Inventory control in multi-item production systems

This thesis focusses on the analysis and construction of control policies in multiitem production systems. In such systems, multiple items can be made to stock, but they have to share the finite capacity of a single machine. This machine can only produce one unit at a time and if it is set-up for one item, a switch-over or set-up time is needed to start the production of another item. Customers arrive to the system according to (compound) Poisson processes and if they see no stock upon arrival, they are either considered as a lost sale or backlogged. In this thesis, we look at production systems with backlog and production systems with lost sales. In production systems with lost sales, all arriving customers are considered lost if no stock is available and penalty costs are paid per lost customer. In production systems with backlog, arriving customers form a queue if they see no stock and backlogging costs are paid for every backlogged customer per time unit. These production systems find many applications in industry, for instance glass and paper production or bulk production of beers, see Anupindi and Tayur [2]. The objective for the production manager is to minimize the sum of the holding and penalty or backlogging costs. At each decision moment, the manager has to decide whether to switch to another product type, to produce another unit of the type that is set-up or to idle the machine. In order to minimize the total costs, a balance must be found between a fast switching scheme that is able to react to sudden changes in demand and a production plan with a little loss of capacity. Unfortunately, a fast switching scheme results in a loss of capacity, because switching from one product type to another requires a switch-over or set-up time. In the optimal production strategy, decisions depend on the complete state of the system. Because the processes at the different product flows depend on these decisions, the processes also depend on the complete state of the system. This means that the processes at the different product flows are not independent, which makes the analysis and construction of the optimal production strategy very complex. In fact, the complexity of the determination of this policy grows exponentially in the number of product types and if this number is too large, the optimal policy becomes intractable. Production strategies in which decisions depend on the complete system are defined as global lot sizing policies and are often difficult to construct or analyse, because of the dependence between the different product flows. However, in this thesis the construction of a global lot sizing policy is presented which also works for production systems with a large number of product types. The key factor that makes the construction possible is the fact that it is based on a fixed cycle policy. In Chapter 2, the fixed cycle policy is analysed for production systems with lost sales and in Chapter 6, the fixed cycle policy is analysed for production systems with backlog. The fixed cycle policy can be analysed per product flow and this decomposition property allows for the determination of the so called relative values. If it is assumed that one continues with a fixed cycle control, the relative values per product type represent the relative expected future costs for each decision. Based on these relative values, an improvement step (see Norman [65]) is performed which results in a ‘one step improvement’ policy. This policy is constructed and analysed in Chapters 2 and 7 for production systems with lost sales and production systems with backlog, respectively. This global lot sizing policy turns out to perform well compared to other, heuristic production strategies, especially in systems with a high load and demand processes with a high variability. A similar approach as for the production system with a single machine is performed in a system with two machines and lost sales in Chapter 3. Results show that in some cases the constructed strategy works well, although in some systems two separate one step improvement policies perform better. Examples of more heuristic production strategies are gated and exhaustive basestock policies. In these ’local lot sizing‘ policies, decisions depend only on the stock level of the product type that is set-up. But even in these policies, the processes at the different product flows are dependent. This makes the analysis difficult, but for production systems with backlog a translation can be made to a queueing system by looking at the number of products short to the base-stock level. So the machine becomes a server and each product flow becomes a queue. In these queueing systems, also known as polling systems, gated and exhaustive base-stock policies become gated and exhaustive visit disciplines. For polling systems, an exact analysis of the queue length or waiting time distribution is often possible via generating functions or Laplace-Stieltjes transforms. In Chapter 5, the determination of the sojourn time distribution of customers in a polling system with a (globally) gated visit discipline is presented, which comes down to the determination of the lead time distribution in the corresponding production system

Discrete Time Analysis of Consolidated Transport Processes

Diese Arbeit beschäftigt sich mit der Entwicklung zeitdiskreter Modelle zur Analyse von Transportbündelungen. Mit den entwickelten Modellen für Bestands- und Fahrzeugbündelungen, insbesondere Milkrun-Systeme, kann eine detaillierte Leistungsbewertung in kurzer Zeit durchgeführt werden. Darüber hinaus erlauben die Modelle die Analyse der Umschlagslagerbündelungen, beispielweise Hub-und-Spoke-Netzwerke, indem sie im Rahmen einer Netzwerkanalyse mit einander verknüpft werden

Order-picking workstations for automated warehouses

The FALCON (Flexible Automated Logistic CONcept) project aims at the development of a new generation of warehouses and distribution centers with a maximum degree of automation. As part of the FALCON project, this dissertation addresses the design and analysis of (automated) workstations in warehouses with an end-of-aisle order-picking system (OPS). Methods are proposed for architecting, quantifying performance, and controlling such a system. Four main topics are discussed in this dissertation. First, a modular architecture for an end-of-aisle OPS with remotely located workstations is presented. This architecture is structured into areas and operational layers. A hierarchical decentralized control structure is applied. A case of an industrial-scale distribution center is presented to demonstrate the applicability of the proposed architecture for performance analysis using the process algebra-based simulation language $\chi$ (Chi). Additionally, it is demonstrated how the architecture allows straightforward modification of the systems configurations, design parameters, and control heuristics. Second, a method to quantify the operational performance of order-picking workstations has been developed. The method is based on an aggregate modeling representation of the workstation using the EPT (Effective Process Time) concept. A workstation is considered in which a human picker is present to process one customer order at a time while products for multiple orders arrive simultaneously at the workstation. The EPT parameters are calculated from arrival and departure times of products using a sample path equation. Two model variants have been developed, namely for workstations with FCFS (First-Come-First-Serve) and for workstations with non-FCFS processing of products and orders. Both models have been validated using data from a real, operating workstation. The results show that the proposed aggregate modeling methodology gives good accuracy in predicting product and order flow time distributions. Third, the dissertation studies the design and control of an automated, remotely located order-picking workstation that is capable of processing multiple orders simultaneously. Products for multiple orders typically arrive out-of-sequence at the workstation as they are retrieved from dispersed locations in the storage area. The design problem concerns the structuring of product/order buffer lanes and the development of a mechanism that overcomes out-of-sequence arrivals of products. The control problem concerns the picking sequence at the workstation, as throughput deteriorates when a poor picking sequence is applied. An efficient control policy has been developed. Its performance is compared to a number of other picking policies including nearest-to-the-head, nearest neighbor, and dynamic programming. Subsequently, the resulting throughput and queue length distribution are evaluated under different settings. Insights for design considerations of such a system are summarized. Finally, the dissertation reflects on the findings from the proposed methods and uses them to come up with comprehensive design principles of end-of-aisle OPS with remotely located workstations. The various issues influencing the performance of such a system are highlighted. Moreover, the contribution of each proposed method with regards to these issues is delineated