End-to-End Supply Chain Planning in the Paper Industry Via Column Generation and Benders Decomposition

Abstract

Problem definition: The paper studies an integrated end-to-end planning problem in large-scale paper manufacturing, where production scheduling, trimming decisions, vehicle loading, and multi-period fulfillment of make-to-order and make-to-stock demand must be coordinated over time. In practice, these decisions are often optimized sequentially, leading to material waste, inefficient transportation, and degraded service levels. Solving the fully integrated problem at industrial scale remains computationally challenging due to its combinatorial structure. Methodology/results: A key structural feature of the problem is that downstream fulfillment decisions depend on upstream production and logistics choices only through aggregate supply availability over time. By exploiting this structure, the paper develops an exact mathematical formulation and proposes a two-phase hybrid framework (BDCG-DP) that integrates column generation (CG) using exact dynamic-programming (DP) for supply-side decisions with Benders decomposition (BD) for downstream fulfillment. Computational experiments on proprietary instances from a major North American paper manufacturer show that BDCG-DP lowers total costs by 24.4% compared to a traditional CG-DP on challenging eight-week planning problems. Median runtime for four-week planning problems decreases from over five hours using CG-DP to under one hour using BDCG-DP. Managerial implications: This paper provides the first exact model that integrates production, trimming, load planning, and multi-period fulfillment at an industrial scale. The proposed approach returns integer-feasible plans within 2.3 to 6 hours for the most complex planning problems, enabling planners to access high-quality implementable schedules within hours, a capability that was previously unavailable in practice.