Prepack Configuration Planning for Retail Demand Allocation
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Solution Overview
Problem
Traditional solutions struggle to efficiently solve prepack problems in supply chain networks due to the complexity of determining how many packages to ship to each retail store, the amount and configuration of items in the packages, and the demand at the retail store, which is a nonlinear optimization problem with numerous factors and constraints.
Innovation Solution
A genetic heuristic and mixed integer problem (MIP) model are used to minimize penalties associated with over-cover and under-cover of demand, with overstock being penalized more heavily than understock, and the amount of items shipped is required to equal demand within a specific range, reducing the complexity and iterations needed to solve the prepack problem.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional solutions are used to solve prepack problems, then the problem can be solved, but the time required to solve the problem is excessive due to the complexity of nonlinear optimization with numerous factors and constraints
Solution Approach 1:
The patent segments the complex nonlinear optimization problem into smaller, more manageable components by introducing a genetic heuristic algorithm that breaks down the prepack configuration into discrete genetic operations (selection, crossover, mutation). This segmentation allows the system to handle the complexity of multiple factors and constraints through modular genetic operators rather than attempting to solve the entire nonlinear optimization problem at once, thereby reducing solution time while maintaining accuracy.
2Productivity
If traditional solutions are used to solve prepack problems, then the problem can be solved, but the number of iterations required is excessive due to the nonlinear optimization complexity
Solution Approach 1:
The patent applies dynamics by implementing a genetic algorithm that evolves prepack configurations through iterative genetic operations. Instead of using static traditional optimization methods, the system dynamically adapts the prepack configuration through selection, crossover, and mutation operations across generations. This dynamic approach allows the system to converge to optimal solutions with fewer iterations by continuously improving the configuration based on fitness evaluation, thereby reducing the excessive iteration count required by traditional nonlinear optimization methods.
3Productivity
If traditional solutions are used to determine prepack configuration, then the problem can be solved, but the computational efficiency is poor due to the nonlinear optimization nature of the problem
Solution Approach 1:
The patent substitutes traditional mechanical optimization methods with a biological-inspired genetic heuristic algorithm. Instead of relying on conventional nonlinear optimization techniques that require extensive computational resources, the system employs genetic operations (selection, crossover, mutation) that mimic natural evolution. This substitution replaces the computationally intensive mechanical optimization process with a more efficient biological metaphor approach, significantly improving computational efficiency while handling the nonlinear optimization complexity of prepack configuration.
Data Source
AI summary
A system and method are disclosed including a prepack planner that determines an initial prepack configuration of a package including two or more items, which include one or more attributes and two or more attribute values. The prepack planner also evaluates the initial prepack configuration by solving a mixed integer problem model and selects the initial prepack configuration to be the parent prepack configuration. The prepack planner further generates one or more child prepack configurations by attributing the number of the two or more attribute values to the one or more child prepack configurations and mutates the one or more child prepack configurations by changing the two or more attribute values with two of the two or more attributes and compares the initial prepack configuration with a stop criteria to determine whether a stop criteria has been reached.


