500 research outputs found

    Design and Control of Warehouse Order Picking: a literature review

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    Order picking has long been identified as the most labour-intensive and costly activity for almost every warehouse; the cost of order picking is estimated to be as much as 55% of the total warehouse operating expense. Any underperformance in order picking can lead to unsatisfactory service and high operational cost for its warehouse, and consequently for the whole supply chain. In order to operate efficiently, the orderpicking process needs to be robustly designed and optimally controlled. This paper gives a literature overview on typical decision problems in design and control of manual order-picking processes. We focus on optimal (internal) layout design, storage assignment methods, routing methods, order batching and zoning. The research in this area has grown rapidly recently. Still, combinations of the above areas have hardly been explored. Order-picking system developments in practice lead to promising new research directions.Order picking;Logistics;Warehouse Management

    Automaattisen varastointi- ja keruujärjestelmän ohjausperiaatteet

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    Automated storage and retrieval systems (AS/RS) are popular for storing semi-fast moving items in distribution centers. They are costly systems whose design involves many critical decisions, which affect the overall performance of the system. This work is focused on the crane control policies of a double-deep dual-shuttle AS/RS. The goal of the thesis is to find out how operating performance of a crane can be improved with storage location assignment, dwell-point positioning and request sequencing. Alternative control rules were developed based on AS/RS literature and tested against those implemented by the supplier of the system. The comparison was carried out with a discrete-event simulation tool, which was built as a part of the thesis. The system was simulated under two different workload scenarios and rack fill levels. The simulation results indicate that sequencing and cycle formation algorithms can have a significant effect on system throughput in periods of high utilization. The effect was found larger with the lower 70 % fill level. The linear programming sequencing algorithm developed in this thesis was found to reduce the average cycle time by 5.3 % compared to the algorithm used by the supplier. In the on-shift scenario, the optimal dwell point strategy could reduce the average crane response time by 10 % compared to the policy used by the supplier. However, this difference was not noticeable when the average request turnover time was used as a measure.Jakelukeskuksissa yleiset hyllystöhissijärjestelmät ovat kalliita investointeja. Niiden keräilytehoa voidaan osaltaan parantaa tehostamalla varastohissin ohjausmenetelmiä. Tämän diplomityön tutkimuksen kohteena on hyllystöhissijärjestelmä, jossa on tuplasyvät hyllyt sekä hissi, jolla on kahden laatikon kantokapasiteetti. Työn tavoitteena oli selvittää, miten järjestelmän suorituskykyä voidaan parantaa hyllypaikkojen allokoinnin, hissin odotuspaikan valinnan, sekä hissitehtävien sekvensoinnin avulla. Järjestelmätoimittajan ohjausperiaatteiden hyvyyttä arvioitiin vertaamalla niitä kirjallisuuden pohjalta kehitettyihin ohjausmenetelmiin. Ohjausten vertailu tehtiin simulointityökalulla, joka rakennettiin työn aikana. Testiskenaarioissa simuloitiin järjestelmää kahdessa eri kuormitustilanteessa ja kahdella eri täyttöasteella. Simulointitulosten perusteella sekvensointi- ja syklinmuodostusalgoritmeilla huomattiin olevan merkittävä vaikutus tilanteissa, joissa hissillä on tehtäväjonoja. Vaikutus oli suurempi matalammalla 70 % täyttöasteella. Työssä kehitetty sekalukuoptimointiin perustuva sekvensointialgoritmi lyhensi keskimääräistä sykliaikaa 5,3 % toimittajan käyttämään algoritmiin verrattuna. Matalan käyttöasteen skenaariossa optimaalisen odotuspaikan valinta lyhensi hissin liikkumisaikaa seuraavan tehtävään 10 %, mutta ero oli käytännössä olematon, kun mittarina käytettiin keskimääräistä aikaa tehtävän saapumisesta sen suorittamiseen

    Design and Control of Warehouse Order Picking: a literature review

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    Order picking has long been identified as the most labour-intensive and costly activity for almost every warehouse; the cost of order picking is estimated to be as much as 55% of the total warehouse operating expense. Any underperformance in order picking can lead to unsatisfactory service and high operational cost for its warehouse, and consequently for the whole supply chain. In order to operate efficiently, the orderpicking process needs to be robustly designed and optimally controlled. This paper gives a literature overview on typical decision problems in design and control of manual order-picking processes. We focus on optimal (internal) layout design, storage assignment methods, routing methods, order batching and zoning. The research in this area has grown rapidly recently. Still, combinations of the above areas have hardly been explored. Order-picking system developments in practice lead to promising new research directions

    Progress in Material Handling Research: 2010

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    Interaction Between Shelf Layout and Marketing Effectiveness and Its Impact On Optimizing Shelf Arrangements

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    Allocating the proper amount of shelf space to stock keeping units [SKUs] is an increasingly relevant and difficult topic for managers. Shelf space is a scarce resource and it has to be distributed across a larger and larger number of items. It is in particular important because the amount of space allocated to a specific item has a substantial impact on the sales level of that item. This relation between shelf space and sales has been widely documented in the literature. However, besides the amount of space, the exact location of the SKU on the shelf is also an important moderator of sales. At the same time, the effectiveness of marketing instruments of an SKU may also depend on the shelf layout. In practice, retailers recognize that these dependencies exist. However, they often revert to rules of thumb to actually arrange their shelf layout. We propose a new model to optimize shelf arrangements in which we use a complete set of shelf descriptors. The goal of the paper is twofold. First of all, we aim to gain insight into the dependencies of SKU sales and SKU marketing effectiveness on the shelf layout. Second, we use these insights to improve the shelf layout in a practical setting. The basis of our model is a standard sales equation that explains sales from item-specific marketing-effect parameters and intercepts. In a Hierarchical Bayes fashion, we augment this model with a second equation that relates the effect parameters to shelf and SKU descriptors. We estimate the parameters of the two-level model using Bayesian methodology, in particular Gibbs sampling. Next, we optimize the total profit over the shelf arrangement. Using the posterior draws from our Gibbs sampling algorithm, we can generate the probability distribution of sales and profit in the optimization period for any feasible shelf arrangement. To find the optimal shelf arrangement, we use simulated annealing. This heuristic approach has proven to be able to effectively search an enormous solution space. Our resu

    Material handling optimization in warehousing operations

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    Tableau d’honneur de la Faculté des études supérieures et postdoctorales, 2018-2019.Les activités de distribution et d’entreposage sont des piliers importants de la chaîne d’approvisionnement. Ils assurent la stabilité du flux de matières et la synchronisation de toutes les parties prenantes du réseau. Un centre de distribution (CD) agit comme un point de découplage entre l’approvisionnement, la production et les ventes. La distribution comprend un large éventail d’activités visant à assurer la satisfaction de la demande. Ces activités passent de la réception au stockage des produits finis ou semi-finis, à la préparation des commandes et à la livraison. Les opérations d’un CD sont maintenant perçues comme des facteurs critiques d’amélioration. Elles sont responsables de la satisfaction d’un marché en évolution, exigeant des délais de livraison toujours plus rapides et plus fiables, des commandes exactes et des produits hautement personnalisés. C’est pourquoi la recherche en gestion des opérations met beaucoup d’efforts sur le problème de gestion des CDs. Depuis plusieurs années, nous avons connu de fortes avancées en matière d’entreposage et de préparation de commandes. L’activité de préparation de commandes est le processus consistant à récupérer les articles à leur emplacement de stockage afin d’assembler des commandes. Ce problème a souvent été résolu comme une variante du problème du voyageur de commerce, où l’opérateur se déplace à travers les allées de l’entrepôt. Cependant, les entrepôts modernes comportent de plus en plus de familles de produits ayant des caractéristiques très particulières rendant les méthodes conventionnelles moins adéquates. Le premier volet de cette thèse par articles présente deux importants et complexes problèmes de manutention des produits lors de la préparation des commandes. Le problème de préparation des commandes a été largement étudié dans la littérature au cours des dernières décennies. Notre recherche élargit le spectre de ce problème en incluant un ensemble de caractéristiques associées aux installations physiques de la zone de prélèvement, comme les allées étroites, et aux caractéristiques des produits (poids, volume, catégorie, fragilité, etc.). Une perspective plus appliquée à la réalité des opérations est utilisée dans notre développement d’algorithmes. Les déplacements liés à la préparation des commandes sont fortement influencés par le positionnement des produits. La position des produits dans la zone de prélèvement est déterminée par une stratégie d’affectation de stockage (storage assignment strategy). Beaucoup de ces stratégies utilisent de l’information sur les ventes des produits afin de faciliter l’accès aux plus populaires. Dans l’environnement concurrentiel d’aujourd’hui, la durée de vie rentable d’un produit peut être relativement courte. Des promotions peuvent également être faites pour pousser différents produits sur le marché. Le positionnement fourni par la stratégie d’hier ne sera probablement plus optimal aujourd’hui. Il existe plusieurs études mesurant l’impact d’une bonne réaffectation de produits sur les opérations de prélèvement. Cependant, ils étudient la différence des performances avec les positionnements passés et actuels. La littérature démontre clairement que cela apporte des avantages en termes d’efficacité. Toutefois, les déplacements nécessaires pour passer d’une position à une autre peuvent constituer une activité très exigeante. Ceci constitue le second volet de cette thèse qui présente des avancées intéressantes sur le problème de repositionnement des produits dans la zone de prélèvement. Nous présentons le problème de repositionnement des produits sous une forme encore peu étudiée aux meilleurs de nos connaissances : le problème de repositionnement. Plus précisément, nous étudions la charge de travail requise pour passer d’une configuration à l’autre. Cette thèse est structuré comme suit. L’introduction présente les caractéristiques et les missions d’un système de distribution. Le chapitre 1 fournit un survol de la littérature sur les principales fonctions d’un centre de distribution et met l’accent sur la préparation des commandes et les décisions qui affectent cette opération. Le chapitre 2 est consacré à l’étude d’un problème de préparation de commandes en allées étroites avec des équipements de manutention contraignants. Dans le chapitre 3, nous étudions un problème de préparation des commandes où les caractéristiques des produits limitent fortement les routes de prélèvement. Le chapitre 4 présente une variante du problème de repositionnement (reassignment) avec une formulation originale pour le résoudre. La conclusion suit et résume les principales contributions de cette thèse. Mots clés : Préparation des commandes, entreposage, problèmes de routage, algorithmes exacts et heuristiques, réaffectation des produits, manutention.Distribution and warehousing activities are important pillars to an effective supply chain. They ensure the regulation of the operational flow and the synchronization of all actors in the network. Hence, distribution centers (DCs) act as crossover points between the supply, the production and the demand. The distribution includes a wide range of activities to ensure the integrity of the demand satisfaction. These activities range from the reception and storage of finished or semi-finished products to the preparation of orders and delivery. Distribution has been long seen as an operation with no or low added value; this has changed, and nowadays it is perceived as one of the critical areas for improvement. These activities are responsible for the satisfaction of an evolving market, requiring ever faster and more reliable delivery times, exact orders and highly customized products. This leads to an increased research interest on operations management focused on warehousing. For several years, we have witnessed strong advances in warehousing and order picking operations. The order picking activity is the process of retrieving items within the storage locations for the purpose of fulfilling orders. This problem has long been solved as a variant of the travelling salesman problem, where the order picker moves through aisles. However, modern warehouses with more and more product families may have special characteristics that make conventional methods irrelevant or inefficient. The first part of this thesis presents two practical and challenging material handling problems for the order picking within DCs. Since there are many research axes in the field of warehousing operations, we concentrated our efforts on the order picking problem and the repositioning of the products within the picking area. The order picking problem has been intensively studied in the literature. Our research widens the spectrum of this problem by including a set of characteristics associated with the physical facilities of the picking area and characteristics of the product, such as its weight, volume, category, fragility, etc. This means that a more applied perspective on the reality of operations is used in our algorithms development. The order picking workload is strongly influenced by the positioning of the products. The position of products within the picking area is determined by a storage assignment strategy. Many of these strategies use product sales information in order to facilitate access to the most popular items. In today’s competitive environment, the profitable lifetime of a product can be relatively short. The positioning provided by yesterday’s assignment is likely not the optimal one in the near future. There are several studies measuring the impact of a good reassignment of products on the picking operations. However, they study the difference between the two states of systems on the picking time. It is clear that this brings benefits. However, moving from one position to another is a very workload demanding activity. This constitutes the second part of this thesis which presents interesting advances on the repositioning of products within the picking area. We introduce the repositioning problem as an innovative way of improving performance, in what we call the reassignment problem. More specifically, we study the workload required to move from one setup to the next. This thesis is structured as follows. The introduction presents the characteristics and missions of a distribution system. Chapter 1 presents an overview of the literature on the main functions of a DC and emphasizes on order picking and decisions affecting this operation. Chapter 2 is devoted to the study of a picking problem with narrow aisles facilities and binding material handling equipment. In Chapter 3, we study the picking problem with a set of product features that strongly constrain the picking sequence. Chapter 4 presents a variant of the reassignment problem with a strong and new formulation to solve it. The conclusion follows and summarizes the main contributions of this thesis. Key words: Order-picking, warehousing, routing problems, exact and heuristic algorithms, products reassignment, material handling

    Improving order-picking operations with precedence constraints through efficient storage location assignment: evidence from a retail company

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    This paper is inspired by a manual picking retail company where shape and weight constraints affect the order-picking process. We proposed an alternative clustering similarity index that considers the similarity, the weight and the shape of products. This similarity index was further incorporated in a storage allocation heuristic procedure to set the location of the products. We test the procedure in a retail company that supplies over 191 stores, in Northern Portugal. When comparing the strategy currently used in the company with this procedure, we found out that our approach enabled a reduction of up to 40% on the picking distance; a percentage of improvement that is 32% higher than the one achieved by applying the Jaccard index, a similarity index commonly used in the literature. This allows warehouses to save time and work faster.info:eu-repo/semantics/publishedVersio

    A reclaimer scheduling problem arising in coal stockyard management

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    We study a number of variants of an abstract scheduling problem inspired by the scheduling of reclaimers in the stockyard of a coal export terminal. We analyze the complexity of each of the variants, providing complexity proofs for some and polynomial algorithms for others. For one, especially interesting variant, we also develop a constant factor approximation algorithm.Comment: 26 page
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