47 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

    Designing a cellular-based fully automated case picking system

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    Order picking (OP) is the most expensive and labor-intensive activity in warehouses. Some authors argue that OP might be responsible for up to 55% of the operating costs in a warehouse. This might be more important for companies that handle large volumes of fast-moving commodities. Full-case picking processes and mixed pallet building are expensive and complex activities. Companies are looking for technologies to improve their efficiency and to reduce the operating costs of non-value added activities in their warehouses and distribution centers (DCs). Nowadays, the designers of order picking systems face great challenges due to increasing labor costs, less space and more frequent small orders with short delivery times. Consequently, there are constant research efforts devoted to finding new innovative full-case picking solutions that reduce operating costs, generate higher productivity, optimize space utilization and enhance customer service levels. This dissertation presents a new fully automated case picking system (ACPS) called the Automated Cellular Case Picking System (ACCPS). The new system is characterized by the full and permanent accessibility of all stock keeping units (SKUs) in the system, which permits a strategic higher picking rate. This new system could be applied to different levels of automation within warehouses and DCs, and it is suitable for a wide range of warehouse automation requirements. The proposed design consists of storage cells with the same design and operating principle as the vertical indexing case elevator, installed on one conveyor to form a storage line. Several storage lines are connected by a distributing conveyor from the inlet side and by a collecting conveyor from the outlet side, to form an ACCPS use-case model. The concept of this new system is based on the A-Farm concept, in order to create a new innovative dispensing and buffering system for cases. ACCPS is a new concept for a full-case picking system that aims to provide better solutions for warehouses and DCs that deal with a high volume and low variety of products, which are handled in plastic crates or trays. ACCPS would be an efficient solution for many types of commodities such as (food, beverage, grocery, dairy, flowers, sausage, bakery and others). Optimizing picking processes, minimizing operating cost, and increasing efficiency are the most important aims of the new proposed design. This research investigates the layout, design, structure, costs, operating principles, cycle time, and throughput of the new system. A simple logic process was applied to create a mathematical model in order to calculate the expected average time of the order picking and the throughput of this new ACPS. A simulation model has been developed to aid in measuring the effectiveness of the ACCPS proposed design under real operating conditions. Two case studies have been used to evaluate the performance of the new system. Based on the real-time data of these two cases, many simulation scenarios were studied and analyzed in order to solve the storage assignment problem and to determine the best order picking strategy. Many optimization scenarios were simulated and analyzed in order to determine the optimum scenario. In order to evaluate the ACCPS performance, a comparison was made between ACCPS and an alternative system with the same features. The alternative system, which is the most competitive system compared to the ACCPS, is the Gantry Robot System (GRS). The costs, throughput, and required areas were chosen as the main criteria for comparison between the two systems. The comparison confirmed the benefits of the ACCPS in decreasing the operating costs, required area, energy consumption, and the picking time. ACCPS also increased the space utilization rate and the throughput. ACCPS provides a new technique for automating the full-case picking process (CPP) that contributes greatly to decreasing total operating cost by minimizing labor requirements, space requirements, and potential errors, and increasing productivity and efficiency. The structure of ACCPS, which is based on individual modules, can further increase the flexibility and the adaptability of the system.Entwurf eines zellbasierten vollautomatischen Full-Case-Kommissioniersystems Der Kommissionierungsprozess (OP) wird als die höchst arbeitsintensive und kostenaufwĂ€ndige TĂ€tigkeit in den Lagern betrachtet. Einige Autoren behaupten, dass der Kommissionierungsprozess fĂŒr bis zu 55 % aller Betriebskosten in einem Lager dafĂŒr verantwortlich sein könnte. Dies könnte möglicherweise wichtiger sein fĂŒr Unternehmen, die große Volumina von schnell bewegenden Waren behandeln. Full-case-picking Prozesse und Mischpaletten von verschiedenen Produkten aufzubauen sind teure und komplexe TĂ€tigkeiten. Firmen suchen nach Technologien, um ihre LeistungsfĂ€higkeit zu verbessern und die Betriebskosten von zusĂ€tzlichen TĂ€tigkeiten die keine Wertschöpfung erbringen in ihren Lagern und Distributionszentren (DCs) zu reduzieren. Heutzutage stehen die Designer der Kommissioniersysteme vor großen Herausforderungen, aufgrund der steigenden Arbeitskosten, weniger Platz und hĂ€ufigere kleine AuftrĂ€ge mit kurzen Lieferzeiten. Deshalb sind stĂ€ndige ForschungsbemĂŒhungen gewidmet, um die Suche nach neuen innovativen Kommissionierlösungen fĂŒr StĂŒckgĂŒter, die die Betriebskosten verringern, die ProduktivitĂ€t erhöhen, die Raumausnutzung optimieren und die Kundenservice verbessern. Diese Dissertation prĂ€sentiert ein neues vollautomatisiertes Kommissioniersystem fĂŒr StĂŒckgĂŒter (ACPS), das als automatisiertes zellulĂ€res Case-picking-system (ACCPS) bezeichnet wird. Das neue System zeichnet sich durch die vollstĂ€ndige und dauerhafte ZugĂ€nglichkeit aller Lagerhaltung Einheiten (SKUs) im System, das einen strategischen höheren Durchsatz des Kommissionierungsprozesses ermöglicht. Dieses neue System könnte auf verschiedene Niveaus der Automation innerhalb von Lagern und DCs angewandt werden, und ist fĂŒr eine breite Reihe von Lagerautomationsvoraussetzungen passend. Das vorgeschlagene Design besteht aus Speicherzellen mit demselben Design und Betriebsprinzip wie der vertikale Senkrechtförderer fĂŒr StĂŒckgĂŒter, der auf einem Förderband installiert ist, um eine Lagerungslinie zu bilden. Mehrere Lagerungslinien werden sich durch einen Verteilförderer von der Einlassseite und durch einen Sammelförderer von der Ausgangsseite verbunden, um ein ACCPS Use-Case-Modell zu bilden. Das Konzept dieses neuen Systems basiert auf dem Konzept des Schachtkommissionsystems (A-Farm), um ein neues innovatives System zum ZufĂŒhren und Puffern von StĂŒckgĂŒtern zu schaffen. ACCPS ist ein neues Konzept fĂŒr eine vollstĂ€ndiges StĂŒckgĂŒtern Schachtkommissionsystem mit dem Ziel, bessere Lösungen fĂŒr Lagern und DCs, die sich mit einer großen Menge und niedrigen Vielfalt von Produkten befassen, die in Kunststoffkisten oder Tablare behandelt werden zur VerfĂŒgung zu stellen. ACCPS wĂŒrde eine effiziente Lösung fĂŒr viele Typen von Waren wie (Nahrung, GetrĂ€nk, Lebensmittel, Molkerei, Blumen, Wurst, BĂ€ckerei und andere) sein. Optimierung der Kommissionierungsprozesse, Minimierung der Betriebskosten und Steigerung der Effizienz sind die wichtigsten Ziele des neuen vorgeschlagenen Designs. Diese Forschung untersucht Layout, Design, Struktur, Kosten, Betriebsprinzipien, Zykluszeit und Durchsatz des neuen Systems. Ein einfacher Logik-Prozess wurde angewendet, um ein mathematisches Modell zu erstellen, damit die erwartete durchschnittliche Zeit der Kommissionierung und der Durchsatz von dieser neuen ACPS zu berechnet werden. Ein Simulationsmodell wurde entwickelt, um bei der Messung der EffektivitĂ€t des vorgeschlagenen Designs der ACCPS unter realen Betriebsbedingungen zu unterstĂŒtzen. Zwei Fallstudien sind verwendet worden, um die Leistung des neuen Systems zu bewerten. GestĂŒtzt auf den Echtzeitdaten dieser zwei FĂ€lle, viele Simulation Szenarien wurden untersucht und analysiert um das Problem der Lagerplatzzuweisung zu beheben und die beste Strategie fĂŒr die Kommissionierung zu bestimmen. Viele Optimierung Szenarien wurden simuliert und analysiert um das optimale Szenario zu bestimmen. Im Hinblick auf die Bewertung der Leistung des ACCPSs, wurde ein Vergleich zwischen ACCPS und ein alternatives System mit denselben Eigenschaften durchgefĂŒhrt. Das Gantry Robot System (GRS), ist das alternative System fĂŒr das am meist konkurrenzfĂ€hige System im Vergleich zum ACCPS. Die Kosten, der Durchsatz und die erforderliche FlĂ€che wurden als die Hauptkriterien zum Vergleich zwischen den beiden Systemen gewĂ€hlt. Der Vergleich hat die Vorteile des ACCPSs im Verringern der Betriebskosten, der erforderlichen FlĂ€che, des Energieverbrauchs und der Entnahmezeit (Pickzeit) bestĂ€tigt. ACCPS stellt eine neue Technik zur VerfĂŒgung, um die Full-case-picking Prozessen (CPP) zu automatisieren, die außerordentlich zum Verringern von Gesamtbetriebskosten durch die Minderung von ArbeitskrĂ€ftebedarf, Platzbedarf und potenziellen Fehlern, und die Erhöhung der ProduktivitĂ€t und LeistungsfĂ€higkeit beitrĂ€gt. Die Struktur von ACCPS, die auf individuellen Modulen basiert, kann weiter die FlexibilitĂ€t und die AnpassungsfĂ€higkeit des Systems vergrĂ¶ĂŸern

    Simulation model used as design improvement decision tool for warehouse material flow

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    Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2005.Includes bibliographical references (p. 109-110).The basis for this thesis involved a six and a half month LFM internship at Efficient Storage, Shipping, and Selection. ES3, Efficient Storage, Shipping, and Selection, is a third party logistics firm that specializes in a vendor-neutral consolidation model for the food distribution industry. ES3 receives, stores, and ships multi-vendor products through a distribution center (DC) in York, Pennsylvania. The product is moved and stored by an Automated Storage and Retrieval System (ASRS) which consists of a network of conveyors, vertical lifts, and Selection and Retrieval Machines (SRMs). The ASRS system is not performing to the designed put-away and shipping rates, thus limiting the DC's overall performance during peak operations. The warehouse operations and warehouse design teams had numerous design suggestions for improving the ASRS operations, but it was difficult to predict the enhancement or impact on performance. A simulation model for the inbound system was created to analyze the impact, prioritize, and develop new ideas for improving the system.by Clifford A. Smith.S.M.M.B.A

    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 workstations for automated warehouses

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    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 χ\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

    Planning in logistics: a survey

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    © 2010 ACMPermission to make digital or hard copies of all or part of this work for personal or classroom use is granted without fee provided that copies are not made or distributed for profit or commercial advantage and that copies bear this notice and the full citation on the first page. To copy otherwise, to republish, to post on servers or to redistribute to lists, requires prior specific permission and/or a fee.Presented at PerMIS’10 September 28-30, 2010, Baltimore, MD, USA.Planning is an essential part of any logistics system. The paper tries to generalize the view of a logistics planner by framing it as a knapsack problem. We show how the various variants of the knapsack problem compare for different types of industries. We also introduce the pallet stacking problem and survey some of the recent advances made towards this problem

    Integrated Models and Tools for Design and Management of Global Supply Chain

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    In modern and global supply chain, the increasing trend toward product variety, level of service, short delivery delay and response time to consumers, highlight the importance to set and configure smooth and efficient logistic processes and operations. In order to comply such purposes the supply chain management (SCM) theory entails a wide set of models, algorithms, procedure, tools and best practices for the design, the management and control of articulated supply chain networks and logistics nodes. The purpose of this Ph.D. dissertation is going in detail on the principle aspects and concerns of supply chain network and warehousing systems, by proposing and illustrating useful methods, procedures and support-decision tools for the design and management of real instance applications, such those currently face by enterprises. In particular, after a comprehensive literature review of the principal warehousing issues and entities, the manuscript focuses on design top-down procedure for both less-than-unit-load OPS and unit-load storage systems. For both, decision-support software platforms are illustrated as useful tools to address the optimization of the warehousing performances and efficiency metrics. The development of such interfaces enables to test the effectiveness of the proposed hierarchical top-down procedure with huge real case studies, taken by industry applications. Whether the large part of the manuscript deals with micro concerns of warehousing nodes, also macro issues and aspects related to the planning, design, and management of the whole supply chain are enquired and discussed. The integration of macro criticalities, such as the design of the supply chain infrastructure and the placement of the logistic nodes, with micro concerns, such the design of warehousing nodes and the management of material handling, is addressed through the definition of integrated models and procedures, involving the overall supply chain and the whole product life cycle. A new integrated perspective should be applied in study and planning of global supply chains. Each aspect of the reality influences the others. Each product consumed by a customer tells a story, made by activities, transformations, handling, processes, traveling around the world. Each step of this story accounts costs, time, resources exploitation, labor, waste, pollution. The economical and environmental sustainability of the modern global supply chain is the challenge to face
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