IDEAS home Printed from https://ideas.repec.org/a/eee/transe/v146y2021ics1366554520308498.html
   My bibliography  Save this article

The impact of integrated cluster-based storage allocation on parts-to-picker warehouse performance

Author

Listed:
  • Mirzaei, Masoud
  • Zaerpour, Nima
  • de Koster, René

Abstract

Order picking is one of the most demanding activities in many warehouses in terms of capital and labor. In parts-to-picker systems, automated vehicles or cranes bring the parts to a human picker. The storage assignment policy, the assignment of products to the storage locations, influences order picking efficiency. Commonly used storage assignment policies, such as full turnover-based and class-based storage, only consider the frequency at which each product has been requested but ignore information on the frequency at which products are ordered jointly, known as product affinity. Warehouses can use product affinity to make informed decisions and assign multiple correlated products to the same inventory “pod” to reduce retrieval time. Existing affinity-based assignments sequentially cluster products with high affinity and assign the clusters to storage locations. We propose an integrated cluster allocation (ICA) policy to minimize the retrieval time of parts-to-picker systems based on both product turnover and affinity obtained from historical customer orders. We formulate a mathematical model that can solve small instances and develop a greedy construction heuristic for solving large instances. The ICA storage policy can reduce total retrieval time by up to 40% compared to full turnover-based storage and class-based policies. The model is validated using a real warehouse dataset and tested against uncertainties in customer demand and for different travel time models.

Suggested Citation

  • Mirzaei, Masoud & Zaerpour, Nima & de Koster, René, 2021. "The impact of integrated cluster-based storage allocation on parts-to-picker warehouse performance," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 146(C).
    • Handle: RePEc:eee:transe:v:146:y:2021:i:c:s1366554520308498
    DOI: 10.1016/j.tre.2020.102207
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S1366554520308498
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.tre.2020.102207?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Yugang Yu & René B.M. Koster & Xiaolong Guo, 2015. "Class-Based Storage with a Finite Number of Items: Using More Classes is not Always Better," Production and Operations Management, Production and Operations Management Society, vol. 24(8), pages 1235-1247, August.
    2. Yugang Yu & René de Koster, 2009. "Optimal zone boundaries for two-class-based compact three-dimensional automated storage and retrieval systems," IISE Transactions, Taylor & Francis Journals, vol. 41(3), pages 194-208.
    3. Roy, Debjit & Nigam, Shobhit & de Koster, René & Adan, Ivo & Resing, Jacques, 2019. "Robot-storage zone assignment strategies in mobile fulfillment systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 122(C), pages 119-142.
    4. Tim Lamballais Tessensohn & Debjit Roy & René B.M. De Koster, 2020. "Inventory allocation in robotic mobile fulfillment systems," IISE Transactions, Taylor & Francis Journals, vol. 52(1), pages 1-17, January.
    5. de Koster, Rene & Le-Duc, Tho & Roodbergen, Kees Jan, 2007. "Design and control of warehouse order picking: A literature review," European Journal of Operational Research, Elsevier, vol. 182(2), pages 481-501, October.
    6. Silva, Allyson & Coelho, Leandro C. & Darvish, Maryam & Renaud, Jacques, 2020. "Integrating storage location and order picking problems in warehouse planning," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 140(C).
    7. Boysen, Nils & de Koster, René & Weidinger, Felix, 2019. "Warehousing in the e-commerce era: A survey," European Journal of Operational Research, Elsevier, vol. 277(2), pages 396-411.
    8. Felix Weidinger & Nils Boysen, 2018. "Scattered Storage: How to Distribute Stock Keeping Units All Around a Mixed-Shelves Warehouse," Service Science, INFORMS, vol. 52(6), pages 1412-1427, December.
    9. Weidinger, Felix & Boysen, Nils, 2018. "Scattered Storage: How to Distribute Stock Keeping Units All Around a Mixed-Shelves Warehouse," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 126188, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    10. Warren H. Hausman & Leroy B. Schwarz & Stephen C. Graves, 1976. "Optimal Storage Assignment in Automatic Warehousing Systems," Management Science, INFORMS, vol. 22(6), pages 629-638, February.
    11. Jane, Chin-Chia & Laih, Yih-Wenn, 2005. "A clustering algorithm for item assignment in a synchronized zone order picking system," European Journal of Operational Research, Elsevier, vol. 166(2), pages 489-496, October.
    12. Dominik Kress & Nils Boysen & Erwin Pesch, 2017. "Which items should be stored together? A basic partition problem to assign storage space in group-based storage systems," IISE Transactions, Taylor & Francis Journals, vol. 49(1), pages 13-30, January.
    13. Tone Lerher, 2018. "Aisle changing shuttle carriers in autonomous vehicle storage and retrieval systems," International Journal of Production Research, Taylor & Francis Journals, vol. 56(11), pages 3859-3879, June.
    14. Yang, Peng & Yang, Kaidong & Qi, Mingyao & Miao, Lixin & Ye, Bin, 2017. "Designing the optimal multi-deep AS/RS storage rack under full turnover-based storage policy based on non-approximate speed model of S/R machine," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 104(C), pages 113-130.
    15. Roodbergen, Kees Jan & Vis, Iris F.A., 2009. "A survey of literature on automated storage and retrieval systems," European Journal of Operational Research, Elsevier, vol. 194(2), pages 343-362, April.
    16. Boysen, Nils & de Koster, René & Weidinger, Felix, 2019. "Warehousing in the e-commerce era: A survey," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 126185, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    17. Yang, Peng & Zhao, Zhijie & Guo, Huijie, 2020. "Order batch picking optimization under different storage scenarios for e-commerce warehouses," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 136(C).
    18. Stephen C. Graves & Warren H. Hausman & Leroy B. Schwarz, 1977. "Storage-Retrieval Interleaving in Automatic Warehousing Systems," Management Science, INFORMS, vol. 23(9), pages 935-945, May.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Vijay Prakash Sharma & Surya Prakash & Ranbir Singh, 2022. "What Prevents Sustainable Last-Mile Delivery in Industry 4.0? An Analysis and Decision Framework," Sustainability, MDPI, vol. 14(24), pages 1-20, December.
    2. Chen, Ran & Yang, Jingjing & Yu, Yugang & Guo, Xiaolong, 2023. "Retrieval request scheduling in a shuttle-based storage and retrieval system with two lifts," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 174(C).
    3. Onal, Sevilay & Zhu, Wen & Das, Sanchoy, 2023. "Order picking heuristics for online order fulfillment warehouses with explosive storage," International Journal of Production Economics, Elsevier, vol. 256(C).
    4. Sadia Samar Ali & Rajbir Kaur & Shahbaz Khan, 2023. "Evaluating sustainability initiatives in warehouse for measuring sustainability performance: an emerging economy perspective," Annals of Operations Research, Springer, vol. 324(1), pages 461-500, May.
    5. Kumar, Suryakant & Sheu, Jiuh-Biing & Kundu, Tanmoy, 2023. "Planning a parts-to-picker order picking system with consideration of the impact of perceived workload," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 173(C).
    6. Dragan Djurdjević & Nenad Bjelić & Dražen Popović & Milan Andrejić, 2022. "A Combined Dynamic Programming and Simulation Approach to the Sizing of the Low-Level Order-Picking Area," Mathematics, MDPI, vol. 10(20), pages 1-23, October.
    7. Zhong, Shuya & Giannikas, Vaggelis & Merino, Jorge & McFarlane, Duncan & Cheng, Jun & Shao, Wei, 2022. "Evaluating the benefits of picking and packing planning integration in e-commerce warehouses," European Journal of Operational Research, Elsevier, vol. 301(1), pages 67-81.
    8. Zhuang, Yanling & Zhou, Yun & Hassini, Elkafi & Yuan, Yufei & Hu, Xiangpei, 2022. "Rack retrieval and repositioning optimization problem in robotic mobile fulfillment systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 167(C).
    9. Silva, Allyson & Roodbergen, Kees Jan & Coelho, Leandro C. & Darvish, Maryam, 2022. "Estimating optimal ABC zone sizes in manual warehouses," International Journal of Production Economics, Elsevier, vol. 252(C).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Guo, Xiaolong & Chen, Ran & Du, Shaofu & Yu, Yugang, 2021. "Storage assignment for newly arrived items in forward picking areas with limited open locations," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 151(C).
    2. Chen, Gang & Feng, Haolin & Luo, Kaiyi & Tang, Yanli, 2021. "Retrieval-oriented storage relocation optimization of an automated storage and retrieval system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 155(C).
    3. Jiang, Min & Leung, K.H. & Lyu, Zhongyuan & Huang, George Q., 2020. "Picking-replenishment synchronization for robotic forward-reserve warehouses," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 144(C).
    4. Boysen, Nils & Schwerdfeger, Stefan & Stephan, Konrad, 2023. "A review of synchronization problems in parts-to-picker warehouses," European Journal of Operational Research, Elsevier, vol. 307(3), pages 1374-1390.
    5. Zhuang, Yanling & Zhou, Yun & Hassini, Elkafi & Yuan, Yufei & Hu, Xiangpei, 2022. "Rack retrieval and repositioning optimization problem in robotic mobile fulfillment systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 167(C).
    6. Li, Xiaowei & Hua, Guowei & Huang, Anqiang & Sheu, Jiuh-Biing & Cheng, T.C.E. & Huang, Fengquan, 2020. "Storage assignment policy with awareness of energy consumption in the Kiva mobile fulfilment system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 144(C).
    7. Silva, Allyson & Roodbergen, Kees Jan & Coelho, Leandro C. & Darvish, Maryam, 2022. "Estimating optimal ABC zone sizes in manual warehouses," International Journal of Production Economics, Elsevier, vol. 252(C).
    8. Zhuang, Yanling & Zhou, Yun & Yuan, Yufei & Hu, Xiangpei & Hassini, Elkafi, 2022. "Order picking optimization with rack-moving mobile robots and multiple workstations," European Journal of Operational Research, Elsevier, vol. 300(2), pages 527-544.
    9. Justkowiak, Jan-Erik & Pesch, Erwin, 2023. "Stronger mixed-integer programming-formulations for order- and rack-sequencing in robotic mobile fulfillment systems," European Journal of Operational Research, Elsevier, vol. 305(3), pages 1063-1078.
    10. Gharehgozli, Amir & Zaerpour, Nima, 2020. "Robot scheduling for pod retrieval in a robotic mobile fulfillment system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 142(C).
    11. Laura Korbacher & Katrin Heßler & Stefan Irnich, 2023. "The Single Picker Routing Problem with Scattered Storage: Modeling and Evaluation of Routing and Storage Policies," Working Papers 2302, Gutenberg School of Management and Economics, Johannes Gutenberg-Universität Mainz.
    12. van der Gaast, Jelmer Pier & Weidinger, Felix, 2022. "A deep learning approach for the selection of an order picking system," European Journal of Operational Research, Elsevier, vol. 302(2), pages 530-543.
    13. Dong, Wenquan & Jin, Mingzhou, 2021. "Travel time models for tier-to-tier SBS/RS with different storage assignment policies and shuttle dispatching rules," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 155(C).
    14. AERTS, Babiche & CORNELISSENS, Trijntje & SÖRENSEN, Kenneth, 2022. "The internal warehouse replenishment problem: the importance of storage and replenishment policies," Working Papers 2022007, University of Antwerp, Faculty of Business and Economics.
    15. Jiang, Min & Huang, George Q., 2022. "Intralogistics synchronization in robotic forward-reserve warehouses for e-commerce last-mile delivery," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 158(C).
    16. Jianming Cai & Xiaokang Li & Yue Liang & Shan Ouyang, 2021. "Collaborative Optimization of Storage Location Assignment and Path Planning in Robotic Mobile Fulfillment Systems," Sustainability, MDPI, vol. 13(10), pages 1-26, May.
    17. Kaveh Azadeh & René De Koster & Debjit Roy, 2019. "Robotized and Automated Warehouse Systems: Review and Recent Developments," Transportation Science, INFORMS, vol. 53(4), pages 917-945, July.
    18. Onal, Sevilay & Zhu, Wen & Das, Sanchoy, 2023. "Order picking heuristics for online order fulfillment warehouses with explosive storage," International Journal of Production Economics, Elsevier, vol. 256(C).
    19. Ang, Marcus & Lim, Yun Fong, 2019. "How to optimize storage classes in a unit-load warehouse," European Journal of Operational Research, Elsevier, vol. 278(1), pages 186-201.
    20. Chen, Ran & Yang, Jingjing & Yu, Yugang & Guo, Xiaolong, 2023. "Retrieval request scheduling in a shuttle-based storage and retrieval system with two lifts," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 174(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:transe:v:146:y:2021:i:c:s1366554520308498. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/600244/description#description .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.