2011. 4.1.1 HISTORICALLY Historically Lantmännen was the one who planned these shipments, and the already constructed and formed LTL-shipment plans were sent to Foria who booked a truck and driver. Foria then planned for loading at the warehouse in Västerås, and then charged Lantmännen based on the amount of kilometer driven, number of stops, waiting time etc. This meant that there were no incentives for Foria and their drivers to be effective and provide any efficiency improvements since they were reimbursed based on the amount of resources that were used to perform the transports. Interviews and field studies have shown that inefficiencies of these shipments were well known among the involved actors. 4.1.2 THE NEW CONTRACT – A SHIFT IN RESPONSIBILITIES The inefficiencies were over time raised as an internal problem at Lantmännen. Negotiations started which led to a new contract with Foria, which will reduce Lantmännen’s Figure 8 Value stream mapping of current operations 27 costs for these shipments. The new contract has a new reimbursement structure where Foria is reimbursed a fixed amount per order based on the distance from Västerås and its transport determining weight. The contract also includes a shift in responsibilities and ownership for some work processes and activities. From December 2011 Foria is also responsible for constructing and planning the LTL-shipments from the available orders, which means they now have a bigger possibility to impact the way these transports are performed. Furthermore, the new contract means that Foria now have incentives to plan and perform these transports as effective and efficient as possible. And to quote the chairman of Foria: “We have to do this in a better way since we won’t get any economy in doing it the old way anymore. The price we have negotiated with Lantmännen for this new contract won’t cover our expenses for this to be run as it always has. “– Håkan Larsson 3 The underlying reason for this thesis from Foria’s perspective is to gain knowledge of possible efficiency improvements. This through analyzing alternative distribution models in order for them to achieve profit in this new contract so the new contract terms becomes a win-win situation for both Lantmännen and Foria. 4.2 THE INVOLVED ACTORS There are currently four different actors involved in these operations. The transport planners at Foria’s office in Nyköping, the local haulage contractors performing the physical transports, Lantmännen AB Division Lantbruk 4 , who is the supplier of cargo, and the end customer, the farmers purchasing agriculture supplies. The following subchapters will describe them closer. 4.2.1 TRANSPORT PLANNERS AT FORIA In Foria’s office in Nyköping sits six transport planners responsible for building and planning shipments from the incoming orders from Lantmännen. This is done manually with the support of IS showing available orders. Figure 28 in Appendix B displays a print screen from the order view from that IS. Stefan Palmgren at Foria management team compares the job as a transport planner at Foria to the work of an air traffic controller 5 . The job requires a high multitasking skill since the planning and optimization work is done manually. The job does not require a university degree but the work profile generally requires a vocational education to become a qualified transport planner. 3 Interview/meeting with Foria and Lantmännen management in Nyköping, Sweden, September 22nd 2011 4 Lantbruk means agriculture in Swedish 5 Interview/meeting with Foria and Lantmännen management in Nyköping, Sweden, September 22nd 2011 28 How the transport planners perform their work The main order information the transport planner use when planning these shipments besides the address where the cargo is heading is:  The method of delivery (“Leveranssätt” in Figure 28) o Some farmers and some cargo require a different unloading method, i.e. crane, forklift or the farmer might want to unload him or herself.  First available day when the cargo is available for loading at Västerås (“1:a dagen då godset finns tillgängligt” in Figure 28) o Some orders are available a long time before the last required departure date; this means that they can be planned optimally.  Last day of delivery (“Sista dag för leverans in Figure 28) o A delivery run for these shipments takes between 1-3 days depending on the number of stops and how widespread the drop-off points are. This means that the transport planner manually needs to estimate when the cargo will be delivered based on other orders on the same truck for the order not to be late. They have a service level requirement of 98% within latest delivery time and currently they are between 96-97% 6 .  Amount/Weight (“Mängd” in Figure 28) o The weight and size of the order is of course vital for the transport planner to know. The cargo is mainly weight dependent but the transport planner needs to manually adjust for some orders that will be limiting when it comes to their size. With this information the transport planner tries to fill trucks so that orders going to the same region will be loaded together to minimize driving distance as well to try to achieve a high fill rate. Besides this they also take into account where the truck will finish so it is possible to find a return shipment to minimize empty driving. 4.2.2 FORI