IDEAS home Printed from https://ideas.repec.org/a/gam/jsusta/v14y2022i8p4611-d792290.html
   My bibliography  Save this article

Increasing Throughput in Warehouses: The Effect of Storage Reallocation and the Location of Input/Output Station

Author

Listed:
  • Mohammed Alnahhal

    (Mechanical and Industrial Engineering Department, American University of Ras Al Khaimah, Ras Al Khaimah P.O. Box 10021, United Arab Emirates)

  • Bashir Salah

    (Department of Industrial Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia)

  • Rafiq Ahmad

    (Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 1H9, Canada)

Abstract

Automatic warehousing systems are a sort of green technology that is becoming increasingly popular in the logistics business. Automated Storage/Retrieval Systems (AS/RS) are one of the most significant components of advanced automated logistics and manufacturing systems. The majority of AS/RS systems use input/output (I/O) points located in the lower left corner of the rack. These systems are reaching their maximum capacity because of their layout design limitations. Breakthrough solutions are needed to enhance the performance of existing systems. In this study, we examined how the location of I/O station can affect the total travel time. Another strategy for enhancement is a two-step preparation method. In this strategy, the allocation of the storage is changed, in the idle time, to be closer to the I/O point to reduce the service time for a class-based storage assignment. An analytical model was used to introduce for the first time optimal configurations of this strategy. We tested the suggested strategy using a simulation model created using R software, specifically designed for this purpose. Results showed that the two-step preparation strategy took between 1.2 and 1.9 h before the shift starts. The enhancement on throughput is almost the same for both possible locations of the I/O point. The results also showed that the two strategies (location of the I/O point and reallocation of storage) could increase throughput by about 21% to 28%, depending on parameters such as the number of orders and the height of the storage rack.

Suggested Citation

  • Mohammed Alnahhal & Bashir Salah & Rafiq Ahmad, 2022. "Increasing Throughput in Warehouses: The Effect of Storage Reallocation and the Location of Input/Output Station," Sustainability, MDPI, vol. 14(8), pages 1-16, April.
    • Handle: RePEc:gam:jsusta:v:14:y:2022:i:8:p:4611-:d:792290
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/2071-1050/14/8/4611/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/2071-1050/14/8/4611/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. 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.
    2. Gu, Jinxiang & Goetschalckx, Marc & McGinnis, Leon F., 2010. "Research on warehouse design and performance evaluation: A comprehensive review," European Journal of Operational Research, Elsevier, vol. 203(3), pages 539-549, June.
    3. Chia-Nan Wang & Thanh-Tuan Dang & Ngoc-Ai-Thy Nguyen, 2020. "A Computational Model for Determining Levels of Factors in Inventory Management Using Response Surface Methodology," Mathematics, MDPI, vol. 8(8), pages 1-23, July.
    4. 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).
    5. Antonella Meneghetti & Eleonora Dal Borgo & Luca Monti, 2015. "Rack shape and energy efficient operations in automated storage and retrieval systems," International Journal of Production Research, Taylor & Francis Journals, vol. 53(23), pages 7090-7103, December.
    6. Jingjing Hao & Haoming Shi & Victor Shi & Chenchen Yang, 2020. "Adoption of Automatic Warehousing Systems in Logistics Firms: A Technology–Organization–Environment Framework," Sustainability, MDPI, vol. 12(12), pages 1-14, June.
    7. Konrad Lewczuk & Michał Kłodawski & Paweł Gepner, 2021. "Energy Consumption in a Distributional Warehouse: A Practical Case Study for Different Warehouse Technologies," Energies, MDPI, vol. 14(9), pages 1-25, May.
    8. 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.
    9. 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.
    10. Nicos Christofides & I. Colloff, 1973. "The Rearrangement of Items in a Warehouse," Operations Research, INFORMS, vol. 21(2), pages 577-589, April.
    11. Bartolini, M. & Bottani, E. & Grosse, E. H., 2019. "Green warehousing: systematic literature review and bibliometric analysis," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 112369, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    12. Jingjing Hao & Yugang Yu & Linda L. Zhang, 2015. "Optimal design of a 3D compact storage system with the I/O port at the lower mid-point of the storage rack," International Journal of Production Research, Taylor & Francis Journals, vol. 53(17), pages 5153-5173, September.
    13. 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.
    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. Xuan Zhang & Tiantian Mo & Yougong Zhang, 2023. "Optimization of Storage Location Assignment for Non-Traditional Layout Warehouses Based on the Firework Algorithm," Sustainability, MDPI, vol. 15(13), pages 1-21, June.

    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. Bortolini, Marco & Faccio, Maurizio & Ferrari, Emilio & Gamberi, Mauro & Pilati, Francesco, 2017. "Time and energy optimal unit-load assignment for automatic S/R warehouses," International Journal of Production Economics, Elsevier, vol. 190(C), pages 133-145.
    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. Mohammed Alnahhal & Bashir Salah & Mohammed Ruzayqat, 2022. "An Efficient Approach to Investigate the Tradeoff between Double Handling and Needed Capacity in Automated Distribution Centers," Sustainability, MDPI, vol. 14(13), pages 1-25, June.
    4. Azadeh, K. & de Koster, M.B.M. & Roy, D., 2017. "Robotized Warehouse Systems: Developments and Research Opportunities," ERIM Report Series Research in Management ERS-2017-009-LIS, Erasmus Research Institute of Management (ERIM), ERIM is the joint research institute of the Rotterdam School of Management, Erasmus University and the Erasmus School of Economics (ESE) at Erasmus University Rotterdam.
    5. 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).
    6. 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.
    7. 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.
    8. 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).
    9. 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.
    10. Hyun-woo Jeon & Ahmad Ebrahimi & Ga-hyun Lee, 2023. "A Simulation-Based Experimental Design for Analyzing Energy Consumption and Order Tardiness in Warehousing Systems," Sustainability, MDPI, vol. 15(20), pages 1-25, October.
    11. 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.
    12. Buckow, Jan-Niklas & Knust, Sigrid, 2023. "The warehouse reshuffling problem with swap moves," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 169(C).
    13. Lanza, Giacomo & Passacantando, Mauro & Scutellà, Maria Grazia, 2022. "Assigning and sequencing storage locations under a two level storage policy: Optimization model and matheuristic approaches," Omega, Elsevier, vol. 108(C).
    14. Polten, Lukas & Emde, Simon, 2022. "Multi-shuttle crane scheduling in automated storage and retrieval systems," European Journal of Operational Research, Elsevier, vol. 302(3), pages 892-908.
    15. 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).
    16. 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).
    17. Marcus Ang & Yun Fong Lim & Melvyn Sim, 2012. "Robust Storage Assignment in Unit-Load Warehouses," Management Science, INFORMS, vol. 58(11), pages 2114-2130, November.
    18. Yu, Y. & de Koster, M.B.M., 2009. "On the Suboptimality of Full Turnover-Based Storage," ERIM Report Series Research in Management ERS-2009-051-LIS, Erasmus Research Institute of Management (ERIM), ERIM is the joint research institute of the Rotterdam School of Management, Erasmus University and the Erasmus School of Economics (ESE) at Erasmus University Rotterdam.
    19. 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.
    20. Yue Chen & Yisong Li, 2024. "Storage Location Assignment for Improving Human–Robot Collaborative Order-Picking Efficiency in Robotic Mobile Fulfillment Systems," Sustainability, MDPI, vol. 16(5), pages 1-25, February.

    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:gam:jsusta:v:14:y:2022:i:8:p:4611-:d:792290. 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: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    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.