Forward-reserve allocation in a warehouse with unit-load replenishments

Many companies configure their warehouse with a forward area and a reserve area. The former is used for efficient order-picking, the latter for replenishing the forward area. We consider a situation in which orders are picked during a certain time period, referred to as the picking period. Prior to the picking period there is sufficient time to replenish the forward area. Our objective is to determine which replenishments minimize the expected amount of labor during the picking period. Further, we present a second model with a constraint on the replenishment activity. We model the problem as a binary programming problem and present efficient heuristics that provide tight performance guarantees. We compare the heuristics with procedures that are popular in practice and show that significant labor-savings are possible.     

A model based evaluation of a commonly used rule of thumb for warehouse layout

A model is formulated to describe the cost effects of alternative warehouse layouts in a dedicated storage warehouse that utilizes dual address order picking cycles. The model is utilized to evaluate a common warehouse layout rule of thumb where stock levels are determined using economic order quantities, and stock locations are obtained using the cube per order index. A simple heuristic procedure is devised to utilize the cost model to obtain warehouse layouts with lower total inventory and order picking cost than those obtained using the rule of thumb. Four test problems are generated to assess the difficulty of obtaining improved warehouse layouts. It is shown that the heuristic procedure can achieve significantly improved warehouse layouts with minimal computational effort.     

考虑商品数量和商品拣选成本的AGV智能仓库订单分批问题研究

AGV(Automated Guided Vehicle,自动导引车)智能仓库是一种基于“货到人”拣选模式的自动化仓库。本文考虑了订单中商品的需求量和货架上商品的存储量,以极小化货架搬运成本和商品拣选成本为目标,建立了AGV智能仓库订单分批问题的整数规划模型。本文针对订单分批问题的特点,提出了一种基于订单和货架交替选择的贪婪求解算法。对比CPLEX求解器的精确最优解,本文提出的贪婪算法的误差百分比不超过10%,平均误差百分比为5.38%;对比基于相似性的分批算法的求解结果,本文提出的贪婪算法不仅运算时间更短,解的质量也更好。进一步地,对比不考虑商品拣选成本的订单分批模型,本文提出的模型在不明显增加货架搬运成本的前提下,可以大幅度降低商品拣选成本。因此,在订单分批模型中考虑商品拣选成本是非常必要的。     

Research on warehouse operation: A comprehensive review

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.     

基于聚类和动态规划的组合路径策略

为提高电商仓库的拣货作业效率,本文提出了基于聚类和动态规划的组合路径策略,实现了生成路径消耗时间和路径长度之间的平衡,并将这一策略成功地应用到多区型仓库。该策略分四步:首先,根据待拣储位分布特征,运用聚类分析法对其进行分类;然后,以各类的首末储位作为节点,运用动态规划法对已得分类进行排序,得到相应的类序;其次,得到各类内部路径;最后,依次拣取待拣商品,并返回出发点完成拣货作业。在提出新的路径策略后,通过仿真方法将新策略与三种传统路径策略(穿越策略、最大间隙策略和混合策略)和一种优质算法(蚁群算法)进行了对比分析,结果表明:该策略具备良好的适用性和实用性。     

基于改进粒子群算法V型非传统布局仓库通道优化设计

V型仓储布局是一种典型的非传统布局方式,针对V型布局主通道设计的问题,将主通道抽象为若干个点连接而成的折线通道,每条拣货通道按物动量大小对仓库进行分区,采用更加符合实际的存取货物作业的概率不相等的非完全随机存储策略,建立最小化平均拣货距离的仓库主通道设计数学优化模型。其次,设计了基于极值扰动算子的改进粒子群优化算法(EDO-PSO)进行算法求解,利用极值扰动算子解决易陷入局部最优问题,采用并行深度搜索策略,提高算法性能,并用Benchmark函数与其他改进PSO算法对比验证算法性能。最后,结合具体实验数据仿真分析,计算结果表明,该方法在相同货位分配策略下,能有效缩短总拣货距离,验证了方法的有效性。     

A branch and bound algorithm for class based storage location assignment

Class-based storage implementation decisions have significant impact on the required storage space and the material handling cost in a warehouse. In this paper, a nonlinear integer programming model is proposed to capture the above. Effects of storage area reduction on order picking and storage space cost are incorporated. A branch and bound algorithm is developed to solve the model. Computational experience with randomly generated data sets and an industrial case shows that branch and bound algorithm is computationally more efficient than a baseline dynamic programming algorithm. It is further observed that the class based policy results in lower total cost of order picking and storage space than the dedicated policy.     

考虑车载容量的多区型仓库拣货路径优化研究

拣货作业是仓库核心作业之一,占据仓库运营大量的时间成本和资金成本.针对多区型仓库拣货路径优化问题,对多区型仓库布局、货位坐标、路径等问题进行了定义,构建了多区型仓库拣货路径优化建模,接着通过大量实验确定了人工鱼群算法在求解拣货路径问题时的最优算法参数组合,通过演示性实验验证了模型与算法的有效性,最后从波次订单对实验结果...     

配送中心订单分拣系统中的拣货路径选择研究

订单分拣是订单履行流程中一项重要活动,分拣成本是配送中心成本的主要组成部分之一。订单分拣系统的设计需要考虑订单类型、产品特点、分拣策略、分拣区域的布局、分拣路径和储位选择等因素。本文主要评价各种拣货路径方法,作者利用方差分析中的最小显著性差异法.1602640178otmail.com对仿真结果进行多重比较。本文的研究结果显示,当订单规模较小时,单区布局下的最优启发式路径方法是最大间隙法;双区布局下的最优启发式路径是组合方法;而且双区布局下的各种路径方法更能节省分拣行走距离。这些结论有助于配送中心管理人员通过分析订单规模来改变分拣路径和布局,进而提高配送中心分拣效率。     

基于AGV的智能仓库系统订单分批问题研究

研究了基于自动引导小车(AGV)的“货到人”智能仓库订单分批拣选问题, 在同时考虑工作人员拣选商品成本和AGV搬运货架成本的前提下, 建立了以总成本极小化为目标函数的订单分批问题整数规划模型。根据订单中包含的商品信息和商品所在的货架信息构建了描述订单之间关系的加权相似度指标, 分析了加权相似度与总拣选成本之间的正相关关系。基于订单之间的加权相似度设计了求解模型的贪婪算法。利用具体算例进行模拟计算, 分析了加权系数的变化对订单分批结果的影响, 以及加权系数λ的取值与工作人员拣取一件商品的成本c₁和AGV搬运一次货架的成本c₂之间的关系, 得到了贪婪算法中加权系数λ的确定方法。进一步分析了贪婪算法的计算时间和计算效果, 结果显示, 通过适当选取加权系数, 利用贪婪算法可以在短时间内得到订单分批问题的近似最优解;对于小规模算例, 贪婪算法在最坏情况下近似比不超过1.35。利用本文的模型和算法进行订单分批, 兼顾了工作人员拣取商品的成本和AGV搬运货架的成本, 可以有效提高订单拣选效率, 降低订单拣选总成本。     

Tabu search heuristics for the order batching problem in manual order picking systems

In a manual order picking system, order pickers walk or ride through a distribution warehouse in order to collect items requested by (internal or external) customers. In order to perform these operations efficiently, it is usually required that customer orders be combined into (more substantial) picking orders that are limited in size. The order batching problem considered in this paper deals with the question of how a given set of customer orders should be combined into picking orders such that the total length of all picker tours necessary for all of the requested items to be collected is minimized. For the solution of this problem the authors suggest two approaches based on the tabu search principle. The first is a (classic) tabu search (TS), and the second is the attribute-based hill climber (ABHC). In a series of extensive numerical experiments, these approaches are benchmarked against other solution methods put forward in the current literature. It is demonstrated that the proposed methods are superior to the existing methods and provide solutions which may allow distribution warehouses to operate more efficiently.     

Routing order pickers in a warehouse with a middle aisle

This paper considers a parallel aisle warehouse, where order pickers can change aisles at the ends of every aisle and also at a cross aisle halfway along the aisles. An algorithm is presented that can find shortest order picking tours in this type of warehouses. The algorithm is applicable in warehouse situations with up to three aisle changing possibilities. Average tour length is compared for warehouses with and without a middle aisle. It appears that in many cases the average order picking time can be decreased significantly by adding a middle aisle to the layout.     

Warehouse design: A structured approach

In spite of the importance of warehousing to the customer service and cost levels of many businesses, there is currently not a comprehensive systematic method for designing warehouses. In this paper, the current literature on the overall methodology of warehouse design is explored, together with the literature on tools and techniques used for specific areas of analysis. The general results from the literature have then been validated and refined with reference to warehouse design companies. The output is a general framework of steps, with specific tools and techniques that can be used for each step. This is intended to be of value to practitioners and to assist further research into the development of a more comprehensive methodology for warehouse design.     

提前期不确定条件下的预防性维修备件存储模型研究

在考虑预防性维修周期和提前期不确定的条件下,分别研究备件存储与其相关的维修费用、缺货费用、库存费用以及订购费用等四种费用之间的关系,明确了备件存储量对各项费用的影响.以各项费用总和最小化为目标,构建了提前期不确定条件下的预防性维修备件存储模型.通过备件存储模型的构建,对备件存储过程中的各项成本进行分析,以期对备件库存策略的确定给出一种解决方案.     

A constructive aisle design model for unit-load warehouses with multiple pickup and deposit points

We develop a network-based warehouse model of individual pallet locations and their interactions with appropriate cross aisles in order to evaluate the expected travel distance of a given design. The model is constructive in that it uses Particle Swarm Optimization to determine the best angles of cross aisles and picking aisles for multiple, pre-determined pickup and deposit (P&D) points in a unit-load warehouse. Our results suggest that alternative designs offer reduced expected travel distance, but at the expense of increased storage space. The opportunity for benefit also seems to decline as P&D points increase in number and dispersion.     

Travel time analysis for general item location assignment in a rectangular warehouse

A travel time model with general item location assignment in a rectangular warehouse system is presented. We give the exact probability mass functions that characterise the tour of an order picker and derive the first and second moments associated with the tour. We apply the model to analysing order batching and storage allocation strategies in an order picking system. The order picking system is modelled as a queueing system with customer batching. The results are compared and validated via simulation. The effects of batching and batch size on the delay time are discussed with consideration to the picking and sorting times for each batch of orders.     

Prioritizing replenishments of the piece picking area

Having sufficient inventories in the forward or piece picking area of a warehouse is an essential condition for warehouse operations. As pickers consume the inventory in the piece racks, there is a risk of stockout. This can be reduced by the timely replenishment of products from the bulk reserve area to the forward area. We develop and compare three policies for prioritizing replenishments for the case where order picking and replenishments occur concurrently because of time restrictions. The first policy, based on the ratio of available inventory to wave demand, reduces the number of stockouts considerably. The other two more sophisticated policies reduce the number of stockouts even more but require much more computation time, and are more costly in terms of implementation, maintenance and software updates. We present the results of implementing one of these policies in the warehouse of a large cosmetics firm.     

基于物料周转率与需求相关性的储位分配优化策略与算法

优化储位分配策略是加快订单拣选速度和提高仓储效率的重要前提。在实际出入库操作中,物料可能具有一定的需求相关性,如螺钉与螺母。若这些需求相关度较高的物料被安排于距离较远的货位,将大大影响其拣选出库的效率。因此,本研究考虑不同储位分配方案的影响,提出将基于物料周转率的存储策略(COI)与物料需求相关度相结合的存储策略,使得周转频率高和相关度大的物料在仓库中的位置接近,且存储于更近仓库出入口的巷道货位。由于模型的计算规模随着参数增长呈指数式增长,本研究开发出一种近似算法,并通过实验证明,相较于商业软件,本算法可更为有效得获取问题的最优或近似解。最后通过实例分析,给出不同COI系数与物料需求度偏好下该仓库的可行储位分配方案     

基于商品关联度的智能仓库储位分配问题研究

储位分配方案是直接影响智能仓库工作效率和拣选成本的关键因素.根据历史订单信息定义了商品之间的关联度,以同一货架上的商品之间的关联度之和极大化为目标建立了智能仓库储位分配问题的数学模型,并设计了求解模型的算法.首先根据历史订单信息计算商品之间的关联度,然后结合商品的周转率、商品之间的关联度等信息,设计了启发式算法求解智能仓库储位分配问题,并且分析了启发式算法的时间复杂度.通过大量的模拟计算验证了本文建立的数学模型和设计的启发式算法的有效性,证明了以同一货架上商品之间关联度极大化为目标和以订单拣选过程中搬运货架总次数极小化为目标的一致性.通过对比分析本文算法得到的储位分配结果与随机储位分配结果可以看出,利用基于商品关联度的启发式算法得到的储位分配方案比随机储位分配方案对应的货架搬运次数平均减少了30.08%.     

Operational research and material handling

A number of material handling research areas are reviewed and opportunities for further research are identified. Included in the review is a consideration of the following areas: robotics, conveyor theory, transfer lines, flexible manufacturing systems, equipment selection, storage alternatives, automated storage and retrieval systems, warehouse layout, palletizing, and order picking and accumulation.