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Journal ArticleDOI: 10.1080/01605682.2019.1700180

High-density storage with mobile racks: Picker routing and product location

04 Mar 2021-Journal of the Operational Research Society (Informa UK Limited)-Vol. 72, Iss: 3, pp 535-553
Abstract: In response to the scarce space in many urban areas, high-density storage has become a widely discussed topic in warehousing research and practice. We investigate a storage setting where mobile rac...

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Open access
Henrik Brynzér1, Mats I. Johansson1Institutions (1)
01 Jan 1994-
Abstract: The stock location assignment problem is concerned and a strategy for prestructuring components and information for the picking work in storehouses is described. This classification is derived from the product structures transformed to support a holistic perception aimed at the material handler/picker. The results imply a more efficient material handling through reorganizing the components in the storage system, in order to support the work from the picker's point of view. A storage location assignment strategy emanating from the product structure is proposed, and is exemplified by using empirical data from a case study. The result from this case study was a reduction in picking information of more than 75%, which in turn greatly reduced the amount of information to the picker.

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Topics: Order picking (61%)

113 Citations


Journal ArticleDOI: 10.1016/J.EJOR.2020.04.058
Abstract: Warehouses are an inevitable component in any supply chain and a vividly investigated object of research. Much attention, however, is absorbed by warehousing systems dedicated to the special needs of online retailers in the business-to-consumer segment. Due to the ever increasing sales volumes of e-commerce this focus seems self-evident, but a much larger fraction of retail sales are still realized by traditional brick-and-mortar stores. The special needs of warehouses servicing these stores are focused in this paper. While e-commerce warehouses face low-volume-high-mix picking orders, because private households tend to order just a few pieces per order from a large assortment, distribution centers of retail chains rather have to process high-volume-low-mix orders. We elaborate the basic requirements within both business segments and identify suited warehousing systems for brick-and-mortar stores (e.g., fully-automated case picking). The setup of each identified warehousing system is described, elementary decision problems are discussed, and the existing literature is surveyed. Furthermore, we identify future research needs.

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Topics: Order (business) (51%), Brick and mortar (50%), Supply chain (50%)

14 Citations


Open accessJournal ArticleDOI: 10.1016/J.COR.2020.105090
Abstract: In this paper we investigate the problem of simultaneously allocating orders and mobile storage racks to static pickers. Here storage racks are allocated to pickers to enable them to pick all of the products for the orders that have been allocated to them. Problems of the type considered here arise in facilities operating as robotic mobile fulfilment systems. We present a formulation of the problem of allocating orders and racks to pickers as an integer program and discuss the complexity of the problem. We present two heuristics (matheuristics) for the problem, one using partial integer optimisation, that are directly based upon our formulation. We also consider the problem of how to sequence the racks for presentation at each individual picker and formulate this problem as an integer program. We prove that, subject to certain conditions being satisfied, a feasible rack sequence for all orders can be produced by focusing on just a subset of the orders to be dealt with by the picker. Computational results are presented, both for order and rack allocation, and for rack sequencing, for randomly generated test problems (that are made publicly available) involving up to 1000 products, 200 orders, 500 racks and 10 pickers.

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9 Citations


Open accessJournal ArticleDOI: 10.1016/J.TRE.2020.102207
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.

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Topics: Order picking (58%)

4 Citations


Open accessPosted Content
Nils Boysen1, Dirk Briskorn2, Simon Emde3Institutions (3)
Abstract: A growing population and increasing real estate costs in many urbanized areas have made space for roomy warehouses with single-deep storage and wide aisles scarce and expensive. Mobile rack warehouses increase the space utilization by providing only a few open aisles at a time for accessing the racks. Whenever a stock keeping unit (SKU) is to be retrieved, neighboring racks mounted on rail tracks have to be moved aside by a strong engine, so that the adjacent aisle opens and the SKU can be accessed. As moving the heavy racks takes considerable time, the resulting waiting time determines large parts of the picking effort. It is, thus, advantageous to sequence picking orders, such that the last aisle visited for the preceding order is also the first aisle to enter when retrieving a subsequent picking order. We formalize the resulting picking order sequencing problem and present suited exact and heuristic solution procedures. These algorithms are tested in a comprehensive computational study and then applied to explore managerial aspects, such as the influence of the number of open aisles on the picking effort.

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Topics: Aisle (53%), Stock keeping unit (52%), Population (51%)

3 Citations


References
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37 results found



Open accessJournal ArticleDOI: 10.1016/J.EJOR.2006.07.009
Abstract: Order picking has long been identified as the most labour-intensive and costly activity for almost every warehouse; the cost of order picking is estimated to be as much as 55% of the total warehouse operating expense. Any underperformance in order picking can lead to unsatisfactory service and high operational cost for the warehouse, and consequently for the whole supply chain. In order to operate efficiently, the order-picking process needs to be robustly designed and optimally controlled. This paper gives a literature overview on typical decision problems in design and control of manual order-picking processes. We focus on optimal (internal) layout design, storage assignment methods, routing methods, order batching and zoning. The research in this area has grown rapidly recently. Still, combinations of the above areas have hardly been explored. Order-picking system developments in practice lead to promising new research directions.

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Topics: Order picking (76%)

1,418 Citations


Journal ArticleDOI: 10.1016/J.EJOR.2006.02.025
Abstract: An extensive review on warehouse operation planning problems is presented. The problems are classified according to the basic warehouse functions, i.e., receiving, storage, order picking, and shipping. The literature in each category is summarized with an emphasis on the characteristics of various decision support models and solution algorithms. The purpose is to provide a bridge between academic researchers and warehouse practitioners, explaining what planning models and methods are currently available for warehouse operations, and what are the future research opportunities.

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Topics: Order picking (62%), Decision support system (51%)

768 Citations


Journal ArticleDOI: 10.1016/J.EJOR.2009.07.031
Abstract: This paper presents a detailed survey of the research on warehouse design, performance evaluation, practical case studies, and computational support tools. This and an earlier survey on warehouse operation provide a comprehensive review of existing academic research results in the framework of a systematic classification. Each research area within this framework is discussed, including the identification of the limits of previous research and of potential future research directions.

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511 Citations


Open accessBook
01 Jan 1976-
Abstract: : The Harpy connected speech recognition system is the result of an attempt to understand the relative importance of various design choices of two earlier speech recognition systems developed at Carnegie-Mellon University: The Hearsay-1 system and the Dragon system. Knowledge is represented in the Hearsay- 1 system as procedures and in the Dragon system as a Markov network with a- priori transition probabilities between states. Systematic performance analysis of various design choices of these two systems resulted in the HARPY system, in which knowledge is represented as a finite state transition network but without the a-priori transition probabilities. Harpy searches only a few 'best' syntactic (and acoustic) paths in parallel to determine the optimal path, and uses segmentation to effectively reduce the utterance length, thereby reducing the number of state probability updates that must be done. Several new heuristics have been added to the HARPY system to improve its performance and speed: detection of common sub-nets and collapsing them to reduce overall network size and complexity, eliminating the need for doing an acoustic match for all phonemic types at every time sample, and semi-automatic techniques for learning the lexical representations (that are needed for a steady-state system of this type) and the phonemic templates from training data, thus automatically accounting for the commonly occurring intra-word coarticulation and juncture phenomena. Inter-word phenomena are handled by the use of juncture rules which are applied at network generation time, thereby eliminating the need for repetitive and time consuming application of phonological rules during the recognition phase.

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Topics: Heuristics (50%)

489 Citations


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No. of citations received by the Paper in previous years
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20214
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20161
19941