Sustainable Rerouting of Production Logistics Under Road Disruptions in Industrial Plants

Road disruptions in industrial plants may force production-logistics tasks to reroute and transfer additional transport workload to tasks that were not directly affected. Such secondary effects remain insufficiently represented in conventional rerouting analysis. This study develops a task-protection-oriented framework for sustainable production-logistics rerouting. Reference transport paths are first constructed from production-logistics relationships and the internal road network to identify directly affected tasks, while additional road-level logistics workload is used to quantify the indirect load exposure of unaffected tasks. The mechanisms underlying this exposure are then examined in terms of disrupted logistics scale, alternative-route availability, and the overlap between alternative routes and roads supporting important unaffected tasks. Three rerouting strategies—shortest detour, road-load balancing, and task protection—are subsequently compared, with an additional-distance budget imposed on affected tasks to characterize the trade-off between transport efficiency and task protection. A case study of a large integrated steel plant shows that most reroutable disruption events still generate indirect load exposure. Exposure is primarily associated with disrupted logistics scale and the spatial overlap of alternative routes, whereas route quantity alone does not provide a stable protective effect. Road-load balancing reduces local workload peaks but does not consistently protect unaffected tasks. In contrast, coordinated task-protection rerouting substantially reduces indirect exposure with only limited additional transport distance and exhibits clear diminishing marginal returns. Robustness tests across OD boundaries, routing parameters, and alternative overlap constructions support the main findings. The results suggest that disruption management in industrial plants should move beyond whether affected tasks can be rerouted toward how rerouting can be organized with lower external impacts on ongoing production tasks.