Planning and consolidating shipments from a warehouse

A typical warehouse or distribution centre ships material to various customer locations across the country, using various modes of transportation. Each mode has different constraints on size of shipment, different cost structures and different transportation times. Typically, for a given warehouse there are certain customer locations that receive frequent shipments of material. It is often possible, therefore, for the warehouse to consolidate different orders for the same customer location into a single shipment. The transportation mode and the day of shipment must be chosen such that the consolidated shipment meets the size constraints and arrives within an agreed-upon ‘delivery window’. In preparing a warehouse distribution plan, a planner seeks to achieve transportation economies of scale (by consolidating two or more orders into fewer shipments) while levelling the workload on warehouse resources and ensuring that material arrives at a customer location during the acceptable delivery window.The problem of deciding what shipments to make daily can be formulated as a set partitioning problem with side constraints. This paper describes a heuristic solution approach for this problem. Computational experiments using actual warehouse select activity indicate that, for moderate-size problems, the heuristic produces solutions with transportation costs that are within a few percent of optimal. Larger problems found in practice are generally too large to be solved by optimal algorithms; the heuristic easily handles such problems. The heuristic has been integrated into the transportation planning system of a leading distributor of telecommunications products.     

Design and control of warehouse order picking: A literature review

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.     

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...     

Optimal model for warehouse location and retailer allocation

Warehouse location and retailer allocation is a high‐level strategic decision problem that is commonly encountered by logisticians and supply chain managers, especially during the supply chain design phase. Considering the product distribution cost and warehouse capital cost trade‐offs, this paper models the warehouse location and retailer allocation problem as a 0–1 integer programming problem and provides an efficient two‐stage set covering heuristic algorithm to solve large‐sized problems. Finally, concluding remarks and some recommendations for further research are also presented. Copyright © 2007 John Wiley & Sons, Ltd.     

Controlling distribution inventory systems with shipment consolidation and compound Poisson demand

We consider a one-warehouse-multiple-retailer inventory system where the retailers face stochastic customer demand, modelled as compound Poisson processes. Deliveries from the central warehouse to groups of retailers are consolidated using a time based shipment consolidation policy. This means that replenishment orders have to wait until a vehicle departures, which increases the lead time for the retailers and therefore also the safety stock. Thus, a trade-off exists between expected shipment costs and holding costs. Our aim is to determine the shipment intervals and the required amount of safety stock for each retailer and the warehouse to minimize total cost, both for backorder costs and fill rate constraints. Previous work has focused on exact solutions which are computationally demanding and not applicable for larger real world problems. The focus of our present work is on the development of computationally attractive heuristics that can be applied in practice. A numerical study shows that the proposed heuristics perform well compared to the exact cost minimizing solutions. We also illustrate that the approaches are appropriate for solving real world problems using data from a large European company.     

油田A类物资采购决策支持系统研究

结合大庆油田物资公司在重要供应链管理环节,即采购、需求和库存中所面临的实际问题(物资需求增加、仓储压力增大、采购成本增多)及三者之间的相互作用,基于预测和优化理论,构建了针对油田A类物资的采购优化和库存管理决策支持系统原型,包括：预测模块、优化模块和方案调整评估模块,为相关部门制定合理物资采购方案提供决策支持.进一步,以银浪仓库中的4种A类物资为例,运用该原型系统进行数值模拟. 结果表明,2009年和2010年4种物资的总成本节省率分别为10.35%和8.07%,效益可观. 考虑到油田物资数据结构不完备及优化模型的复杂性,该原型系统在大庆油田大规模推广方面仍需进一步完善.     

Developing new formulations and relaxations of single stage capacitated warehouse location problem (SSCWLP): Empirical investigation for assessing relative strengths and computational effort

In literature, single/multistage warehouse location problems have been attempted by Geoffrion and Graves [A.M. Geoffrion, G.W. Graves, Multicommodity distribution system design by Benders decomposition, Management Science 2 (1974) 82–114] and Sharma [R.R.K. Sharma, Modeling a fertilizer distribution system, European Journal of Operational Research 51 (1991) 24–34] among others and they have given completely different formulations. We use the formulation style given by Sharma and Sharma [R.R.K. Sharma, K.D. Sharma, A new dual based procedure for the transportation problem, European Journal of Operational Research 122 (3) (2000) 96–109] to develop variety of constraints that link real and 0–1 integer variables; thus developing many formulations of single stage capacitated warehouse location problem (SSCWLP). We relax the integer constraints on 0–1 variables to obtain their relaxations.     

Investigation of two-warehouse inventory problems in interval environment under inflation via particle swarm optimization

ABSTRACT

In this paper, a two-warehouse inventory problem has been investigated under inflation with different deterioration effects in two separate warehouses (rented warehouse, RW, and owned warehouse, OW). The objective of this investigation is to determine the lot-size of the cycle of the two-warehouse inventory system by minimizing the average cost of the system. Considering different inventory policies, the corresponding models have been formulated for linear trend in demand and interval valued cost parameters. In OW, shortages, if any, are allowed and partially backlogged with a variable rate dependent on the duration of the waiting time up to the arrival of the next lot. The corresponding optimization problems have been formulated as non-linear constrained optimization problems with interval parameters. These problems have been solved by an efficient soft computing method, viz. practical swarm optimization. To illustrate the model, a numerical example has been solved with different partially backlogging rates. Then to study the effect of changes of different system parameters on the optimal policy, sensitivity analyses have been carried out graphically by changing one parameter at a time and keeping the others at their original values. Finally, a fruitful conclusion has been reached regarding the selection of an appropriate inventory policy of the two-warehouse system.     

Redesigning a warehouse network

To take advantage of economies of scale, a growing number of firms have begun to explore the possibility of integrating supply chain activities. The advent of such a possibility would necessitate the redesign of a warehouse network. Typically, a warehouse redesign problem involves the consolidation of regional warehouses into a fewer number of master stocking points and the subsequent phase-out of redundant or underutilized warehouses without deteriorating customer services. This paper develops a mixed-integer programming model to solve the warehouse redesign problem. The usefulness of the model was validated by its successful application to a real-world problem and by its sensitivity analyses when used with changing scenarios within a warehouse network configuration.     

Strategic design of distribution systems with economies of scale in transportation

We formulate and analyze a strategic design model for multi-product multi-echelon distribution systems where there are significant economies of scale in the transportation movements. The key design decisions considered are: the number and locations of distribution centers (DC's) in the system, the number and locations of consolidation centers (CC's), the inventory levels of the various products to be held at the distribution centers, and the routing of shipments (through a consolidation center or direct) between plants and distribution centers. A heuristic solution method is developed that can efficiently find near-optimal solutions. The quality of solutions to a series of test problems is evaluated---by comparison to exact solutions created by enumeration in small tests, and by comparison to lower bounds developed for larger test problems. In the problems for which exact solutions are available, the heuristic solution is within 1% of optimal. The computational procedure appears to hold substantial promise for effective solution of large distribution system design problems.     

Model and algorithm for inventory/routing decision in a three-echelon logistics system

This paper addresses an integrated inventory and routing problem in a three-echelon logistics system, which consists of a supplier, a central warehouse and a group of retailers. The inventory decision of each member and the routing decision among members of the system are made simultaneously, with the objective of minimizing the overall average cost of the system. A strategy named fixed partition and power-of-two (FP–POT) is proposed for the considered problem and a variable large neighborhood search (VLNS) algorithm, which is a special case of variable neighborhood search (VNS) algorithm, is developed. The efficiency of the strategy as well as the algorithm is illustrated by comparing computational results with a lower bound. The advantage of the proposed VLNS algorithm is further shown by getting better results for the problems in a two-echelon logistics system, which have been solved by a Tabu Search algorithm recently.     

A two warehouse inventory model for a deteriorating item with partially/fully backlogged shortage and fuzzy lead time

An optimization inventory policy for a deteriorating item with imprecise lead-time, partially/fully backlogged shortages and price dependent demand is developed under two-warehouse system. For display and storage, the retailer hires one warehouse of finite capacity at market place, treated as own warehouse (OW) and another warehouse of large capacity as it may be required at a distance place from the market, treated as rented warehouse (RW). Holding cost at RW decreases with the increase of distance from the market place. Units are transferred from RW to OW in bulk release pattern and sold from OW. Using the nearest interval approximation method the estimated fuzzy average profit function is defuzzified and transformed to multiple crisp objective functions which are solved by Global Criteria Method. The models are illustrated numerically. Sensitivity of the inventory costs on the location of RW has been depicted graphically. Also loss in profit due to deteriorations for both models have been presented.     

Stepwise decomposition approaches for large scale cell formation problems

Cell formation is one of the major steps in cellular manufacturing system (CMS) design. In this paper, two stepwise decomposition approaches are proposed to solve large scale industrial problems. Both of them analyze the part-machine relations, decompose the original system to several large subsystems and then use an optimal solution technique to solve each. Several results are proved to show the conditions under which optimal solutions are obtained.     

An inexact interior point method for L 1-regularized sparse covariance selection

Sparse covariance selection problems can be formulated as log-determinant (log-det) semidefinite programming (SDP) problems with large numbers of linear constraints. Standard primal–dual interior-point methods that are based on solving the Schur complement equation would encounter severe computational bottlenecks if they are applied to solve these SDPs. In this paper, we consider a customized inexact primal–dual path-following interior-point algorithm for solving large scale log-det SDP problems arising from sparse covariance selection problems. Our inexact algorithm solves the large and ill-conditioned linear system of equations in each iteration by a preconditioned iterative solver. By exploiting the structures in sparse covariance selection problems, we are able to design highly effective preconditioners to efficiently solve the large and ill-conditioned linear systems. Numerical experiments on both synthetic and real covariance selection problems show that our algorithm is highly efficient and outperforms other existing algorithms.     

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.     

Vehicle routing in an automated warehouse: Analysis and optimization

This study concerns the design of an operating system for vehicles in an automated warehouse. The layout of the warehouse and the number and properties of the vehicles are given. The objective is to maximize the throughput. Using a partial enumeration technique, we simulate several alternatives for the control and interplay of the vehicles within a reasonable time horizon. A subproblem is solved by network flow techniques. The algorithm is implemented as part of an automatic control system, and it has led to a satisfactory performance.     

A parallel integer linear programming algorithm

The solution of large scale integer linear programming models is generally dependent, in some way, upon the branch and bound technique, which can be quite time consuming. This paper describes a parallel branch and bound algorithm which achieves super linear efficiency in solving integer linear programming models on a multiprocessor computer. The algorithm is used to solve the Haldi and IBM test problems as well as a system design model.     

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.     

Progress in the dual simplex method for large scale LP problems: practical dual phase 1 algorithms

The dual simplex algorithm has become a strong contender in solving large scale LP problems. One key problem of any dual simplex algorithm is to obtain a dual feasible basis as a starting point. We give an overview of methods which have been proposed in the literature and present new stable and efficient ways to combine them within a state-of-the-art optimization system for solving real world linear and mixed integer programs. Furthermore, we address implementation aspects and the connection between dual feasibility and LP-preprocessing. Computational results are given for a large set of large scale LP problems, which show our dual simplex implementation to be superior to the best existing research and open-source codes and competitive to the leading commercial code on many of our most difficult problem instances.     

Integrated location and two-echelon inventory network design under uncertainty

In this paper, we propose a two-stage stochastic model to address the design of an integrated location and two-echelon inventory network under uncertainty. The central issue in this problem is to design and operate an effective and efficient multi-echelon supply chain distribution network and to minimize the expected system-wide cost of warehouse location, the allocation of warehouses to retailers, transportation, and two-echelon inventory over an infinite planning horizon. We structure this problem as a two-stage nonlinear discrete optimization problem. The first stage decides the warehouses to open and the second decides the warehouse-retailer assignments and two-echelon inventory replenishment strategies. Our modeling strategy incorporates various probable scenarios in the integrated multi-echelon supply chain distribution network design to identify solutions that minimize the first stage costs plus the expected second stage costs. The two-echelon inventory cost considerations result in a nonlinear objective which we linearize with an exponential number of variables. We solve the problem using column generation. Our computational study indicates that our approach can solve practical problems of moderate-size with up to twenty warehouse candidate locations, eighty retailers, and ten scenarios efficiently.