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Modeling, Analysis, and Design Insights for Shuttle-Based Compact Storage Systems

Author

Listed:
  • Elena Tappia

    (Politecnico di Milano, 20156 Milano, Italy)

  • Debjit Roy

    (Indian Institute of Management, Ahmedabad, Gujarat 380015, India)

  • René de Koster

    (Rotterdam School of Management, Erasmus University, 3000 DR Rotterdam, Netherlands)

  • Marco Melacini

    (Politecnico di Milano, 20156 Milano, Italy)

Abstract

Shuttle-based compact systems are new automated multideep unit-load storage systems with lifts that can potentially achieve both low operational cost and large volume flexibility. In this paper, we develop novel queuing network models to estimate the performance of both single-tier and multitier shuttle-based compact systems. Each tier is modeled as a multiclass semi-open queuing network, whereas the vertical transfer is modeled using an open queue. For a multitier system, the models corresponding to tiers and vertical transfer are linked together using the first and second moment information of the queue departure processes. The models can handle both specialized and generic shuttles and both continuous and discrete lifts. The accuracy of the models is validated through both simulation and a real case. Errors are acceptable for conceptualizing initial designs. Numerical studies provide new design insights. Results show that the best way to minimize expected throughput time in single-tier systems is to have a depth/width ratio around 1.25. Moreover, specialized shuttles are recommended for multitier systems because the higher cost of generic shuttles is not balanced by savings in reduced throughput time and equipment needs.

Suggested Citation

  • Elena Tappia & Debjit Roy & René de Koster & Marco Melacini, 2017. "Modeling, Analysis, and Design Insights for Shuttle-Based Compact Storage Systems," Transportation Science, INFORMS, vol. 51(1), pages 269-295, February.
    • Handle: RePEc:inm:ortrsc:v:51:y:2017:i:1:p:269-295
    DOI: 10.1287/trsc.2016.0699
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    References listed on IDEAS

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    Cited by:

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    2. Amjath, Mohamed & Kerbache, Laoucine & Smith, James MacGregor & Elomri, Adel, 2022. "Fleet sizing of trucks for an inter-facility material handling system using closed queueing networks," Operations Research Perspectives, Elsevier, vol. 9(C).
    3. Bipan Zou & Yeming (Yale) Gong & Xianhao Xu & Zhe Yuan, 2017. "Assignment rules in robotic mobile fulfilment systems for online retailers," International Journal of Production Research, Taylor & Francis Journals, vol. 55(20), pages 6175-6192, October.
    4. 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).
    5. Kumawat, Govind Lal & Roy, Debjit & De Koster, René & Adan, Ivo, 2021. "Stochastic modeling of parallel process flows in intra-logistics systems: Applications in container terminals and compact storage systems," European Journal of Operational Research, Elsevier, vol. 290(1), pages 159-176.
    6. Yang, Jingjing & de Koster, René B.M. & Guo, Xiaolong & Yu, Yugang, 2023. "Scheduling shuttles in deep-lane shuttle-based storage systems," European Journal of Operational Research, Elsevier, vol. 308(2), pages 696-708.
    7. Wenquan Dong & Mingzhou Jin & Yanyan Wang & Peter Kelle, 2021. "Retrieval scheduling in crane-based 3D automated retrieval and storage systems with shuttles," Annals of Operations Research, Springer, vol. 302(1), pages 111-135, July.
    8. Emilio Moretti & Elena Tappia & Martina Mauri & Marco Melacini, 2022. "A performance model for mobile robot-based part feeding systems to supermarkets," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 580-613, September.
    9. Yanyan Wang & Jinning Qin & Shandong Mou & Ke Huang & Xiaofeng Zhao, 2023. "DSS approach for sustainable system design of shuttle-based storage and retrieval systems," Flexible Services and Manufacturing Journal, Springer, vol. 35(3), pages 698-726, September.
    10. 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).
    11. Bipan Zou & René De Koster & Xianhao Xu, 2018. "Operating Policies in Robotic Compact Storage and Retrieval Systems," Transportation Science, INFORMS, vol. 52(4), pages 788-811, August.
    12. Marco Melacini & Elena Tappia, 2018. "A Critical Comparison of Alternative Distribution Configurations in Omni-Channel Retailing in Terms of Cost and Greenhouse Gas Emissions," Sustainability, MDPI, vol. 10(2), pages 1-15, January.
    13. Lei Deng & Lei Chen & Jingjie Zhao & Ruimei Wang, 2021. "Modeling and performance analysis of shuttle-based compact storage systems under parallel processing policy," PLOS ONE, Public Library of Science, vol. 16(11), pages 1-26, November.

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