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

Author

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  • 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
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    References listed on IDEAS

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    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.

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