Refuse or reuse: managing the quality of returns in product recovery systems

Abstract

Increasing legislative and societal pressures are forcing manufacturers to become environmentally-conscious and take responsibility for the fate of their goods after they have been used by consumers. As a result, some manufacturers operate hybrid systems which produce new goods and recover used goods. Product recovery describes the process by which used products are returned to their manufacturers or sent to a specialised facility for recovery, before being sold on the original or a secondary market. The quality of the returned goods is a significant issue in product recovery systems as it can affect both the type of recovery and costs associated with it. Quality in product recovery systems has not been adequately studied, with many authors either ignoring the possibility of receiving lower quality returns, or assuming they are disposed of rather than recovered. However, such assumptions ignore the possibility that the firm might be able to salvage value from lower quality returns by using them for parts or materials. This thesis presents four models that investigate the importance of considering the quality of returns in the management of inventory in a product recovery system, by examining the cost-effectiveness of recovering both high quality and low quality returns. The first model is a deterministic lot-sizing model of a product recovery system. It was found that performing both high and low quality recovery reduced the sensitivity of the optimal cost to operational restrictions on the choice of decision variables. The second model is a discrete-time, periodic-review model formulated as a Markov decision process (MDP) and introduces uncertainty in demand, returns, and the quality of the returns. It was found that performing both types of recovery can lead to cost savings and better customer service for firms through an increased fill rate. The third model addresses those industries where produced and recovered goods cannot be sold on the same market due to customers’ perceptions and environmental legalisation. Using an MDP formulation, the model examines a product recovery system in which produced and recovered goods are sold on separate markets. The profitability of offering two-way substitution between these markets was investigated. It was found that offering substitution can allow firms to increase both their profits and fill rates. The fourth model examines the issue of separate markets and substitution in the continuous time domain using a semi-Markov decision process. The continuous nature of the model allows more detailed examination of the substitution decision. It was found that offering substitution can allow firms to increase their profit and in some cases also increase their fill rate. In some cases, production is performed less frequently when downward substitution can be offered, and recovery is performed less often when upward substitution can be offered. The findings of this thesis could be used to help a firm that is currently recovering high quality returns assess the cost-effectiveness of also recovering lower quality returns. Recovering low-quality items, rather than disposing of them, may allow a firm to increase the amount it recycles. The findings highlight the importance of considering the quality of returns when managing a product recovery system as they show that economic gains can be achieved by reusing rather than refusing low quality returns.