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Gołebiewski2013 (RL91)
Gołebiewski2013 (RL91)
Gołebiewski2013 (RL91)
a r t i c l e i n f o a b s t r a c t
Article history: The technical progress causes that increasing number of used devices presents a threat for environment,
Received 6 February 2013 particularly in the rural areas. It can be prevented by organizing a proper system of waste disposal. Cur-
Received in revised form 8 July 2013 rently, the most important problem to solve is recycling of vehicles. The key element for the improvement
Accepted 14 July 2013
of the functioning of the recycling network in Poland is to redesign the system so that it will allow for a
reduction of the total cost related to the vehicle recycling. This paper presents a modelling approach that
Keywords:
could be used to establish one important part of the reverse logistics (RL) network for end-of-life vehicles
Reverse logistic
(ELVs) by defining the optimum locations for dismantling facilities. The proposed modelling approach is
End-of-life vehicles
Case study
illustrated using Mazovia province in Poland as an example. The optimization criteria for the location of
Genetic algorithms the elements of the recycling network are the components of the total cost of the ELV’s recycling. Due to
high complexity of the model a genetic algorithm has been adapted for solving the model and getting a
good solution in a reasonable run time. The criteria of optimization was cost of the following processes:
transportation, storage, and dismantling of ELVs. The results of simulation proved that the transportation
costs of parts and materials may amount to about 70%, and that the cost of dismantling may exceed 25%
of the total cost of recycling. The obtained results confirmed that genetic algorithm method can be used
effectively to location the ELV’s dismantling facilities. The effect of changing the location of processing
facilities on the location of dismantling stations was also studied. The developed model is universal and
may be used to determine the locations of different kinds of facilities organized in a reverse recycling
network.
Crown Copyright © 2013 Published by Elsevier B.V. All rights reserved.
0921-3449/$ – see front matter. Crown Copyright © 2013 Published by Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.resconrec.2013.07.005
B. Goł˛ebiewski et al. / Resources, Conservation and Recycling 80 (2013) 10–20 11
3.2. Formulation of the optimization task nth collection point, Sk is the daily stream of parts and materials in
the kth processing facility, j, k, n are the summing indexes, Cs is the
3.2.1. Assumptions unit cost of transporting from the collection point to the disman-
Initial assumptions were formulated regarding the support sys- tling station, Cm is the unit cost of storing vehicles in the dismantling
tem for the selection of the location of the dismantling stations in station, Cd is the unit cost of dismantling in the dismantling station,
a vehicle-recycling network: Cc is the unit cost of transporting parts and materials from the dis-
mantling station to the processing facilities, Ls (i, j)min is the the
1. The location of a dismantling station is sought that takes into minimum distance between the collection points and dismantling
consideration the location of the existing processing facilities, station, Lc (j, k)min is the minimum distance between the disman-
and the suggested location of vehicle collection points. tling station and the processing facilities, Ej is the correction factor
2. The number of vehicle collection points depends on the selected in the jth station, and D is the daily capacity for processing of vehicle
area as well as the assumed territorial and legal conditions. in the dismantling stations.
3. Vehicles collected in collection points are transported to the It is at the dismantling stations that the main part of the pro-
nearest dismantling station. cess takes place, which is the dismantling of vehicles as well as
4. The concentration of the dismantling station depends on storing both the vehicles and dismantled parts to be transported to
demand. However, the distance from the collection points processing or utilizing the facilities.
should also be taken into consideration. It is assumed that the cost of storing vehicles at a dismantling
5. The network should include at least one processing facility. station Km is considered only when the number of cars deposited
6. The vehicle-recycling network has been designed using a speci- at the station is greater than the daily throughput of the station.
fied, limited area. The cost of dismantling Kd depends on the scope of work and
is calculated for each vehicle in each station. The cost includes the
The objective of the optimization task, with the above assump-
following:
tions, regards the number and location of vehicle dismantling
stations. The optimization task concerning the location of disman-
– cost of dismantling work that depends on the labor cost,
tling stations is formulated relative to the minimization of the
investment costs and depreciation, fixed (operational) cost, and
objective function.
internal transport cost and
3.2.2. Mathematical formulation – cost of utilization of non-recyclable waste material.
2010 (Statistical Yearbook, 2010), there were 3.541 million reg- 600
Un it co st o f d isman tlin g , PL N
istered vehicles. Based on the data obtained from the Driver and
500
Vehicle Licensing Centers it was assumed that 25% of the passen-
ger cars registered in the province should be withdrawn from use. 400
Due to the territorial division of Poland into provinces and districts,
300
it was assumed that a collection point should be located in each dis-
trict. Thus, a potential dismantling station will be located in one of 200
37 district towns. Hence, J ≤ N ≤ 37. As there are a lot of processing
100
facilities in Poland, with different scopes of activity and throughput,
the most important ones were selected for analyzing the system. 0
Thus, the number K = 6 of such facilities as well as their location 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
south of the Mazovia province. The number of vehicles, pcs.
The daily number of EOL cars is calculated for each district in
Fig. 3. The dependence of the unit cost of dismantling in the station located within
the form of the Qn stream. The parameters of the distribution are
Warsaw’s city boundaries on the number of vehicles.
calculated on the basis of information about the number of vehicles
registered in a given district and the index of scrapped cars using
3.4. Structure of the decision support system
the following formulae:
The system supporting the selection of the location of vehicle
Pn · w1
Qn = , (10) dismantling stations is presented in Fig. 4.
d The intelligent support system for dismantling station location,
based on the selected input parameters, needed to optimize the
where d is the number of working days in a calendar year, w1 is the
number of dismantling stations of vehicles and their locating in
index of scrapped vehicles, Pn is the number of cars registered in
the selected area. The result is not the only optimal number of dis-
the nth district, For the purpose of simulation tests of the system,
mantling stations but also received information, where to locate
the following was assumed: d = 250, w1 = 0.25.
these stations under certain conditions. Simulation studies using
Furthermore, from the own study it was concluded that the dif-
this system will provide the basis for decision support in vehicle
ference between minimum and average value of stream equals no
dismantling station location.
more than 55%.
Input data: it is a module where data about the objects of the
Hence, it was assumed that the Qn stream is treated as a random
recycling network (e.g. J, K, N, . . .), and the matrix of the distance
variable, and is generated using a normal distribution generator
between them for a selected area are input, and numbers Qi of the
N(Qn , n /3), because in the range m ± 3 there are 99% all of the
vehicles to be recycled are generated.
random variables with distribution N (m, ).
Coding of the optimization task: each variant of the number and
For the purpose of simplification, a fixed daily rate for storing
location of the dismantling station being analyzed in the system is
one vehicle amounting to km = 2.50 [PLN/day] is used in the algo-
coded in the form of an ordered binary sequence, called a chromo-
rithm for determining the cost of storing vehicles in the dismantling
some. The recycling cost is calculated for each chromosome.
station. In order to calculate the cost of transport, it is assumed
Cost determination algorithms: these are responsible for the cal-
that the unit cost for transporting 1 ton of end-of-use cars amounts
culation of all costs that constitute the total recycling cost, and the
to ks = 1.62 [PLN/km], and the respective cost of transport of the
objective function with constraints.
dismantled parts and materials to processing facilities amounts to
Optimization using genetic algorithms: it is the most important
kc = 2.21 [PLN/km], (Bentkowska-Senator et al., 2010). It is assumed
module of the system that finds the optimum solution – the number
that the unit cost is fixed.
of dismantling stations as well as their topographic location.
The analysis of the cost connected with dismantling one vehi-
cle showed that the dependence of the cost on the demand for 3.5. Coding and solving the optimization task
the dismantling service is nonlinear; e.g. Fig. 3 presents the unit
cost kd determined for the dismantling station located within the A binary location vector that represents chromosomes in the
Warsaw’s city boundaries. applied genetic algorithm was used to code potential locations of all
Input data
Presentation
of results
End
Fig. 4. The system supporting decision-making concerning the location of vehicle dismantling stations.
B. Goł˛ebiewski et al. / Resources, Conservation and Recycling 80 (2013) 10–20 15
Table 1
An example of coding and finding the solution of the task.
Place of location, matrix [ajn ] A aj1 B aj2 C aj3 D aj4 E aj5 F aj6
A C E
the dismantling stations (DS) in the recycling network. The number 3.6. Optimization using the genetic algorithms
of the vector’s coordinates is equal to the number of vehicle collec-
tion points; in the analyzed case of N = 37. The coordinate xn of the The solution of the optimization task, formulated in the paper,
location vector (n = 1, . . ., N) provides information as to whether is sought using the developed genetic algorithm (the method of
there is a dismantling station (DS) in the nth vehicle collection point transformation of the population of chromosomes which code the
(CP). The value equalling “1” denotes that a dismantling station is selection of DS after considering the minimum cost of recycling).
located in this place, and the value equalling “0” denotes that there The flowchart of the genetic algorithm is presented in Fig. 6.
is no such station. The uniqueness of this information results from The algorithm uses the following genetic operators: mutation,
the initial assignment of the chromosome coordinates to the CP crossover and reproduction (Gen and Cheng, 1997).
locations; e.g. chromosome (1, 0, 1, 0, 1, 0) denotes that dismantling Gene mutation: the mutation operator is introduced (with a
stations are located in the first, third and fifth location of all of the probability of 1) in the chromosomes which are identical (in the
six locations being analyzed. The shortest distance criterion is used deterministic selection) in order to introduce diversity to the
to indicate the CP points from which the vehicles are transported population, which (at least partially) prevents the premature con-
to these three DS stations. As such, in the distance matrix [ajn ], the vergence of the algorithm.
values x1n1 = min a1n , x2n2 = min a2n , x6n6 = min a6n are sought Crossover: the crossover operator is used only in cases of selected
for n = 1,3,5. Indexes n1 , n2 , . . ., n6 indicate the number of places individuals (the most promising ones), and the point of crossover
of location of the station (DS). The example below presents the is selected at random.
assignment of vehicle dismantling station (DS) locations to vehi- Reproduction: an elite strategy and genetic algorithm with a par-
cle collection points (CP). In the example N = 6, symbols A, B, . . ., F tial exchange of population. The elite strategy involves protection
denotes the locations of vehicle collection points (CP) (Table 1). of the best chromosomes in successive iterations. In the genetic
As the example shows, six CP points are assigned a DS located algorithm with a partial exchange of population, only part of the
in A, C and E. population which is to form the next generation, does not undergo
Fig. 5 presents the assignment: namely, to which dismantling any modifications; i.e. crossover and mutation. In this particular
station (DS) the vehicles from the vehicle collection points (CP) case, it applies to the best (the fittest) individual from the popula-
will be transported. Each chromosome contains information about tion.
the number of vehicle dismantling stations and their locations in a Selection: the individuals to form the next generation are
given area. selected based on the ranking method. Each individual is assigned
the number specifying his location on a list – a rank.
Halt condition: no improvement in the adaptation function 4. Numerical results in the case of the Mazovia province
(minimization of the recycling cost) in 10 successive iterations
(generations). 4.1. Cost analysis
The optimization is used by Visual Basic language, which is
implemented in Microsoft Excel. The value of the genetic algo- The cost of recycling vehicles Krec is calculated based on the
rithm parameters are as follows: the number of generations are stream Q of utilized vehicles, and the location of the processing
200, the population size is 36, the type of selection is tournament, facilities (north – ZPpn or south – ZPpd ) in the Mazovia province and
the mutation faction equals 1, and the probability of crossover is the unit costs ks , kd , km , kc . The results of the simulated locations of
0.77, respectively. the dismantling stations for selected input variables are presented
The originality of the method used involves automatic forma- graphically both on the maps of the province and in the form of
tion of new chromosomes (by the developed decision support graphs. The diagram in Fig. 7 presents the system of simulation
system) which indicate potentially possible locations were the cost experiments; the symbol wp denotes a coefficient of percentage
is calculated. The chromosome, which is impossible to significantly change in the cost components by 50%, 25%, . . ., 100%).
improve the calculated objective function (1) of the optimization The comparative analysis is based on the cost of recycling calcu-
task, is assumed to meet the optimization criterion. lated for the maximum stream of vehicles directed to all recycling
Fig. 8. The results of the optimization of: (A) the cost of recycling Krec in successive iterations for the basic set of input data and (B) the location of dismantling stations.
B. Goł˛ebiewski et al. / Resources, Conservation and Recycling 80 (2013) 10–20 17
stations in the Mazovia province and other parameters identified Analysis of the cost of recycling
for this area, Krec = f (Qmax , PFpd , ks , kd , km , kc ). The obtained value 75
of Krec for the identified data that constitutes the basic set of data
in the conducted research is presented in Fig. 8. The result F = 2056
million [PLN], considered the best due to the value of the adaptation 50
Fig. 10. The influence of the increase by 100% of the cost connected with the following: (A) transportation of vehicles, (B) storage, (C) dismantling, and (D) transportation of
parts and materials on the optimum number of dismantling stations and their locations.
18 B. Goł˛ebiewski et al. / Resources, Conservation and Recycling 80 (2013) 10–20
consequence of the long distances between stations and processing The influence of the stream of vehicles on cost
facilities. 120
The increase of individual component costs used in the process
by 100% results in different locations of dismantling stations. Fig. 10 100
presents locations of stations in the case of an increase in the cost
20
• the transportation of vehicles results in a significant increase in
the number of dismantling stations from 17 to 30, and a small 0
increase in the total cost of recycling by 0.8%; 0 500 1000 1500 2000 2500 3000
• storage results in a significant increase in the number of disman- Stream of vehicles [vehicles/day]
tling stations from 17 to 30, and a small increase in the total cost
Fig. 11. Percentage change in the cost of recycling depending on the stream of
of recycling by 1%;
vehicles.
• dismantling results in a significant increase in the number of dis-
mantling stations from 17 to 29, and an increase in the total cost
of recycling by 29%;
Fig. 12. Location of dismantling stations in the Mazovia province for the (A) minimum, (B) medium, and (C) maximum stream of vehicles.
B. Goł˛ebiewski et al. / Resources, Conservation and Recycling 80 (2013) 10–20 19
Fig. 13. Location of dismantling stations when processing facilities are located in the north of the country (A) and in the south (B).
• the transportation of parts and materials results in a significant the proposed method of optimization can be considered logically
decrease in the number of dismantling stations from 17 to 4, and verified.
an increase of the total cost of recycling by as much as 62%. The developed system may be used to analyze the cost-
effectiveness of the proposed recycling network. The developed
system provides information on the incurred cost. It may also
4.3. Analysis of the stream of utilized vehicles be extended to include transportation problems concerning the
risk and the profit from the sales of dismantled parts and mate-
Simulations testing the influence of the value of the ELV stream rials. Then, the balance of the cost and profits would allow for an
in the province on the total cost of recycling show that the size of improvement in the cost-effectiveness of the network.
the stream of vehicles has an influence on the location of disman-
tling stations as well as their number. Calculations were performed
for the following stream of vehicles: minimum – 756 vehicles 5. Conclusions
daily where 6 dismantling stations are indicated; medium – 1685
vehicles daily with 8 dismantling stations, and maximum – 2640 The research conducted here is related to the problem of locat-
vehicles daily, with 17 dismantling stations. ing the dismantling facilities which play an important role in the
The values of the objective function (1), as determined by the process of recycling ELVs due to the direct impact on the cost of
simulations, are presented in Fig. 11, and the location of the dis- logistics. The main intention of the research from a theoretical
mantling stations within the analyzed area is shown in Fig. 12. The point of view was to develop the modelling approach that could be
optimum number of dismantling stations obtained for the mini- used to establish an RL network for ELVs by defining the optimum
mum, medium and maximum stream of utilized vehicles is equal locations for dismantling facilities.
to 6, 8 and 17, respectively. The authors also intended to achieve a more practical objective
by illustrating the proposed modelling approach using the Mazovia
province as an example. The location of the dismantling facilities
4.4. Analysis of the influence of the location of processing facilities determined the cost of dismantling, besides the location of the
facilities that processed the dismantled parts. The results of the
The influence of changing the location of processing facilities on simulation that used the developed model proved that changes in
the location of dismantling stations is also studied. The basic vari- the cost of the components depend linearly on the total recycling
ant, presented in Fig. 8 and in Fig. 13B, assumes that the materials cost within the variability range of ±100%.
and parts are transported to processing facilities located south of Simulation studies for Mazovia province showed that the great-
the area being analyzed. Fig. 13A shows the consequences of locat- est impact on the value of the total costs of recycling vehicles
ing these facilities north of the Mazovia province. DS located in the are distances between objects recycling networks (transportation
same places on maps A and B in Fig. 13 are marked by the symbol costs). Changes the value of the cost of transportation of parts and
䊉. materials by 50% resulted in a change of the total costs of recycling
The results obtained by simulation correspond with both the by 36%.
empirical research results and logical analysis. The more stations Simulations testing the influence of the value of the ELV stream
and the shorter distances, the lower the total cost of transport and in the province on the total cost of recycling also showed that the
storage, and the greater the total cost of dismantling, provided that size of the stream of vehicles has an influence on the location of
the supply of vehicles is small. As the simulations show, the num- dismantling stations as well as their number.
ber of dismantling stations increases together with the increase This study also confirmed that the strategic meaning during
in the number of vehicles, which is also logically justified. The the design of the reverse logistic network has the location of the
change in the location of the processing facilities results in shif- processing facilities, which always determines the location and
ting the locations of dismantling stations toward them, which can number of dismantling stations. Moreover, the study demonstrated
also be logically justified, too. Following analysis of the obtained that genetic algorithms were useful tools for simulating and opti-
results of the simulation research, both the developed system and mizing the location of vehicle recycling facilities.
20 B. Goł˛ebiewski et al. / Resources, Conservation and Recycling 80 (2013) 10–20
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Acknowledgment Lee JE, Gen M, Rhee KG. Network model and optimization of reverse logistics
by hybrid genetic algorithm. Computers & Industrial Engineering 2009;56:
The authors wish to thank professor Choromański from Fac- 951–64.
Mahmoudzadeh M, Mansour S, Karimi B. A decentralized reverse logistics network
ulty of Transport, Warsaw University of Technology for his valuable
for end of life vehicles from third party provider perspective. In: Proceedings of
suggestions. the 12th International Conference on Environmental Science and Technology;
2011a.
Mahmoudzadeh M, Mansour S, Shokoohyar S, Karimi B. Designing modelling a third
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