Optimization of Reverse Logistics Networks for Hazardous Waste Incorporating Health, Safety, and Environmental Management: Insights from Large Cruise Ship Construction

Cruise construction involves a lengthy logistical cycle, complex processes, and large volumes of diverse materials, inevitably generating reverse flows. To mitigate risks such as stock congestion, production disruption, and occupational hazards, this study proposes a novel reverse logistics network optimization model that integrates cost, efficiency, and Health, Safety, Environment (HSE) risk factors. Realistic factors including vehicle load, transport cost, loading time, and risk weight were considered to improve model applicability. Fuzzy time windows quantify worker risk exposure and operational efficiency, adding decision-making complexity. A three-phase Levy mutation discrete crow search algorithm (DCSA) was developed, introducing the Levy flight strategy to replace random search and enhance the discretization and solution diversity. The comparative analysis shows that DCSA performs as well as NSGA-II, while outperforming DGWO, demonstrating both stability and efficiency. Comparative analysis with a cost-only scenario revealed that although short-term economic gains may be achieved under cost minimization, such approaches often overlook risks with potential long-term impacts. This highlights the necessity of integrating safety concerns into reverse logistics planning, and confirms the model’s robustness and practical value, thus supporting decision makers in aligning reverse logistics planning in shipyards with sustainability and operational efficiency goals.