MODELING AND ANALYSIS OF
MANUFACTURING SYSTEMS
Session 14 WAREHOUSING
E. Gutierrez- Miravete
Spring 2001
WHY WAREHOUSING?
• FOR PARTS DISTRIBUTION
• FOR SPARE PARTS PROVISIONING
• TO ASSEMBLE PRODUCT BATCHES
PRIOR TO DELIVERY
• CRITICAL PART STOCKPILING
• FOR REGIONAL DISTRIBUTION FOR
QUICK DELIVERY
WAREHOUSING SYSTEMS
FACILITIES ACTIVITIES
• STORAGE RACKS • STORAGE
• QUALITY CONTROL • INSPECTION
• RECEIVING DOCK • UNLOADING +
• STORE/RETRIEVE • TRANSPORT +
• MANUFACTURING • PARTS PREP.
• SHIPPING DOCK • PACKING +
WAREHOUSE TYPES
• FULLY AUTOMATED
• MANUALLY CONTROLLED
• IN BETWEEN
WAREHOUSE
COMPONENTS
• BUILDING SHELL
• MEDIUM STORAGE
– PALLET RACKS
• TRANSPORT MECHANISMS
– S/R MACHINES
• CONTROLS
– DEDICATED STORAGE
– OPEN STORAGE
WAREHOUSE DESIGN
• THE 85 PERCENT RULE
• STANDARD WAREHOUSE (F10.3)
– RECTANGULAR BUILDING
– I/O AT ONE END
– TRAVEL ALONG AISLES
• DESIGN GOAL: TO MINIMIZE
AVERAGE STORAGE/RETRIEVAL
TIMES
WAREHOUSE DESIGN
• NUMBER OF STORAGE ROWS a
• NUMBER OF BAYS IN A ROW b
• WAREHOUSE LENGTH a
• WAREHOUSE WIDTH b
• NUMBER OF LEVELS n
• TOTAL NUMBER OF NEEDED
STORAGE LOCATIONS K
WAREHOUSE DESIGN
• GOAL
MINIMIZE a/2 + b/4
• SUBJECT TO
nab > K
WAREHOUSE DESIGN
• SOLVE FOR a FROM THE
CONSTRAINT, SUBSTITUTE IN THE
GOAL FUNCTION THEN MINIMIZE
WITH RESPECT TO b TO OBTAIN
b* = (2 K/ n) 1/2
a* = ( K/2 n) 1/2
QUESTIONS
• WHAT IS THE LENGTH/WIDTH
RATIO OF THE OPTIMAL
WAREHOUSE?
• WHAT IS THE RATIO OF THE
NUMBER OF STORAGE LOCATIONS
ALONG THE WIDTH TO THAT
ALONG THE LENGTH?
• Ex. 10.1, p. 333
QUESTIONS
• HOW TO DETERMINE THE
HEIGHT OF THE OPTIMAL
WAREHOUSE?
• WHAT IS THE CHEBYSHEV
MEASURE TRAVEL TIME?
MAX ( z/v z , x/v x )
QUESTIONS
• WHAT DETERMINES THE OPTIMAL
WAREHOUSE SHAPE?
• CONSTANT TRAVEL TIME CONTOURS
• Figs. 10.4a, 10.4b, 10.4c
• WHAT IS THE APPROPRIATE RACK
ORIENTATION?
• TRANSVERSE (Fig.10.3) VS
LONGITUDINAL (Fig.10.5)
STACKING PATTERNS
• RACK STACKING
• BLOCK STACKING (Fig. 10.6)
• HONEYCOMB LOSS
RENTAL IN
WAREHOUSES
• HOW TO ASSIGN INCOMING LOADS
TO STORAGE LOCATIONS?
• WHAT IS THE EFFECT OF
EXPECTED TURNAROUND OF THE
LOAD?
• WHAT IS THE EFFECT OF
DEDICATED VS OPEN STORAGE ON
THE LOCATION DECISION?
DEDICATED STORAGE
• SIMPLIFIED CONTROL
• SIMPLIFIED STATUS CHECKING
• PRODUCT ORDERS FROM VISUAL
INSPECTION
• LOW OCCUPANCY LEVELS
• Ex. 10.2, p. 337
DEDICATED STORAGE
• PRODUCTS TO BE ALLOCATED TO
STORAGE LOCATIONS N
• DIVIDE WAREHOUSE SPACE INTO M
SQUARE ISOCAPACITY GRIDS
• EACH PRODUCT REQUIRES SOME
GRIDS FOR ITS STORAGE
• NUMBER OF SHIPPING/RECEIVING
PORTS P
DEDICATED STORAGE
• NUMBER OF TRIPS OF PRODUCT i
THROUGH PORT p w ip
• DISTANCE FROM CENTER OF GRID j
TO PORT p d pj
• TRAVEL COST PER PERIOD DUE TO
STORAGE OF i IN j c ij
• GOAL: FIND THE SET OF GRIDS A i
TO ASSIGN TO EACH PRODUCT i
DEDICATED STORAGE
• VARIABLE DECISION x ij
• GOAL
MINIMIZE i j c ij x ij
• SUBJECT TO
j x ij = A i FOR ALL i
i x ij = 1 FOR ALL j
DEDICATED STORAGE
• PROGRAMMING PROBLEM IS
ANALOGOUS TO TRANSPORTATION
PROBLEM
• Ex. 10.3; Tables 10.4a, 10.4b, 10.5
• WHAT HAPPENS IF ALL PRODUCTS
USE ALL PORTS IN THE SAME
PROPORTION?
DEDICATED STORAGE
• WHAT IS THE FACTORING
ASSUMPTION?
w ip = c i *w p
– pp. 340-341
• Ex. 10.4, p. 341
– Table 10.6; Fig. 10.8
OPEN STORAGE
• COMPUTER CONTROLLED
WAREHOUSES
• Ex. 10.5, p. 343
• THROUGHPUT: THE NUMBER OF
STORAGE AND RETRIEVAL
REQUESTS THAT CAN BE HANDLED
BY THE S/R MACHINE PER UNIT
TIME
OPEN STORAGE
• RACK STRUCTURE FOR TRAVEL
TIME CALCULATION (Fig. 10.9)
• X, Z HORIZONTAL AND VERTICAL
LENGTHS OF STORAGE RACKS
• vx, vz HORIZONTAL AND VERTICAL
SPEEDS OF S/R VEHICLE
• tpd FIXED TIME FOR
PICKUP/DEPOSIT
OPEN STORAGE
• TOTAL SINGLE COMMAND TRIP
TIME (Eqn. 10.8-10.10)
T = v x Z 2 /(3 v z 2 X) + X/v x + 2 t pd
• Ex. 10.6, p. 344
• DUAL COMMAND TRIP TIME (Eqn.
10.11)
• Ex. 10.7, p. 345
OPEN STORAGE
• CLASS-BASED STORAGE (OP)
– EXPECTED LENGTH OF STAY IN
STORAGE
• STORING COMPLEMENTARY ITEMS
(OP)
– LOCATING ITEMS WHICH ARE
ORDERED TOGETHER NEAR TO EACH
OTHER
ORDER PICKING
• PICKING SMALL ITEMS FROM A
WAREHOUSE TO FILL ORDERS
• DESIGN PROBLEM
– SHOULD PARTS COME TO PICKERS?
– SHOULD PICKERS GO TO PART
RACKS?
ORDER PICKING SYSTEM
CONSIDERATIONS
• STORAGE HEIGHT
• THROUGHPUT VOLUME
• LEVEL OF COMPUTERIZATION
• PRODUCT WEIGHT
• DEGREE OF PRODUCT
PROTECTION REQUIRED
ORDER-PICKING
PROBLEM
COMBINE CUSTOMER ORDERS
INTO PICK LISTS THEN PLAN
THE SEQUENCING OF VISITS
TO STORAGE LOCATIONS IN
EACH LIST
FORMING PICK LISTS
• KEY: BATCHING ORDERS INTO
PICK LISTS
• C CARRYING CAPACITY OF S/R
MACHINE
• K TOTAL NUMBER OF ORDERS
• Qk SIZE OF k-th ORDER
• CLUSTERING ALGORITHM
PICK LISTS
• QUESTION: HOW TO DETERMINE
SIMILARITY BETWEEN ORDERS?
• S/R MACHINE PERFORMS
CHEBYSHEV TRAVEL (Fig. 10.10)
PICK LIST CREATION
• FIND THE AREA OF TRAVEL
REGIONS FOR ORDERS (Ex. 10.8)
• FIND INTERSECTIONS OF TRAVEL
REGIONS (Ex. 10.9)
• FIND SIMILARITY COEFFICIENTS
(E10.9)
• BATCH ORDERS INTO LISTS (Ex.
10.10)
PICK SEQUENCING
• LIKE TRAVELING SALESMAN
PROBLEM
• TECHNICAL SOLUTIONS
– OPTIMIZATION
– HEURISTICS (CLOSEST INSERTION
PROCEDURE)
PICK LISTS
• Ex. 10.8, Table 10.8
• Ex. 10.9, Tables 10.9, 10.10
