Logistical Packaging Evaluation in Automotive Supply Chains: A Multicriteria Decision-Making Approach with Industry Evidence

Abstract

The selection of packaging containers is a critical component of the global automotive industry’s logistics strategy, influencing operational efficiency and environmental sustainability. This study proposes a multicriteria decision-making approach using the Analytic Hierarchy Process to evaluate packaging container alternatives for knock-down parts logistics. A key contribution of the study is the development of practical evaluation criteria derived from expert interviews, structured into five key dimensions. Evaluations were conducted in two stages: company-wide and origin–destination specific. Survey data from six Japanese automotive companies were analyzed using a unified group approach to ensure consistency. The importance of the evaluation criteria across companies was compared using the results to identify preferred container alternatives under each scenario. Additionally, actual container usage data were compared with the model outcomes to validate the findings. The analysis revealed diverse corporate strategies and highlighted the gap between model-based rational choices and real-world practices. Notably, many firms adopt returnable containers at levels exceeding model recommendations. For outer packaging, the actual returnable-to-one-way ratio exceeded the model-based ratio for five out of six companies, with differences ranging, suggesting that environmental initiatives, such as promoting reusable assets, play a central role in decision-making. The proposed model is a structured, practical tool to support container selection decisions, providing insights into the trade-offs among logistics performance, environmental goals, and operational realities.