A continuous approximation approach for the integrated facility-inventory allocation problem

In today’s retail business many companies have a complex distribution network with several national and regional distribution centers. This article studies an integrated facility location and inventory allocation problem for designing a distribution network with multiple distribution centers and retailers. The key decisions are where to locate the regional distribution centers (RDCs), how to assign retail stores to RDCs and what should be the inventory policy at the different locations such that the total network cost is minimized. Due to the complexity of the problem, a continuous approximation (CA) model is used to represent the network. Nonlinear programming techniques are developed to solve the optimization problems. The main contribution of this work lies in developing a new CA modeling technique when the discrete data cannot be modeled by a continuous function and applying this technique to solve an integrated facility location-allocation and inventory-management problem. Our methodology is illustrated with the network from a leading US retailer. Numerical analysis suggests that the total cost is significantly lower in the case of the integrated model as compared with the non-integrated model, where the location-allocation and inventory-management problems are considered separately. This paper also studies the effects of changing parameter values on the optimal solutions and to point out some management implications.