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Optimal class boundaries, number of aisles, and pick list size for low-level order picking systems

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  • Subir Rao
  • Gajendra Adil

Abstract

This article considers a two-block warehouse with low-level aisles having dedicated pickers who follow a return routing policy within the aisle. Travel distance models are formulated assuming a given product density distribution in aisles for multi-item picks. An analytical recursive procedure is developed to find optimal n-class partitions of each warehouse aisle. A range on the number of classes and number of picks for which class-based storage is an attractive option over the random storage policy is determined through a computational study. The article also presents an iterative hierarchical framework to simultaneously obtain pick list size, number of aisles, and class storage boundaries. A sensitivity analysis of optimal pick travel distance against important warehouse design parameters is presented.

Suggested Citation

  • Subir Rao & Gajendra Adil, 2013. "Optimal class boundaries, number of aisles, and pick list size for low-level order picking systems," IISE Transactions, Taylor & Francis Journals, vol. 45(12), pages 1309-1321.
    • Handle: RePEc:taf:uiiexx:v:45:y:2013:i:12:p:1309-1321
    DOI: 10.1080/0740817X.2013.772691
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    Citations

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    Cited by:

    1. Manzini, Riccardo & Accorsi, Riccardo & Gamberi, Mauro & Penazzi, Stefano, 2015. "Modeling class-based storage assignment over life cycle picking patterns," International Journal of Production Economics, Elsevier, vol. 170(PC), pages 790-800.
    2. Dijkstra, Arjan S. & Roodbergen, Kees Jan, 2017. "Exact route-length formulas and a storage location assignment heuristic for picker-to-parts warehouses," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 102(C), pages 38-59.
    3. De Santis, Roberta & Montanari, Roberto & Vignali, Giuseppe & Bottani, Eleonora, 2018. "An adapted ant colony optimization algorithm for the minimization of the travel distance of pickers in manual warehouses," European Journal of Operational Research, Elsevier, vol. 267(1), pages 120-137.
    4. 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).
    5. Rao, Subir S. & Adil, Gajendra K. & Venkitasubramony, Rakesh, 2020. "On the expectation of the largest gap in a warehouse," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 143(C).
    6. Subir S. Rao & Gajendra K. Adil, 2017. "Analytical models for a new turnover-based hybrid storage policy in unit-load warehouses," International Journal of Production Research, Taylor & Francis Journals, vol. 55(2), pages 327-346, January.
    7. 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).

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