A new truck based order picking model for automated storage and retrieval system (AS/RS)

Mücahit Soyaslan, Cemil Kozkurt, Ahmet Fenercioglu

Abstract


This paper examines a single-direction, high density, deep-lane warehouse and develops a truck based, one-cycle order picking automated storage and retrieval system (AS/RS) that minimizes
either travel time or energy consumption. The warehouse is considered completely full at the beginning of the picking task, and the alignment of the trucks at the output station is known before they arrive. The time and energy based algorithm assigns the best cell address of the product
pallet and optimum shuttle robot according to the truck order picking instructions. Unlike previous studies, this study focuses on a reserved storage part in the warehouse for orders of trucks and defines overall aisle and shuttle robot components. Different from most algorithms, the algorithm used in this study identifies not only the minimum travel time route, but also the least energy consuming route as two different cases. The order picking task with the reserved storage area as the destination is formulated as an analytical problem. Energy and time based order picking period simulation results are compared, and real applications in the warehouse of the project partner firm are discussed.


Keywords


AS/RS; energy and time optimization; order picking; warehouse automation.

Full Text:

PDF

References


Barenji, A. V., Barenji, R. V. & Hashemipour, M. 2014. A framework for structural modeling of an

RFID-enabled intelligent distributed manufacturing control system. South African Journal of Industrial

Engineering, 25(2): 48 -66.

Chang, F. L., Liu, Z. X., Zheng, X. & Liu, D. D. 2007. Research on order picking optimization problem of

automated warehouse. Systems Engineering-Theory & Practice 27(2): 139 -143.

Chan, F. T. & Hing K. C. 2011. Improving the productivity of order picking of a manual-pick and multilevel

rack distribution warehouse through the implementation of class-based storage. Expert Systems

with Applications 38(3): 2686 -2700.

Chen, F., Wang, H., Qi, C. & Xie, Y. 2013. An ant colony optimization routing algorithm for two order

pickers with congestion consideration. Computers & Industrial Engineering 66(1): 77- 85.

Chuang, Yi-Fei, Hsu-Tung Lee & Yi-Chuan Lai. 2012. Item-associated cluster assignment model on

storage allocation problems. Computers & Industrial Engineering 63(4): 1171 -1177.

De Koster, René, Tho Le-Duc & Kees Jan Roodbergen. 2007. Design and control of warehouse order

picking: A literature review. European Journal of Operational Research 182(2): 481 -501.

Fenercioglu, A., Soyaslan, M. & Kozkurt, C. 2011. Automatic Storage And Retrieval System (AS/RS)

Based On Cartesian Robot For Liquid Food Industry. 12th International Workshop on Research and

Education in Mechatronics, REM’11, Kocaeli, Turkey.

Ko, Hyun Jeung, Chang Seong Ko & Taioun Kim. 2006. A hybrid optimization/simulation approach for a

distribution network design of 3PLS. Computers & Industrial Engineering 50(4): 440 -449.

Le-Duc, Tho & Rene MBM de Koster. 2007. Travel time estimation and order batching in a 2-block

warehouse. European Journal of Operational Research176(1): 374 -388.

Makris, P. A., A. P. Makri & C. G. Provatidis. 2006. Energy-saving methodology for material handling

applications. Applied energy 83(10): 1116- 1124.

Meneghetti, Antonella, Eleonora Dal Borgo & Luca Monti. 2015. Decision support optimization models

for design of sustainable automated warehouses. International Journal of Shipping and Transport

Logistics 7(3): 266- 294.

Onut, Semih, Umut R. Tuzkaya & Bilgehan Dogac. 2008. A particle swarm optimization algorithm for the

multiple-level warehouse layout design problem. Computers & Industrial Engineering 54(4): 783 -799.

Pan, Jason Chao-Hsien & Po-Hsun Shih. 2008. Evaluation of the throughput of a multiple-picker order

picking system with congestion consideration. Computers & Industrial Engineering 55(2): 379- 389.

Pan, Jason Chao-Hsien & Ming-Hung Wu. 2012. Throughput analysis for order picking system with multiple

pickers and aisle congestion considerations. Computers & Operations Research 39(7): 1661 -1672.

Parikh, Pratik J. & Russell D. Meller. 2008. Selecting between batch and zone order picking strategies in a

distribution center. Transportation Research Part E: Logistics and Transportation Review 44(5): 696 -719.

Park, Byung Chun, Robert D. Foley & Edward H. Frazelle. 2006. Performance of miniload systems with

two-class storage. European Journal of Operational Research 170(1): 144 -155.

Schleyer, Marc & Kevin Gue. 2012. Throughput time distribution analysis for a one-block

warehouse. Transportation Research Part E: Logistics and Transportation Review 48(3): 652- 666.

Shiau, Jiun-Yan & Ming-Chang Lee. 2010. A warehouse management system with sequential picking for

multi-container deliveries. Computers & Industrial Engineering 58(3): 382- 392.

Soyaslan, M., Fenercioglu, A. & Kozkurt, C. 2012. An Approach of Control System for Automated Storage

and Retrieval System (AS/RS). International Journal of Mechanical, Aerospace, Industrial, Mechatronic

and Manufacturing Engineering, 6(9): 1950 -1954.

Van Den Berg, Jeroen P. & A. J. R. M. Gademann. 2000. Simulation study of an automated storage/

retrieval system. International Journal of Production Research 38(6): 1339- 1356.

Van Nieuwenhuyse, Inneke & René BM de Koster. 2009. Evaluating order throughput time in 2-block

warehouses with time window batching. International Journal of Production Economics 121(2): 654 -664.

Wang, Hsiao-Fan & Ching-Hsiang Chan. 2014. Multi-objective optimisation of automated guided dispatching

and vehicle routing system. International Journal of Modelling in Operations Management 4.1(2): 35 -52.

Wu, M. F. & Sung, P. C. 2014. Optimization of a multi-product EPQ model with scrap and an improved

multi-delivery policy. Journal of Engineering Research, 2(4): 1- 16.

Yu, Mengfei & René BM De Koster. 2009. The impact of order batching and picking area zoning on order

picking system performance. European Journal of Operational Research 198(2): 480- 490.

Yu, Yugang & M. B. M. De Koster. 2009. Designing an optimal turnover-based storage rack for a 3D compact

automated storage and retrieval system. International Journal of Production Research 47(6): 1551- 1571.


Refbacks

  • There are currently no refbacks.