Performance Approximation and Design of Pick-and-Pass Order Picking Systems

In this paper, we discuss an approximation method based on G/G/m queuing network modeling using Whitt’s (1983) queuing network analyzer to analyze pick-and-pass order picking systems. The objective of this approximation method is to provide an instrument for obtaining rapid performance estimates (such as order lead time and station utilization) of the order picking system. The pick-and-pass system is decomposed into conveyor pieces and pick stations. Conveyor pieces have a constant processing time, whereas the service times at a pick station depend on the number of order lines in the order to be picked at the station, the storage policy at the station, and the working methods. Our approximation method appears to be sufficiently accurate for practical purposes. It can be used to rapidly evaluate the effects of the storage methods in pick stations, the number of order pickers at stations, the size of pick stations, the arrival process of customer orders, and the impact of batching and splitting orders on system performance.simulation;warehousing;order picking;queuing network;pick-and-pass

Modeling Conveyor Merges in Zone Picking Systems

In many order picking and sorting systems conveyors are used to transport products through the system and to merge multiple flows of products into one single flow. In practice, conveyor merges are potential points of congestion, and consequently can lead to a reduced throughput. In this paper, we study merges in a zone picking system. The performance of a zone picking system is, for a large part, determined by the performance of the merge locations. We model the system as a closed queueing network that describes the conveyor, the pick zones, and the merge locations. The resulting model does not have a product-form stationary queue-length distribution. This makes exact analysis practically infeasible. Therefore, we approximate the behavior of the model using the aggregation technique, where the resulting subnetworks are solved using matrix-geometric methods. We show that the approximation model allows us to determine very accurate estimates of the throughput when compared with simulation. Furthermore, our model is in particular well suited to evaluate many design alternatives, in terms of number of zones, zone buffer lengths, and maximum number of totes in the systems. It also can be used to determine the maximum throughput capability of the system and, if needed, modify the system in order to meet target performance levels

Performance Approximation and Design of Pick-and-Pass Order Picking Systems

In this paper, we discuss an approximation method based on G/G/m queuing network modeling using Whitt’s (1983) queuing network analyzer to analyze pick-and-pass order picking systems. The objective of this approximation method is to provide an instrument for obt

Design and Control of Warehouse Order Picking: a literature review

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

Optimizing the Performance of Robotic Mobile Fulfillment Systems

A robotic mobile fulfillment system is a novel type of automated part-to-picker material handling system. In this type of system, robots transport mobile shelves, called pods, containing items between the storage area and the workstations. It is well suited to e-commerce, due to its modularity and it's ability to adapt to changing orders patterns. Robots can nearly instantaneously switch between inbound and outbound tasks, pods can be continually repositioned to allow for automatic sorting of the inventory, pods can contain many different types of items, and unloaded robots can drive underneath pods, allowing them to use completely different routes than loaded robots. This thesis studies the performance of robotic mobile fulfillment systems by solving decision problems related to warehouse design, inventory and resource allocation, and real-time operations. For warehouse design, a new queueing network is developed that incorporates realistic robot movement, storage zones, and multi-line orders. For inventory allocation, we develop a new type of queueing network, the cross-class matching multi-class semi-open queueing network, which can be applied to other systems as well. Resource (re)allocation is modeled by combining queueing networks with Markov decision processes while including time-varying demand. This model compares benchmark policies from practice wit

Conveyor merges in zone picking systems: A tractable and accurate approximate model

. Sequential zone picking systems are popular conveyor-based picker-to-parts order picking systems that divide the order picking area in work zones. When designing a zone picking system, it is important to know whether the throughput capability of the system can meet customer demand. However, the performance and maximum throughput capability of a zone picking system is largely determined by congestion and blocking that occur at the various conveyor merges in the system. In this paper we develop an analytical model to study the impact of conveyor merges in sequential zone picking systems. Because of finite buffers, blocking, recirculation, and merging, the resulting queueing model does not have a product-form stationary queue-length distribution which makes exact analysis practically infeasible. Therefore, we develop an approximate solution by using an aggregation technique and matrix-geometric methods to study the throughput capability of the system. The model is suitable to support rapid design of complex zone picking systems, in terms of number and length of zones, input and output buffer capacities, and storage allocation of products to zones to meet prespecified performance targets. Comparison of the approximation results to simulation show that for a wide range of parameters the mean relative error in the system throughput is typically less than 5%. The model accurately predicts the loss in throughput due to congestion and blocking at the merges, and can be used to allocate input and output buffer spaces to maximize the throughput capability of the system

Optimizing the delivery of multimedia over mobile networks

Mención Internacional en el título de doctorThe consumption of multimedia content is moving from a residential environment to mobile phones. Mobile data traffic, driven mostly by video demand, is increasing rapidly and wireless spectrum is becoming a more and more scarce resource. This makes it highly important to operate mobile networks efficiently. To tackle this, recent developments in anticipatory networking schemes make it possible to to predict the future capacity of mobile devices and optimize the allocation of the limited wireless resources. Further, optimizing Quality of Experience—smooth, quick, and high quality playback—is more difficult in the mobile setting, due to the highly dynamic nature of wireless links. A key requirement for achieving, both anticipatory networking schemes and QoE optimization, is estimating the available bandwidth of mobile devices. Ideally, this should be done quickly and with low overhead. In summary, we propose a series of improvements to the delivery of multimedia over mobile networks. We do so, be identifying inefficiencies in the interconnection of mobile operators with the servers hosting content, propose an algorithm to opportunistically create frequent capacity estimations suitable for use in resource optimization solutions and finally propose another algorithm able to estimate the bandwidth class of a device based on minimal traffic in order to identify the ideal streaming quality its connection may support before commencing playback. The main body of this thesis proposes two lightweight algorithms designed to provide bandwidth estimations under the high constraints of the mobile environment, such as and most notably the usually very limited traffic quota. To do so, we begin with providing a thorough overview of the communication path between a content server and a mobile device. We continue with analysing how accurate smartphone measurements can be and also go in depth identifying the various artifacts adding noise to the fidelity of on device measurements. Then, we first propose a novel lightweight measurement technique that can be used as a basis for advanced resource optimization algorithms to be run on mobile phones. Our main idea leverages an original packet dispersion based technique to estimate per user capacity. This allows passive measurements by just sampling the existing mobile traffic. Our technique is able to efficiently filter outliers introduced by mobile network schedulers and phone hardware. In order to asses and verify our measurement technique, we apply it to a diverse dataset generated by both extensive simulations and a week-long measurement campaign spanning two cities in two countries, different radio technologies, and covering all times of the day. The results demonstrate that our technique is effective even if it is provided only with a small fraction of the exchanged packets of a flow. The only requirement for the input data is that it should consist of a few consecutive packets that are gathered periodically. This makes the measurement algorithm a good candidate for inclusion in OS libraries to allow for advanced resource optimization and application-level traffic scheduling, based on current and predicted future user capacity. We proceed with another algorithm that takes advantage of the traffic generated by short-lived TCP connections, which form the majority of the mobile connections, to passively estimate the currently available bandwidth class. Our algorithm is able to extract useful information even if the TCP connection never exits the slow start phase. To the best of our knowledge, no other solution can operate with such constrained input. Our estimation method is able to achieve good precision despite artifacts introduced by the slow start behavior of TCP, mobile scheduler and phone hardware. We evaluate our solution against traces collected in 4 European countries. Furthermore, the small footprint of our algorithm allows its deployment on resource limited devices. Finally, in an attempt to face the rapid traffic increase, mobile application developers outsource their cloud infrastructure deployment and content delivery to cloud computing services and content delivery networks. Studying how these services, which we collectively denote Cloud Service Providers (CSPs), perform over Mobile Network Operators (MNOs) is crucial to understanding some of the performance limitations of today’s mobile apps. To that end, we perform the first empirical study of the complex dynamics between applications, MNOs and CSPs. First, we use real mobile app traffic traces that we gathered through a global crowdsourcing campaign to identify the most prevalent CSPs supporting today’s mobile Internet. Then, we investigate how well these services interconnect with major European MNOs at a topological level, and measure their performance over European MNO networks through a month-long measurement campaign on the MONROE mobile broadband testbed. We discover that the top 6 most prevalent CSPs are used by 85% of apps, and observe significant differences in their performance across different MNOs due to the nature of their services, peering relationships with MNOs, and deployment strategies. We also find that CSP performance in MNOs is affected by inflated path length, roaming, and presence of middleboxes, but not influenced by the choice of DNS resolver. We also observe that the choice of operator’s Point of Presence (PoP) may inflate by at least 20% the delay towards popular websites.This work has been supported by IMDEA Networks Institute.Programa Oficial de Doctorado en Ingeniería TelemáticaPresidente: Ahmed Elmokashfi.- Secretario: Rubén Cuevas Rumín.- Vocal: Paolo Din

Development of a reconfigurable assembly system with enhanced control capabilities and virtual commissioning

Thesis (M. Tech. (Engineering: Electrical)) -- Central University of technology, Free State, 2013The South African (SA) manufacturing industry requires developing similar levels of sophistication and expertise in automation as its international rivals to compete for global markets. To achieve this, manufacturing plants need to be managed extremely efficiently to ensure the quality of manufactured products and these plants must also have the relevant infrastructure. Furthermore, this industry must also compensate for rapid product introduction, product changes and short product lifespan. To support this need, this industry must engage in the current trend in automation known as reconfigurable manufacturing. The aim of the study is to develop a reconfigurable assembly system with enhanced control capabilities by utilizing virtual commissioning. In addition, this system must be capable of assembling multiple different products of a product range; reconfigure to accommodate the requirements of these products; autonomously reroute the product flow and distribute workload among assembly cells; handle erroneous products; and implement enhanced control methods. To achieve this, a literature study was done to confirm the type of components to be used, reveal design issues and what characteristics such a system must adhere to. Software named DELMIA was used to create a virtual simulation environment to verify the system and simultaneously scrutinize the methods of verification. On completion, simulations were conducted to verify software functions, device movements and operations, and the control software of the system. Based on simulation results, the physical system was built, and then verified with a multi agent system as overhead control to validate the entire system. The final results showed that the project objectives are achievable and it was also found that DELMIA is an excellent tool for system verification and will expedite the design of a system. By obtaining these results it is indicated that companies can design and verify their systems earlier through virtual commissioning. In addition, their systems will be more flexible, new products or product changes can be introduced more frequently, with minimum cost and downtime. This will enable SA manufacturing companies to be more competitive, ensure increased productivity, save time and so ensure them an advantage over their international competition