Analytical Optimization for the Warehouse Sizing Problem Under Class-Based Storage Policy

Main Article Content

Luis F. Cardona https://orcid.org/0000-0002-5633-8970
Leonardo Rivera http://orcid.org/0000-0001-9942-5188
Héctor Jairo Martínez http://orcid.org/0000-0001-9747-0671

Keywords

warehouse layout, warehouse design, storage policy, warehouse sizing problem, nonlinear programming

Abstract

The aim of this paper study the impact of class-based storage policy based on the optimal configuration of U-flow single command warehouses using a on an ABC product classification. For that purpose, the authors propose a non linear optimization model to minimize the expected travel distance of the warehouse and use analytical methods to solve it. The most important contribution is to provide a mathematical proof that regardless of the storage policy (It does not matter the specifics of the turnover pattern of the products), the optimal warehouse has a width that is the double of its length, and the pick and deposit point should be located in the middle of the width of the warehouse. In addition, authors perform a sensitivity analysis that indicates that the optimal solution is robust, meaning that a certain deviation from the optimum layout does not impose a significant penalty on the expected travel distance of the warehouse. 

Downloads

Download data is not yet available.
Abstract 1967 | PDF Downloads 944

References

[1] B. Rouwenhorst, B. Reuter, V. Stockrahm, G. van Houtum, R. Mantel, and W. Zijm, “Warehouse design and control: Framework and literature review,” European Journal of Operational Research, vol. 122, no. 3, pp. 515 – 533, 2000. 222

[2] G. Richards, Warehouse management: A complete guide to improving efficiency and minimizing costs in the modern warehouse. Kogan Page, 2011. 222

[3] R. L. Francis, “On some problems of rectangular warehouse design and layout,” The Journal of Industrial Engineering, vol. 18, no. 10, pp. 595–604, 1967. 222, 223

[4] G. Cormier and E. A. Gunn, “A review of warehouse models,” European Journal of Operational Research, vol. 58, no. 1, pp. 3 – 13, 1992. 222

[5] Y. Bassan, Y. Roll, and M. J. Rosenblatt, “Internal layout design of a warehouse,” AIIE Transactions, vol. 12, no. 4, pp. 317–322, 1980. 222, 223

[6] J. Gu, M. Goetschalckx, and L. F. McGinnis, “Research on warehouse design and performance evaluation: A comprehensive review,” European Journal of Operational Research, vol. 203, no. 3, pp. 539–549, 2010. 222, 223

[7] K. R. Gue and R. D. Meller, “Aisle configurations for unit-load warehouses,” IIE Transactions, vol. 41, no. 3, pp. 171 – 182, 2009. 222

[8] L. F. Cardona, L. Rivera, and H. J. Martínez, “Analytical study of the fishbone warehouse layout,” International Journal of Logistics Research and Applications, vol. 15, no. 6, pp. 365–388, 2012. 222

[9] J. Xiao and L. Zheng, “A correlated storage location assignment problem in a single-block-multi-aisles warehouse considering bom information,” International Journal of Production Research, vol. 48, no. 5, pp. 1321 – 1338, 2010. 222

[10] Y. Yu, R. B. de Koster, and X. Guo, “Class-Based Storage with a Finite Number of Items: Using More Classes is not Always Better,” Production and Operations Management, no. August 2015, pp. 1235–1247, 2015. 223

[11] L. Hsieh and L. Tsai, “The optimum design of a warehouse system on order picking efficiency,” International Journal of Advanced Manufacturing Technology , vol. 28, no. 5-6, pp. 626–637, MAR 2006. 223

[12] G. Zhang and K. Lai, “Combining path relinking and genetic algorithms for the multiple-level warehouse layout problem,” European Journal of Operational research, vol. 169, no. 2, pp. 413–425, MAR 1 2005. 223

[13] R. Ballou, Business Logistics: Supply Chain Management. Prentice Hall, 2004. 223

[14] R. L. Francis and J. A. White, “Facility layout and location — an analytical approach,” International Journal of Production Research, vol. 13, no. 2, pp. 219–219, 1975. 223

[15] L. M. Pohl, R. D. Meller, and K. R. Gue, “Turnover-based storage in nontraditional unit-load warehouse designs,” IIE Transactions, vol. 43, no. 10, pp. 703 – 720, 2011. 223, 224, 225

[16] X. Guo, Y. Yu, and R. B. D. Koster, “Impact of required storage space on storage policy performance in a unit-load warehouse,” International Journal of Production Research, vol. 54, no. 8, pp. 2405–2418, 2016. 223

[17] L. M. Thomas and R. D. Meller, “Analytical models for warehouse configuration,” IIE Transactions, vol. 46, no. 9, pp. 928–947, 2014. 224

[18] ——, “Developing design guidelines for a case-picking warehouse,” International Journal of Production Economics, vol. 170, Part C, pp. 741 – 762, 2015. 224

[19] K. J. Roodbergen, I. F. Vis, and G. D. T. Jr, “Simultaneous determination of warehouse layout and control policies,” International Journal of Production Research, vol. 53, no. 11, pp. 3306–3326, 2015. 224

[20] T. Larson, H. March, and A. Kusiak, “A heuristic approach to warehouse layout with class-based storage,” IIE Transactions, vol. 29, no. 4, pp. 337– 348, 1997. 224

[21] M. Celik and H. Sural, “Order picking under random and turnover-based storage policies in fishbone aisle warehouses,” IIE Transactions, vol. 46, no. 3, pp. 283–300, 2014. 224

[22] T. Le-Duc and R. M. B. M. De Koster, “Travel distance estimation and storage zone optimization in a 2-block class-based storage strategy warehouse,” International Journal of Production Research, vol. 43, no. 17, pp. 3561 – 3581, 2005. 224

[23] S. S. Rao and G. K. Adil, “A mathematical model for optimal partitions of warehouse storage space based on turnover density,” in 2011 Fifth Asia Modelling Symposium. IEEE, 2011, pp. 133–137. 227