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

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

Warehouse Operations Revisted: Novel Challenges and Methods

Vis, I.F.A. [Promotor]Boter, J. [Promotor

Correlated storage assignment approach in warehouses: A systematic literature review

Purpose: Correlation-based storage assignment approach has been intensively explored during the last three decades to improve the order picking efficiency. The purpose of this study is to present a comprehensive assessment of the literature about the state-of-the-art techniques used to solve correlated storage location assignment problems (CSLAP). Design/methodology/approach: A systematic literature review has been carried out based on content analysis to identify, select, analyze, and critically summarize all the studies available on CSLAP. This study begins with the selection of relevant keywords, and narrowing down the selected papers based on various criteria. Findings: Most correlated storage assignment problems are expressed as NP-hard integer programming models. The studies have revealed that CSLAP is evaluated with many approaches. The solution methods can be mainly categorized into heuristic approach, meta-heuristic approach, and data mining approach. With the advancement of computing power, researchers have taken up the challenge of solving more complex storage assignment problems. Furthermore, applications of the models developed are being tested on actual industry data to comprehend the efficiency of the models. Practical implications: The content of this article can be used as a guide to help practitioners and researchers to become adequately knowledgeable on CSLAP for their future work. Originality/value: Since there has been no recent state-of-the-art evaluation of CSLAP, this paper fills that need by systematizing and unifying recent work and identifying future research scopes

Optimization of storage and picking systems in warehouses

La croissance du commerce électronique exige une hausse des performances des systèmes d'entreposage, qui sont maintenant repensés pour faire face à un volume massif de demandes à être satisfait le plus rapidement possible. Le système manuel et le système à robots mobile (SRM) sont parmi les plus utilisés pour ces activités. Le premier est un système centré sur l'humain pour réaliser des opérations complexes que les robots actuels ne peuvent pas effectuer. Cependant, les nouvelles générations de robots autonomes mènent à un remplacement progressif par le dernier pour augmenter la productivité. Quel que soit le système utilisé, plusieurs problèmes interdépendants doivent être résolus pour avoir des processus de stockage et de prélèvement efficaces. Les problèmes de stockage concernent les décisions d'où stocker les produits dans l'entrepôt. Les problèmes de prélèvement incluent le regroupement des commandes à exécuter ensemble et les itinéraires que les cueilleurs et les robots doivent suivre pour récupérer les produits demandés. Dans le système manuel, ces problèmes sont traditionnellement résolus à l'aide de politiques simples que les préparateurs peuvent facilement suivre. Malgré l'utilisation de robots, la même stratégie de solution est répliquée aux problèmes équivalents trouvés dans le SRM. Dans cette recherche, nous étudions les problèmes de stockage et de prélèvement rencontrés lors de la conception du système manuel et du SRM. Nous développons des outils d'optimisation pour aider à la prise de décision pour mettre en place leurs processus, en améliorant les mesures de performance typiques de ces systèmes. Certains problèmes traditionnels sont résolus avec des techniques améliorées, tandis que d'autres sont intégrés pour être résolus ensemble au lieu d'optimiser chaque sous-système de manière indépendante. Nous considérons d'abord un système manuel avec un ensemble connu de commandes et intégrons les décisions de stockage et de routage. Le problème intégré et certaines variantes tenant compte des politiques de routage communes sont modélisés mathématiquement. Une métaheuristique générale de recherche de voisinage variable est présentée pour traiter des instances de taille réelle. Des expériences attestent de l'efficience de la métaheuristique proposée par rapport aux modèles exacts et aux politiques de stockage communes. Lorsque les demandes futures sont incertaines, il est courant d'utiliser une stratégie de zonage qui divise la zone de stockage en zones et attribue les produits les plus demandés aux meilleures zones. Les tailles des zones sont à déterminer. Généralement, des dimensions arbitraires sont choisies, mais elles ignorent les caractéristiques de l'entrepôt et des demandes. Nous abordons le problème de dimensionnement des zones pour déterminer quels facteurs sont pertinents pour choisir de meilleures tailles de zone. Les données générées à partir de simulations exhaustives sont utilisées pour trainer quatre modèles de régression d'apprentissage automatique - moindres carrés ordinaire, arbre de régression, forêt aléatoire et perceptron multicouche - afin de prédire les dimensions optimales des zones en fonction de l'ensemble de facteurs pertinents identifiés. Nous montrons que tous les modèles entraînés suggèrent des dimensions sur mesure des zones qui performent meilleur que les dimensions arbitraires couramment utilisées. Une autre approche pour résoudre les problèmes de stockage pour le système manuel et pour le SRM considère les corrélations entre les produits. L'idée est que les produits régulièrement demandés ensemble doivent être stockés près pour réduire les coûts de routage. Cette politique de stockage peut être modélisée comme une variante du problème d'affectation quadratique (PAQ). Le PAQ est un problème combinatoire traditionnel et l'un des plus difficiles à résoudre. Nous examinons les variantes les plus connues du PAQ et développons une puissante métaheuristique itérative de recherche tabou mémétique en parallèle capable de les résoudre. La métaheuristique proposée s'avère être parmi les plus performantes pour le PAQ et surpasse considérablement l'état de l'art pour ses variantes. Les SRM permettent de repositionner facilement les pods d'inventaire pendant les opérations, ce qui peut conduire à un processus de prélèvement plus économe en énergie. Nous intégrons les décisions de repositionnement des pods à l'attribution des commandes et à la sélection des pods à l'aide d'une stratégie de prélèvement par vague. Les pods sont réorganisés en tenant compte du moment et de l'endroit où ils devraient être demandés au futur. Nous résolvons ce problème en utilisant la programmation stochastique en tenant compte de l'incertitude sur les demandes futures et suggérons une matheuristique de recherche locale pour résoudre des instances de taille réelle. Nous montrons que notre schéma d'approximation moyenne de l'échantillon est efficace pour simuler les demandes futures puisque nos méthodes améliorent les solutions trouvées lorsque les vagues sont planifiées sans tenir compte de l'avenir. Cette thèse est structurée comme suit. Après un chapitre d'introduction, nous présentons une revue de la littérature sur le système manuel et le SRM, et les décisions communes prises pour mettre en place leurs processus de stockage et de prélèvement. Les quatre chapitres suivants détaillent les études pour le problème de stockage et de routage intégré, le problème de dimensionnement des zones, le PAQ et le problème de repositionnement de pod. Nos conclusions sont résumées dans le dernier chapitre.The rising of e-commerce is demanding an increase in the performance of warehousing systems, which are being redesigned to deal with a mass volume of demands to be fulfilled as fast as possible. The manual system and the robotic mobile fulfillment system (RMFS) are among the most commonly used for these activities. The former is a human-centered system that handles complex operations that current robots cannot perform. However, newer generations of autonomous robots are leading to a gradual replacement by the latter to increase productivity. Regardless of the system used, several interdependent problems have to be solved to have efficient storage and picking processes. Storage problems concern decisions on where to store products within the warehouse. Picking problems include the batching of orders to be fulfilled together and the routes the pickers and robots should follow to retrieve the products demanded. In the manual system, these problems are traditionally solved using simple policies that pickers can easily follow. Despite using robots, the same solution strategy is being replicated to the equivalent problems found in the RMFS. In this research, we investigate storage and picking problems faced when designing manual and RMFS warehouses. We develop optimization tools to help in the decision-making process to set up their processes and improve typical performance measures considered in these systems. Some classic problems are solved with improved techniques, while others are integrated to be solved together instead of optimizing each subsystem sequentially. We first consider a manual system with a known set of orders and integrate storage and routing decisions. The integrated problem and some variants considering common routing policies are modeled mathematically. A general variable neighborhood search metaheuristic is presented to deal with real-size instances. Computational experiments attest to the effectiveness of the metaheuristic proposed compared to the exact models and common storage policies. When future demands are uncertain, it is common to use a zoning strategy to divide the storage area into zones and assign the most-demanded products to the best zones. Zone sizes are to be determined. Commonly, arbitrary sizes are chosen, which ignore the characteristics of the warehouse and the demands. We approach the zone sizing problem to determine which factors are relevant to choosing better zone sizes. Data generated from exhaustive simulations are used to train four machine learning regression models - ordinary least squares, regression tree, random forest, and multilayer perceptron - to predict the optimal zone sizes given the set of relevant factors identified. We show that all trained models suggest tailor-made zone sizes with better picking performance than the arbitrary ones commonly used. Another approach to solving storage problems, both in the manual and RMFS, considers the correlations between products. The idea is that products constantly demanded together should be stored closer to reduce routing costs. This storage policy can be modeled as a quadratic assignment problem (QAP) variant. The QAP is a traditional combinatorial problem and one of the hardest to solve. We survey the most traditional QAP variants and develop a powerful parallel memetic iterated tabu search metaheuristic capable of solving them. The proposed metaheuristic is shown to be among the best performing ones for the QAP and significantly outperforms the state-of-the-art for its variants. The RMFS allows easy repositioning of inventory pods during operations that can lead to a more energy-efficient picking process. We integrate pod repositioning decisions with order assignment and pod selection using a wave picking strategy such that pods are parked after being requested considering when and where they are expected to be requested next. We solve this integrated problem using stochastic programming considering the uncertainty about future demands and suggest a local search matheuristic to solve real-size instances. We show that our sample average approximation scheme is effective to simulate future demands since our methods improve solutions found when waves are planned without considering the future demands. This thesis is structured as follows. After an introductory chapter, we present a literature review on the manual and RMFS, and common decisions made to set up their storage and picking processes. The next four chapters detail the studies for the integrated storage and routing problem, the zone sizing problem, the QAP, and the pod repositioning problem. Our findings are summarized in the last chapter

Designing new models and algorithms to improve order picking operations

Order picking has been identified as a crucial factor for the competitiveness of a supply chain because inadequate order picking performance causes customer dissatisfaction and high costs. This dissertation aims at designing new models and algorithms to improve order picking operations and to support managerial decisions on facing current challenges in order picking. First, we study the standard order batching problem (OBP) to optimize the batching of customer orders with the objective of minimizing the total length of order picking tours. We present a mathematical model formulation of the problem and develop a hybrid solution approach of an adaptive large neighborhood search and a tabu search method. In numerical studies, we conduct an extensive comparison of our method to all previously published OBP methods that used standard benchmark sets to investigate their performance. Our hybrid outperforms all comparison methods with respect to average solution quality and runtime. Compared to the state-of-the-art, the hybrid shows the clearest advantages on the larger instances of the existing benchmark sets, which assume a larger number of customer orders and larger capacities of the picking device. Finally, our method is able to solve newly generated large-scale instances with up to 600 customer orders and six items per customer order with reasonable runtimes and convincing scaling behavior and robustness. Next, we address a problem based on a practical case, which is inspired by a warehouse of a German manufacturer of household products. In this warehouse, heavy items are not allowed to be placed on top of light items during picking to prevent damage to the light items. Currently, the case company determines the sequence for retrieving the items from their storage locations by applying a simple S-shape strategy that neglects this precedence constraint. As a result, order pickers place the collected items next to each other in plastic boxes and sort the items respecting the precedence constraint at the end of the order picking process. To avoid this sorting, we propose a picker routing strategy that incorporates the precedence constraint by picking heavy items before light items, and we develop an exact solution method to evaluate the strategy. We assess the performance of our strategy on a dataset provided to us by the manufacturer. We compare our strategy to the strategy used in the warehouse of the case company, and to an exact picker routing approach that does not consider the given precedence constraint. The results clearly demonstrate the convincing performance of our strategy even if we compare our strategy to the exact solution method that neglects the precedence constraint. Last, we investigate a new order picking problem, in which human order pickers of the traditional picker-to-parts setup are supported by automated guided vehicles (AGVs). We introduce two mathematical model formulations of the problem, and we develop a heuristic to solve the NP-hard problem. In numerical studies, we assess the solution quality of the heuristic in comparison to optimal solutions. The results demonstrate the ability of the heuristic in finding high-quality solutions within a negligible computation time. We conduct several computational experiments to investigate the effect of different numbers of AGVs and different traveling and walking speed ratios between AGVs and order pickers on the average total tardiness. The results of our experiments indicate that by adding (or removing) AGVs or by increasing (or decreasing) the AGV speed to adapt to different workloads, a large number of customer orders can be completed until the respective due date

Planning and Scheduling Optimization

Although planning and scheduling optimization have been explored in the literature for many years now, it still remains a hot topic in the current scientific research. The changing market trends, globalization, technical and technological progress, and sustainability considerations make it necessary to deal with new optimization challenges in modern manufacturing, engineering, and healthcare systems. This book provides an overview of the recent advances in different areas connected with operations research models and other applications of intelligent computing techniques used for planning and scheduling optimization. The wide range of theoretical and practical research findings reported in this book confirms that the planning and scheduling problem is a complex issue that is present in different industrial sectors and organizations and opens promising and dynamic perspectives of research and development