Production
https://prod.org.br/article/doi/10.1590/0103-6513.20240004
Production
Research Article

A framework for supporting warehouse design

Lucas Eric da Silva; José Geraldo Vidal Vieira; João Eduardo Azevedo Ramos da Silva; Kaique Doratiotto; Gilberto Montibeller

Downloads: 0
Views: 54

Abstract

Paper aims: This paper proposes a warehouse design framework for evaluating the most robust combination of layout alternatives, tactical (picking, storage) and operational (routing) control policies, considering simultaneously the service level, costs and resource utilization criteria.

Originality: We applied an innovative Morphological Analysis to reduce the number of alternatives and evaluate the uncertainties in warehouse design. We also address the effect of congestion and options for configuring the layout of aisles.

Research method: We apply multicriteria decision analysis and discrete event simulation to evaluate the most robust combination between layout alternatives and operational control policies. We also suggest the use of scenario planning to deal with the high uncertainties involved in the order picking activity.

Main findings: Our framework captures the warehouse manager’s preference and experience by means of weight elicitation, value functions, scenario planning and an inter-scenario robustness index to provide a robust final solution.

Implications for theory and practice: For theory, we highlight the combination of methods applied to a strategic, tactical and operational warehouse design problem in an environment with uncertainties. For practice, warehouse managers may use the framework to explore and find out which combination of control policies and layout can meet the company’s objectives.

Supplementary Material

 

Keywords

Warehouse layout, Warehouse control policies, Multicriteria decision analysis, Discrete event simulation, Scenario planning

References

Ahmadi Keshavarz, A. R., Jaafari, D., Khalaj, M., & Dokouhaki, P. (2021). A survey of the literature on order-picking systems by combining planning problems. Applied Sciences (Basel, Switzerland), 11(22), 10641. http://doi.org/10.3390/app112210641.

Altarazi, S. A., & Ammouri, M. M. (2018). Concurrent manual-order-picking warehouse design: a simulation-based design of experiments approach. International Journal of Production Research, 56(23), 7103-7121. http://doi.org/10.1080/00207543.2017.1421780.

Amer, M., Daim, T. U., & Jetter, A. (2013). A review of scenario planning. Futures, 46, 23-40. http://doi.org/10.1016/j.futures.2012.10.003.

Azadeh, K., De Koster, R., & Roy, D. (2019). Robotized and automated warehouse systems: Review and recent developments. Transportation Science, 53(4), 917-945. http://doi.org/10.1287/trsc.2018.0873.

Bahrami, B., Aghezzaf, E. H., & Limère, V. (2019). Enhancing the order picking process through a new storage assignment strategy in forward-reserve area. International Journal of Production Research, 57(21), 6593-6614. http://doi.org/10.1080/00207543.2019.1567953.

Baker, P., & Canessa, M. (2009). Warehouse design: a structured approach. European Journal of Operational Research, 193(2), 425-436. http://doi.org/10.1016/j.ejor.2007.11.045.

Balarezo, J., & Nielsen, B. B. (2017). Scenario planning as organizational intervention: an integrative framework and future research directions. Review of International Business and Strategy, 27(1), 2-52. http://doi.org/10.1108/RIBS-09-2016-0049.

Briant, O., Cambazard, H., Cattaruzza, D., Catusse, N., Ladier, A. L., & Ogier, M. (2020). An efficient and general approach for the joint order batching and picker routing problem. European Journal of Operational Research, 285(2), 497-512. http://doi.org/10.1016/j.ejor.2020.01.059.

Cao, Z., Zhou, L., Lin, C., & Zhou, M. (2023). Solving an order batching, picker assignment, batch sequencing and picker routing problem via information integration. Journal of Industrial Information Integration, 31, 100414. http://doi.org/10.1016/j.jii.2022.100414.

Casella, G., Volpi, A., Montanari, R., Tebaldi, L., & Bottani, E. (2023). Trends in order picking: a 2007–2022 review of the literature. Production & Manufacturing Research, 11(1), 2191115. http://doi.org/10.1080/21693277.2023.2191115.

Chackelson, C., Errasti, A., Ciprés, D., & Lahoz, F. (2013). Evaluating order picking performance trade-offs by configuring main operating strategies in a retail distributor: a design of experiments approach. International Journal of Production Research, 51(20), 6097-6109. http://doi.org/10.1080/00207543.2013.796421.

Chan, F. T., & Chan, H. K. (2011). Improving the productivity of order picking of a manual-pick and multi-level rack distribution warehouse through the implementation of class-based storage. Expert Systems with Applications, 38(3), 2686-2700. http://doi.org/10.1016/j.eswa.2010.08.058.

Chen, C. M., Gong, Y., De Koster, R. B., & Van Nunen, J. A. (2010). A flexible evaluative framework for order picking systems. Production and Operations Management, 19(1), 70-82. http://doi.org/10.1111/j.1937-5956.2009.01047.x.

Chen, P. S., Huang, C. Y., Yu, C. C., & Hung, C. C. (2017). The examination of key performance indicators of warehouse operation systems based on detailed case studies. Journal of Information and Optimization Sciences, 38(2), 367-389. http://doi.org/10.1080/02522667.2016.1224465.

De Koster, R., Le-Duc, T., & Roodbergen, K. J. (2007). Design and control of warehouse order picking: a literature review. European Journal of Operational Research, 182(2), 481-501. http://doi.org/10.1016/j.ejor.2006.07.009.

Dekker, R., De Koster, M. B. M., Roodbergen, K. J., & van Kalleveen, H. (2004). Improving order-picking response time at Ankor’s warehouse. Interfaces, 34(4), 303-313. http://doi.org/10.1287/inte.1040.0083.

Derhami, S., Smith, J. S., & Gue, K. R. (2020). A simulation-based optimization approach to design optimal layouts for block stacking warehouses. International Journal of Production Economics, 223, 107525. http://doi.org/10.1016/j.ijpe.2019.107525.

Destro, I. R., Staudt, F. H., Somensi, K., & Taboada, C. (2023). The impacts of inventory record inaccuracy and cycle counting on distribution center performance. Production, 33, e20220077. http://doi.org/10.1590/0103-6513.20220077.

Edwards, W., & Barron, F. H. (1994). SMARTS and SMARTER: Improved simple methods for multiattribute utility measurement. Organizational Behavior and Human Decision Processes, 60(3), 306-325. http://doi.org/10.1006/obhd.1994.1087.

Elbert, R. M., Franzke, T., Glock, C. H., & Grosse, E. H. (2017). The effects of human behavior on the efficiency of routing policies in order picking: The case of route deviations. Computers & Industrial Engineering, 111, 537-551. http://doi.org/10.1016/j.cie.2016.11.033.

Fontana, M. E., & Nepomuceno, V. S. (2017). Multi-criteria approach for products classification and their storage location assignment. International Journal of Advanced Manufacturing Technology, 88(9-12), 3205-3216. http://doi.org/10.1007/s00170-016-9040-3.

Fontana, M. E., López, J. C. L., Cavalcante, C. A. V., & Noriega, J. J. S. (2020a). Multi-criteria assignment model to solve the storage location assignment problem. Investigação Operacional, 41(7), 1019-1029.

Fontana, M. E., Nepomuceno, V. S., & Garcez, T. V. (2020b). A hybrid approach development to solving the storage location assignment problem in a picker-to-parts system. Brazilian Journal of Operations & Production Management, 17(1), 1-14. http://doi.org/10.14488/BJOPM.2020.005.

Franzke, T., Grosse, E. H., Glock, C. H., & Elbert, R. (2017). An investigation of the effects of storage assignment and picker routing on the occurrence of picker blocking in manual picker-to-parts warehouses. International Journal of Logistics Management, 28(3), 841-863. http://doi.org/10.1108/IJLM-04-2016-0095.

Gong, Y., & Koster, R. B. (2011). A review on stochastic models and analysis of warehouse operations. Logistics Research, 3(4), 191-205. http://doi.org/10.1007/s12159-011-0057-6.

Goodwin, P., & Wright, G. (2004). Decision Analysis for Management Judgment, Business. Chichester: Wiley. http://doi.org/10.2307/3010535.

Hashemkhani Zolfani, S., Görçün, Ö. F., & Küçükönder, H. (2023). Evaluation of the special warehouse handling equipment (turret trucks) using integrated fucom and waspas techniques based on intuitionistic fuzzy dombi aggregation operators. Arabian Journal for Science and Engineering, 48(11), 15561-15595. http://doi.org/10.1007/s13369-023-07615-0.

Heath, B. L., Ciarallo, F. W., & Hill, R. R. (2013). An agent-based modeling approach to analyze the impact of warehouse congestion on cost and performance. International Journal of Advanced Manufacturing Technology, 67(1-4), 563-574. http://doi.org/10.1007/s00170-012-4505-5.

Keeney, R. L. (1996). Value-focused thinking: Identifying decision opportunities and creating alternatives. European Journal of Operational Research, 92(3), 537-549. http://doi.org/10.1016/0377-2217(96)00004-5.

Kelton, W. D., Sadowski, R. P., & Sturrock, D. T. (2007). Simulation with ARENA (4th ed.). New York: McGraw-Hill Higher Education.

Logullo, Y., Bigogno-Costa, V., Silva, A., & Belderrain, M. C. (2022). A prioritization approach based on VFT and AHP for group decision making: a case study in the military operations. Production, 32, e20210059. http://doi.org/10.1590/0103-6513.20210059.

Micale, R., La Fata, C. M., & La Scalia, G. (2019). A combined interval-valued ELECTRE TRI and TOPSIS approach for solving the storage location assignment problem. Computers & Industrial Engineering, 135, 199-210. http://doi.org/10.1016/j.cie.2019.06.011.

Min, H. (2009). Application of a decision support system to strategic warehousing decisions. International Journal of Physical Distribution & Logistics Management, 39(4), 270-281. http://doi.org/10.1108/09600030910962230.

Montanari, R., Micale, R., Bottani, E., Volpi, A., & La Scalia, G. (2021). Evaluation of routing policies using an interval-valued TOPSIS approach for the allocation rules. Computers & Industrial Engineering, 156, 107256. http://doi.org/10.1016/j.cie.2021.107256.

Montibeller, G., Gummer, H., & Tumidei, D. (2006). Combining scenario planning and multi‐criteria decision analysis in practice. Journal of Multi-Criteria Decision Analysis, 14(1‐3), 5-20. http://doi.org/10.1002/mcda.403.

Petersen, C. G. (1997). An evaluation of order picking routeing policies. International Journal of Operations & Production Management, 17(11), 1098-1111. http://doi.org/10.1108/01443579710177860.

Petersen, C. G. (1999). The impact of routing and storage policies on warehouse efficiency. International Journal of Operations & Production Management, 19(10), 1053-1064. http://doi.org/10.1108/01443579910287073.

Petersen, C. G. (2000). An evaluation of order picking policies for mail order companies. Production and Operations Management, 9(4), 319-335. http://doi.org/10.1111/j.1937-5956.2000.tb00461.x.

Petersen, C. G. (2002). Considerations in order picking zone configuration. International Journal of Operations & Production Management, 22(7), 793-805. http://doi.org/10.1108/01443570210433553.

Petersen, C. G., & Schmenner, R. W. (1999). An evaluation of routing and volume‐based storage policies in an order picking operation. Decision Sciences, 30(2), 481-501. http://doi.org/10.1111/j.1540-5915.1999.tb01619.x.

Petersen, C. G., & Aase, G. (2004). A comparison of picking, storage, and routing policies in manual order picking. International Journal of Production Economics, 92(1), 11-19. http://doi.org/10.1016/j.ijpe.2003.09.006.

Petersen, C. G., & Aase, G. R. (2017). Improving order picking efficiency with the use of cross aisles and storage policies. Open Journal of Business and Management, 5(01), 95-104. http://doi.org/10.4236/ojbm.2017.51009.

Petersen, C. G., Aase, G. R., & Heiser, D. R. (2004). Improving order‐picking performance through the implementation of class‐based storage. International Journal of Physical Distribution & Logistics Management, 34(7), 534-544. http://doi.org/10.1108/09600030410552230.

Pohl, L. M., Meller, R. D., & Gue, K. R. (2011). Turnover-based storage in non-traditional unit-load warehouse designs. IIE Transactions, 43(10), 703-720. http://doi.org/10.1080/0740817X.2010.549098.

Pourhassan, M. R., & Raissi, S. (2017). An integrated simulation-based optimization technique for multi-objective dynamic facility layout problem. Journal of Industrial Information Integration, 8, 49-58. http://doi.org/10.1016/j.jii.2017.06.001.

Ram, C., Montibeller, G., & Morton, A. (2011). Extending the use of scenario planning and MCDA for the evaluation of strategic options. The Journal of the Operational Research Society, 62(5), 817-829. http://doi.org/10.1057/jors.2010.90.

Roodbergen, K. J., & Koster, R. (2001). Routing methods for warehouses with multiple cross aisles. International Journal of Production Research, 39(9), 1865-1883. http://doi.org/10.1080/00207540110028128.

Roodbergen, K. J., Vis, I. F., & Taylor Junior, G. D. (2015). Simultaneous determination of warehouse layout and control policies. International Journal of Production Research, 53(11), 3306-3326. http://doi.org/10.1080/00207543.2014.978029.

Rouwenhorst, B., Reuter, B., Stockrahm, V., van Houtum, G. J., Mantel, R. J., & Zijm, W. H. (2000). Warehouse design and control: Framework and literature review. European Journal of Operational Research, 122(3), 515-533. http://doi.org/10.1016/S0377-2217(99)00020-X.

Roy, D., Krishnamurthy, A., Heragu, S. S., & Malmborg, C. J. (2015). Stochastic models for unit-load operations in warehouse systems with autonomous vehicles. Annals of Operations Research, 231(1), 129-155. http://doi.org/10.1007/s10479-014-1665-8.

Schoemaker, P. J. (1995). Scenario planning: a tool for strategic thinking. MIT Sloan Management Review

Shqair, M., Altarazi, S., & Al-Shihabi, S. (2014). A statistical study employing agent-based modeling to estimate the effects of different warehouse parameters on the distance traveled in warehouses. Simulation Modelling Practice and Theory, 49, 122-135. http://doi.org/10.1016/j.simpat.2014.08.002.

Silva, D. D., Vasconcelos, N. V. C., & Cavalcante, C. A. V. (2015). Multicriteria decision model to support the assignment of storage location of products in a warehouse. Mathematical Problems in Engineering, 2015, 1-8. http://doi.org/10.1155/2015/481950.

Silva, A., Coelho, L. C., Darvish, M., & Renaud, J. (2020). Integrating storage location and order picking problems in warehouse planning. Transportation Research Part E, Logistics and Transportation Review, 140, 102003. http://doi.org/10.1016/j.tre.2020.102003.

Stewart, T. J., French, S., & Rios, J. (2013). Integrating multicriteria decision analysis and scenario planning—Review and extension. Omega, 41(4), 679-688. http://doi.org/10.1016/j.omega.2012.09.003.

Timperio, G., Tiwari, S., Gaspar Sánchez, J. M., García Martín, R. A., & De Souza, R. (2020). Integrated decision support framework for distribution network design. International Journal of Production Research, 58(8), 2490-2509. http://doi.org/10.1080/00207543.2019.1680894.

Tompkins, J. A., White, J. A., Bozer, Y. A., & Tanchoco, J. M. A. (2010). Facilities planning (4th ed.). New Jersey: John Wiley & Sons.

Tutam, M., & White, J. A. (2024). Comparison of expected distances in traditional and non-traditional layouts. Asia-Pacific Journal of Operational Research, 41, 2350024.

van Gils, T., Caris, A., Ramaekers, K., Braekers, K., & de Koster, R. B. (2019). Designing efficient order picking systems: the effect of real-life features on the relationship among planning problems. Transportation Research Part E, Logistics and Transportation Review, 125, 47-73. http://doi.org/10.1016/j.tre.2019.02.010.

van Gils, T., Ramaekers, K., Braekers, K., Depaire, B., & Caris, A. (2018a). Increasing order picking efficiency by integrating storage, batching, zone picking, and routing policy decisions. International Journal of Production Economics, 197, 243-261. http://doi.org/10.1016/j.ijpe.2017.11.021.

van Gils, T., Ramaekers, K., Caris, A., & De Koster, R. B. (2018b). Designing efficient order picking systems by combining planning problems: state-of-the-art classification and review. European Journal of Operational Research, 267(1), 1-15. http://doi.org/10.1016/j.ejor.2017.09.002.

Vieira, J. G. V., Toso, M. R., Silva, J. E. A. R., & Ribeiro, P. C. C. (2017). An AHP-based framework for logistics operations in distribution centres. International Journal of Production Economics, 187, 246-259. http://doi.org/10.1016/j.ijpe.2017.03.001.

Yerlikaya, M. A. (2020). Storage location assignment with fuzzy PROMETHEE method in warehouse systems with uncertain demand. Journal of the Institute of Electronics and Computer, 2(1), 142-150.

Zhang, Z. Y., Liang, Y., Hou, Y. P., & Wang, Q. (2021). Designing a warehouse internal layout using a parabolic aisles based method. Advances in Production Engineering & Management, 16(2), 223-239. http://doi.org/10.14743/apem2021.2.396.

Zhou, L., Zhao, J., Liu, H., Wang, F., Yang, J., & Wang, S. (2022). Stochastic models of routing strategies under the class-based storage policy in fishbone layout warehouses. Scientific Reports, 12(1), 12876. http://doi.org/10.1038/s41598-022-17240-w. PMid:35896676.
 


Submitted date:
01/07/2024

Accepted date:
10/09/2024

67504114a9539555fb587995 production Articles
Links & Downloads

Production

Share this page
Page Sections