ChapterPDF Available

Operational Research Methods for Efficient Warehousing

December 2005

In book: Logistics Systems: Design and Optimization (pp.93-122)

Authors:

Alfaisal University

The design and operation of a warehouse entail many challenging decision problems. We begin by providing definitions as well as qualitative descriptions of two actual warehouses. This will then set the stage for an overview of representative operational research models and solution methods for efficient warehousing. Problems which will be exposed can be classified into three major categories: throughput capacity models, storage capacity models, and warehouse design models. We conclude by identifying future research opportunities.

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Warehousing literature

version 9 (November 5, 2007)

This list attempts to give an overview of all books, Ph.D theses, and scientiﬁc articles on ware-

housing. Excluded from the list are conference proceedings and book chapters. Furthermore,

literature on subjects such as automated guided vehicles (AGV), facility layout (other than

directly applied to warehousing), facility location and inventory models, is not included.

Please, do not contact me to obtain a copy of any of these books or articles. First of all, I do

not have every article or book myself. Secondly, this would violate international copyright laws.

If you know of any books or articles missing on this list, please send your suggestions to me

through the webform at http://www.roodbergen.com

K.J. Roodbergen

1 Journal articles

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OPTIMIZATION ALGORITHMS FOR IMPROVING THE EFFICIENCY OF ORDER PICKING PROCESSES IN WAREHOUSES

Thesis

Full-text available

Jul 2022

Esra Yaşar Boz

Customers nowadays expect to receive their orders within a specified time window. The process of reaching customers on time is especially challenging for businesses to handle. Because effective management of this process demands the integration of in- warehouse and out-of-warehouse operations. The relevant process begins as soon as the customer order arrives at the company, and the "Order Picking/Batching" process inside the warehouse follows the "Vehicle Routing" process outside the warehouse. These processes become more crucial for companies, especially following the living conditions demanded by causes such as the pandemic, and are a very common problem in real life. The literature refers to this integrated process as the "Order Batching and Vehicle Routing Problem with Time Window." By reviewing the available literature for the related problem, a new mixed integer linear mathematical model was built in light of limitations and assumptions in this study. Small, medium, and large data sets were constructed for the developed issue, and a solution was attempted using the CPLEX solver. However, only a portion of a small data set could be solved with this solver, and no solution could be found for medium or large data sets. As a result, the Genetic Algorithm, a metaheuristic search algorithm, is suggested, and the related problem is solved using various picker routing heuristics for small, medium, and large data samples, with good outcomes. The results were successful, and the best acceptable picker routing heuristic was proposed, based on real and hypothetical data tested on the proposed mathematical model.

Methods of Data Collection, Aggregation, and Dissemination and Their Application

Chapter

Sep 2022

Aurelija Burinskiene

The flows of data and methods for their revision are different and depend on the needs of the transport business. Various parameters are communicated and regularly transmitted during cargo delivery. The set of data is compiled for each point in time and includes all the information and review of big data for making decisions about the transportation of goods.The author divided the description into two parts. The beginning of the chapter is devoted to the collection of data from various sources, and the second part is devoted to the revision of data sets. Finally, the chapter ends with issues of trust and confidentiality in cases of data analysis.KeywordsData collectionData analysisGrubb testBig dataOperational data revisionConflicts resolutionDecision hierarchyTrust and privacy data review

The order batching problem: A state-of-the-art review

Article

Full-text available

Jun 2022

The Order Batching Problem (OBP) has received a lot of attention from researchers in recent years. Until now, this problem has been considered as a whole with different problems or it has been studied on its own, with different solution methods, in different warehouse layouts, with different data structures. The aim of this study is to provide the researchers with a general analysis for studies using the OBP. In accordance with this purpose; the OBP is analyzed by an extensive literature review that includes all relevant studies to date. This literature review is based on a specific method and the studies are grouped into specific classes. Accordingly, the most studied problem with the OBP is the Picker Routing Problem (PRP) with 17% and 51% of the studies were solved by metaheuristic algorithms. The most widely used metaheuristic algorithms are Neighborhood Search and Genetic Algorithms.

Optimal Order Batching in Warehouse Management: A Data-Driven Robust Approach

Article

Jan 2022

Optimizing warehouse processes has direct impact on supply chain responsiveness, timely order fulfillment, and customer satisfaction. In this work, we focus on the picking process in warehouse management and study it from a data perspective. Using historical data from an industrial partner, we introduce, model, and study the robust order batching problem (ROBP) that groups orders into batches to minimize total order processing time accounting for uncertainty caused by system congestion and human behavior. We provide a generalizable, data-driven approach that overcomes warehouse-specific assumptions characterizing most of the work in the literature. We analyze historical data to understand the processes in the warehouse, to predict processing times, and to improve order processing. We introduce the ROBP and develop an efficient learning-based branch-and-price algorithm based on simultaneous column and row generation, embedded with alternative prediction models such as linear regression and random forest that predict processing time of a batch. We conduct extensive computational experiments to test the performance of the proposed approach and to derive managerial insights based on real data. The data-driven prescriptive analytics tool we propose achieves savings of seven to eight minutes per order, which translates into a 14.8% increase in daily picking operations capacity of the warehouse.

Maximizing Storage Density of Steel Pipes: Optimization Modeling

Conference Paper

Full-text available

May 2021

Robust possibilistic programming for joint order batching and picker routing problem in warehouse management

Article

Full-text available

Jun 2020

Decisions made for designing and operating a warehouse system are of great significance. These operational decisions are strongly affected by total logistics costs, including investment and direct operating costs. The number of orders made by customers in the logistics section of warehouse management is very high because the number, type of products and items ordered by different customers vary broadly. However, machines layout for picking up products at logistics centres is minimal, inflexible, and, in some cases, inconclusive. In this study, we address joint order batching procedures of orders considering picker routing problem as a mixed-integer programming model. Extensive numerical experiments were generated in small, medium, and large sizes. In order to consider the uncertainty of parameters, we applied robust possibilistic programming for this problem. Three different meta-heuristic algorithms; genetic algorithm, particle swarm optimisation algorithm, and honey artificial bee colony algorithms are used as solution approaches to solve the formulated model. The performance of solution approaches over the problem was analysed using several test indexes. In all three group examples, there was no significant difference among mean values of the objective function, while there was a remarkable difference among computing times.

Simulation and order picking in a very-narrow-aisle warehouse

Article

Full-text available

Oct 2018

The revolution of information brought new possibilities for the business organisations: new management methods for managing supply chains, logistic processes and warehouses appear as well as innovative process management methods in the sense of knowledge management. The order picking process in the warehouse should be emphasised as one of the most laborious activities, since it consumes 55% of the warehouse labour activities. This study pays special attention to the order picking process in a very-narrow-aisle (V.N.A.) warehouse, with the aim to identify solutions for the reduction of total travel distance and costs. The methods of the scientific literature analysis and synthesis simulation were applied. The results of the simulation confirmed the application of a pick-by-article strategy that is implemented with ‘seed’ sorting by order solution in low-income countries.

Critical Success Factors for Warehousing Performance Improvement in Moroccan Companies

Article

Full-text available

Dec 2016

This research aims to identify Critical Success Factors (CSF) for warehousing performance improvement in Moroccan companies. Firstly, the paper defines through a literature review the warehousing performance and explains the reasons to introduce the concept of critical success factors in this study. Next, on the basis of an action research and a survey, the importance of the warehousing function and obstacles of its performance are presented. Then, CSF for warehousing performance improvement in Moroccan companies found in this research are shown. The results may be useful for managers and specialists in warehousing as well as researchers and scholars interested in developing studies on warehousing performance improvement.

Context-Aware Service Support Efficiency Improvement in the Transport System

Chapter

Sep 2022

Aurelija Burinskiene

The advance of the Internet of Things (IoT) technology and the development of sensors have allowed transport services to apply the Intelligent Transport Systems (ITS). The use of object-to-object communications has led to large amounts of contextual data sets generated for ITS. This basic information must be handled to obtain context and to suggest services that can communicate with various types of trucks about traffic, accidents, forecasting, etc. Since 2014 researchers are paying more attention to the transport systems. It covers processes including routing, clients clustering, backhauling management, and scheduling. The author targets in this chapter to revise the use of context in ITS.KeywordsTransport systemRouting algorithmsClusteringCosts metricsBackhaulingSchedulingIntelligent Transport System

Evaluation Method of Energy Consumption in Logistic Warehouse Systems

Article

Jan 2015

Pawel Zajac

This book focuses on guidelines for reducing the energy consumption in warehousing processes. It presents a model of formal assessment for energy consumption in the context of storage-system logistics, as well as a computational model consisting of three sub-models: energy consumption models for forklifts and stacker cranes, respectively, and an energy intensity model for roller conveyors. The concept model is based on the assumption that the unit load is received at a zero-energy warehouse. Subsequent handling, transport and storage processes, in which the unit load is moved vertically and horizontally through the system, equate to changes in energy intensity within the logistics warehouse management system. Energy recovery based on the handling equipment used can be collected in batteries. The evaluation method takes into account the intensity of the energy supplied to the logistics system and reduces the storage of the recovered energy - this figure represents the energy needed to pass through the logistics unit load storage system, and can be expressed in an energy intensity map.

Order Accumulation and Sorting Using an Automated Storage and Retrieval System

Conference Paper

Jul 2023

A pick-and-sort (PAS) system consists of a picking system (PS) and an accumulation/sorting system (A/SS). In a PAS, picking and order accumulation are highly interdependent. In general, the more orders that are being processed simultaneously, the greater the potential efficiency of picking as the motion required to move between successive storage locations can be decreased. Conversely, a larger number of orders being processed simultaneously increases the order accumulation cost. An automated storage/retrieval system (AS/RS) may be used for accumulating and sorting a large number of orders. In terms of the total cost of a PAS system, an AS/RS is a potentially low cost alternative to a conveyor system for order accumulation/Sorting. An approximate analytical performance model for rotary rack A/SS has been developed, as well as a cost model for a PS, in terms of the number of orders in process. A numerical example for a warehouse is presented.

Eaches or Pieces Order Fulfillment, Design, and Operations Handbook

Book

Jan 2007

David E. Mulcahy

Order-Fulfillment and Across-the-Dock Concepts, Design, and Operations Handbook

Book

Dec 2003

HEURISTIC ALGORITHMS FOR HANDLING ORDERS WITHIN A WAREHOUSE.

Article

Jan 1980

This paper presents two heuristic algorithms for handling orders within a warehouse. It is assumed that the number of items per order will not be greater than the capacity of the order picking vehicle. The algorithms select the orders that will be picked in one tour in order to minimize the total traveled distance of the vehicle within the warehouse. Computer programs were developed for both algorithms and the optimal tours were found by using the traveling salesman algorithm. The programs were run for several problems where optimum or near-optimum solutions were obtained.

Buffer sizing models for end-of-aisle order picking systems

Article

Jan 1999

We study an end-of-aisle order picking system with inbound and outbound buffer positions. The system is referred to as a miniload system with a horse-shoe front-end configuration, and is modeled as a two-stage cyclic queueing system with limited capacity. We analyze the system by utilizing known queueing results. Closed form expressions are developed for system performance measures, including the steady-state probability and system throughput. To provide some decision criteria in the design of buffer capacity, we examine the effect of the buffer size on system throughput. We give examples to illustrate how the results developed can be applied to solving real world problems. It is also shown that under heavy retrieval system demand, the system naturally achieves its optimal operating condition in the long run and it always performs dual command cycles.

Practical Handbook of Warehousing

Book

Jan 1997

Kenneth B. Ackerman

Part I: Background of the warehouse industry. The evolving role of warehousing. The functions of warehousing. The pros and cons of contract warehousing. Warehousing and corporate strategy. Part II: The elements of warehouse management. Communications and electronic data interchange. Packaging and identification. Transportation. Accountability. Starting-Up or moving a warehouse operation. Auditing warehouse performance. Part III: Real estate aspects of warehousing. Finding the right location. Building or rehabilitating your warehouse. The 21st century warehouse. Part IV: Planning warehouse operations. Planning for future uses. Space planning. Planning for people and equipment. Contingency planning. Postponement. Picking public warehouses. Selecting a third-party operator. Part V: Protecting the warehouse operation. Preventing casualty losses. Mysterious disappearance. Safety, sanitation and housekeeping. Verification of invetories and cycle counting. Part VI: The human element. Orientation and training. Labor relations. Motivation. Improving people performance. Part VII: Productivity and quality control. Making warehousing more efficient. Monitoring productivity. Scheduling warehouse operations. Customer satisfaction - the role of the warehouse. Improving asset utilization. Just in time and its variations. Warehousing costs. Management productivity. Reducing errors. Part VIII: The handling of materials. Receiving at the warehouse. Shipping. Cross-docking in the warehouse. Specialized warehousing. Order-picking. Storage equipment. Mobile equipment. Approaching warehouse automation. Pallets and unit loads. Dealing with damage. Reverse logistics in the warehouse. Part IX: Handling of information. Clerical procedures. Computers and warehouse Management. Electronic identification.

Ranking Alternative Warehouse Area Assignments: A Multiattribute Approach

Article

Mar 1982

Outsourcing the warehousing function: Economic and strategic consideration

Article

Jan 1994

Arnold Maltz

A graph-theoretic approach to a pallet loading problem

Article

Jan 1985

Kathryn Dowsland

Carousel system performance

Article

Sep 2003

We analyse the performance of a material handling system consisting of two carousels and one picker. We derive expressions for the system throughput and picker utilization. We work out the throughput and picker utilization for two different pick-time distributions: deterministic, which might be a reasonable model when a robot is picking, and exponential, which might be a reasonable model when a person is picking.

Operational Research Methods for Efficient Warehousing

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