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12th IMHRC Proceedings (Gardanne, France – 2012)

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Full-Text Articles in Operations Research, Systems Engineering and Industrial Engineering

Estimating Travel Distances And Optimizing Product Placement For Dedicated Warehouses With Manual Picking, Uday Venkatadri, Sachin Kubasad Jan 2012

Estimating Travel Distances And Optimizing Product Placement For Dedicated Warehouses With Manual Picking, Uday Venkatadri, Sachin Kubasad

12th IMHRC Proceedings (Gardanne, France – 2012)

This paper looks at the problem of estimating travel distances for rectangular warehouse sections with manual picking. This study was motivated by a real-life case in the food and beverage industry where case picking occurred in a rectangular section of the warehouse In particular, we are interested in estimating the distance travelled by an order picker whose picking route begins and ends at a single depot. One of the assumptions in many distance approximation papers is that any location is equally likely to be picked. However, this assumption is unrealistic in the case of dedicated warehouse layout, where products are ...


Functional Design Of Physical Internet Facilities: A Road-Based Crossdocking Hub, Russell D. Meller, Benoit Montreuil, Collin Thivierge, Zachary Montreuil Jan 2012

Functional Design Of Physical Internet Facilities: A Road-Based Crossdocking Hub, Russell D. Meller, Benoit Montreuil, Collin Thivierge, Zachary Montreuil

12th IMHRC Proceedings (Gardanne, France – 2012)

As part of the 2010 IMHRC, Montreuil, Meller and Ballot proposed a set of facility types that would be necessary to operate a Physical Internet (PI, π), which they termed nodes. This paper is part of a three-paper series for the 2012 IMHRC where the authors provide functional designs of three PI facilities. This paper covers a unimodal road-based crossdocking hub designed specifically to exploit the characteristics of Physical Internet modular containers so as to enable the efficient and sustainable transhipment of each of them from its inbound truck to its outbound truck. The objective of the paper is to ...


Safe Control Of Manufacturing Vehicles Research Towards Standard Test Methods, Roger Bostelman, Will Shackleford, Geraldine Cheok, Kamel Saidi Jan 2012

Safe Control Of Manufacturing Vehicles Research Towards Standard Test Methods, Roger Bostelman, Will Shackleford, Geraldine Cheok, Kamel Saidi

12th IMHRC Proceedings (Gardanne, France – 2012)

The National Institute of Standards and Technology‟s Intelligent Systems Division has been researching several areas leading to safe control of manufacturing vehicles to improve automated guided vehicle (AGV) safety standards. The research areas include:  AGV safety and control based on advanced two-dimensional (2D) sensors that detect moving standard test pieces representing humans;  Ability of advanced 3D imaging sensors, when mounted to an AGV or forklift, to detect stationary or moving objects and test pieces on the ground or hanging over the work area; and  Manned forklift safety based on advanced 3D imaging sensors that detect visible and non-visible regions ...


Functional Design Of Physical Internet Facilities: A Road-Rail Hub, Eric Ballot, Benoit Montreuil, Collin Thivierge Jan 2012

Functional Design Of Physical Internet Facilities: A Road-Rail Hub, Eric Ballot, Benoit Montreuil, Collin Thivierge

12th IMHRC Proceedings (Gardanne, France – 2012)

As part of the 2010 IMHRC, Montreuil, Meller and Ballot enumerated the type of facilities that would be necessary to operate a Physical Internet (PI, π), which they termed, “π-nodes.” This paper is part of a three-paper series for the 2012 IMHRC where the authors provide functional designs of three PI facilities. This paper covers a PI road-rail hub. The purpose of a PI road-rail node is to enable the transfer of PI containers from their inbound to outbound destinations. Therefore, a road-rail π-hub provides a mechanism to transfer π-containers from a train to another one or a truck or ...


A Multi-Objective Optimization Approach For Designing Automated Warehouses, Tone Lerher, Matej Borovinšek, Iztok Potrč, Matjaž Šraml Jan 2012

A Multi-Objective Optimization Approach For Designing Automated Warehouses, Tone Lerher, Matej Borovinšek, Iztok Potrč, Matjaž Šraml

12th IMHRC Proceedings (Gardanne, France – 2012)

A multi objective optimization of automated warehouses is discussed and evaluated in present paper. Since most of researchers in material handling community had performed optimization of decision variables with single objective function only (usually named with minimum travel time, maximum throughput capacity, minimum cost, etc.), the multi objective optimization (travel time – cost – quality) will be presented. For the optimization of decision variables in objective functions, the method with genetic algorithms is used. To find the Pareto optimal solutions, the NSGA II genetic algorithm was used. The main objective of our contribution is to determine the performance of the system according ...


Performance Trade-Offs In Layouts For Relief Centers, Ananth Krishnamurthy, Sanket Bhat, Debjit Roy Jan 2012

Performance Trade-Offs In Layouts For Relief Centers, Ananth Krishnamurthy, Sanket Bhat, Debjit Roy

12th IMHRC Proceedings (Gardanne, France – 2012)

At a disaster affected region, relief centers distribute critical supplies and aid to the affected victims. Unlike traditional distribution centers, relief centers experience significant ‘crowd effects’ due to the sudden influx of victims in a confined space. Using knowledge from studies on pedestrian traffic flow, specialized state dependent queuing models are developed to model the flow of victims along the walkways setup at a relief center. The underlying queuing network model is analyzed to derive expressions for the average times that victims experience before they receive the service at the relief center. The research shows that crowd density effects lead ...


Analysis Of Parameters Influencing In-Plant Milk Run Design For Production Supply, Eva Klenk, Stefan Galka, Willibald A. Günthner Jan 2012

Analysis Of Parameters Influencing In-Plant Milk Run Design For Production Supply, Eva Klenk, Stefan Galka, Willibald A. Günthner

12th IMHRC Proceedings (Gardanne, France – 2012)

In-plant milk-run systems are a transport concept for in-plant material delivery which is becoming more and more applicable especially in the automotive industry. This is due to the system characteristic of providing materials in small lot sizes and with high frequency. As there is a number of different milk run concepts applied and there are several parameters influencing the efficiency and stability of these systems, this paper aims at presenting an overview of common concepts and their properties together with key figures based on an empirical study. The concepts are further analyzed and evaluated with respect to resulting lead times ...


Knowledge-Based Methods For Efficient Material Handling Equipment Development, Dirk Jodin, Christian Landschützer Jan 2012

Knowledge-Based Methods For Efficient Material Handling Equipment Development, Dirk Jodin, Christian Landschützer

12th IMHRC Proceedings (Gardanne, France – 2012)

This paper focuses on the Knowledge-based engineering (KBE) method and general Knowledge-based technologies for automated design of material handling products. As in vehicle and aerospace engineering this is a widespread technology, the authors try to introduce the main benefits of KBE for the material handling equipment design. The benefits of KBE, as faster and more accurate (safer) product development, customized products and knowledge of employees captured within a knowledge management system, let KBE hold many promising possibilities within, to deal with nowadays demands on engineering development, driven by cost reductions and time shortcuttings. The authors introduce the actual stage of ...


Simulation-Based Performance Improvement Of A Defense Logistics Warehouse, Banu Y. Ekren, Gerald W. Evans, Sunderesh S. Heragu, John S. Usher Jan 2012

Simulation-Based Performance Improvement Of A Defense Logistics Warehouse, Banu Y. Ekren, Gerald W. Evans, Sunderesh S. Heragu, John S. Usher

12th IMHRC Proceedings (Gardanne, France – 2012)

Warehouses play a critical role in supply chains. They serve as a vital link between manufacturers and customers. In this study, we investigate performance of the largest warehouse (Eastern Distribution Center - EDC) of the Defense Logistics Agency (DLA) located in New Cumberland, PA and propose a near optimum design for the receiving area of the warehouse to improve its performance. First, we develop a simulation model of the system. Second, we interface an optimization model with the simulation in order to optimize the number of people working at the induction stations. In the optimization model, our goal is to minimize ...


A High-Density, Puzzle-Based Order Picking System, Kevin R. Gue, Onur Uludag Jan 2012

A High-Density, Puzzle-Based Order Picking System, Kevin R. Gue, Onur Uludag

12th IMHRC Proceedings (Gardanne, France – 2012)

We present a new semi-automated system for carton and piece picking operations in the distribution centers. The system features decentralized control based on a message-passing protocol in which cells communicate with their neighbors to determine action in each step. The result is a dynamically changing pick face that provides high sku density and reduced worker travel. We describe an example in which pickers are 20% to 50% more productive than they would be in an equivalent ow rack system.


Design & Modeling Of A Single Machine Flow Rack As/Rs, Zaki Sari, Nadir Hakim Bessenouci Jan 2012

Design & Modeling Of A Single Machine Flow Rack As/Rs, Zaki Sari, Nadir Hakim Bessenouci

12th IMHRC Proceedings (Gardanne, France – 2012)

In this paper, we aim to introduce a new variation of the flow rack automated storage and retrieval system (AS/RS) using a single machine for storage and retrieval operations instead of two machines. Also, analytical expressions are derived for expected single and dual cycle times of the storage and retrieval machine. For that, randomized storage assignment, and Tchebychev travel are assumed. Two dwell point positions are investigated and compared to determine the best one. Finally an experimental validation using simulation is conducted to verify the quality of the developed.


Optimal Design Of Container Terminal Layout, Debjit Roy, Ren´E De Koster Jan 2012

Optimal Design Of Container Terminal Layout, Debjit Roy, Ren´E De Koster

12th IMHRC Proceedings (Gardanne, France – 2012)

Due to rapid growth in foreign trade using sea vessels, there is a growing focus in improving the infrastructure and operational efficiencies at the container terminals. Particularly, the operational responsiveness of loading and unloading of containers, affects the vessel idle times and profitability of the shipping liners. In this research, we deter- mine optimal stack layout design, which minimizes the container unload times using Automated Guided Vehicles (AGVs). To analyze alternate stack layout designs, we develop integrated queuing network models that capture the stochastic interactions among the container terminal processes (quayside, vehicle transport, and stack side), and provides realistic estimates ...


Modeling The Inventory Requirement And Throughput Performance Of Picking Machine Order-Fulfillment Technology, Jennifer A. Pazour, Russell D. Meller Jan 2012

Modeling The Inventory Requirement And Throughput Performance Of Picking Machine Order-Fulfillment Technology, Jennifer A. Pazour, Russell D. Meller

12th IMHRC Proceedings (Gardanne, France – 2012)

Picking machines, also known as remote-order-picking systems, are an example of a stock-to-picker piece-level order-fulfillment technology that consists of two or more pick stations and a common storage area. An integrated closed-loop conveyor decouples the pick stations from the storage area by transporting the needed totes to and from the storage area and the pick stations. We develop a probabilistic model capable of quantifying the inventory differences between order-fulfillment technologies that pool inventory with technologies that do not pool inventory. To determine the throughput of a picking machine, we develop a methodology that incorporates existing analytical models for the picking ...


Functional Design Of Physical Internet Facilities: A Road-Based Transit Center, Russell D. Meller, Benoit Montreuil, Collin Thivierge, Zachary Montreuil Jan 2012

Functional Design Of Physical Internet Facilities: A Road-Based Transit Center, Russell D. Meller, Benoit Montreuil, Collin Thivierge, Zachary Montreuil

12th IMHRC Proceedings (Gardanne, France – 2012)

In their 2010 IMHRC paper, Montreuil, Meller and Ballot proposed a set of facility types that would be necessary to operate a Physical Internet, which they termed “π-nodes.” This paper is part of a three-paper series for the 2012 IMHRC where the authors provide functional designs of three PI facilities. This paper covers a road-based transit center, or road-based π- transit. The mission of a π-transit node is to enable the transfer of π - carriers from their inbound to outbound destinations. Therefore, a road based π-transit provides a mechanism to transfer π-trailers from one truck to another. The objective of ...


How To Choose An Order-Picking System, Marita Ellinger, Tim Geißen, Detlef Spee Jan 2012

How To Choose An Order-Picking System, Marita Ellinger, Tim Geißen, Detlef Spee

12th IMHRC Proceedings (Gardanne, France – 2012)

Order-Picking-Systems are the parts of material flow systems, which have the largest variance of deployment alternatives. Since a long time there have been many attempts to systematize the way of identification of the order-picking- ystem that the “correct” solution can be found. The previous methods could not be enforced universally. Thus nearly all the material handling system suppliers have their own approach to find the right system, as it turned out at a market analysis of Fraunhofer IML. With the presented concept of finding a solution, a structured, fast method for system identification shall be presented. A stepwise approach to ...


An Extended Double Row Layout Problem, Chase C. Murray, Xingquan Zuo, Alice E. Smith Jan 2012

An Extended Double Row Layout Problem, Chase C. Murray, Xingquan Zuo, Alice E. Smith

12th IMHRC Proceedings (Gardanne, France – 2012)

The double row layout problem (DRLP) seeks to determine optimal machine locations on either side of an aisle, where the objective has been defined as the minimization of material ow cost among ma- chines while meeting machine clearance constraints. In this paper, we extend existing DRLP formulations in two respects. First, we consider the minimization of layout area besides the usual material ow cost objective. Second, we present a mixed integer linear programming formulation that permits non-zero aisle widths. This new formulation also includes new constraints that eliminate layout \mirroring," thus reducing the solution space significantly and thus solution times ...


Process Analysis For Material Flow Systems, Thorsten Schmidt, David Wustmann, Robert Schmaler Jan 2012

Process Analysis For Material Flow Systems, Thorsten Schmidt, David Wustmann, Robert Schmaler

12th IMHRC Proceedings (Gardanne, France – 2012)

This paper describes a generic approach for analysis of internal behavior of logistic systems based on event logs. The approach is demonstrated by an example of event data from the simulation model of an automated material handling system (MHS) in a manufacturing company. The purpose of the analysis is the identification of design and operation problems and their causes, prospectively. As a result, the simulation model developer obtains the condensed and ranked information on events. These events describe the internal system behavior with anomalies pointing at either possible problems or capacity reserves.


Evaluation Of Environmental Benefits Of Che Emerging Technologies By Using Lca, Nenad Zrnić, Andrija Vujičić Jan 2012

Evaluation Of Environmental Benefits Of Che Emerging Technologies By Using Lca, Nenad Zrnić, Andrija Vujičić

12th IMHRC Proceedings (Gardanne, France – 2012)

In the era of climate change combat transport industry is recognized as a sector with one of the largest environmental footprints. A part of transport industry is container shipping and handling division, which is currently growing with the fastest rate. This massive growth of container sector is due to containers pouring from Asia, mainly from China. Thus, container port operations are also experiencing significant increase in port emissions. This fact puts port authorities in position to find a way to reduce environmental impact of port operations and at the same time withhold increase in number containers being handled. In response ...


Column Generation For The Container Relocation Problem, Elisabeth Zehendner, Dominique Feillet Jan 2012

Column Generation For The Container Relocation Problem, Elisabeth Zehendner, Dominique Feillet

12th IMHRC Proceedings (Gardanne, France – 2012)

Container terminals offer transfer facilities to move containers from vessels to trucks, trains and barges and vice versa. Within the terminal the container yard serves as a temporary buffer where incoming containers are piled up in stacks. Only the topmost container of each stack can be accessed. If another container has to be retrieved, containers stored above it must be relocated first. Containers need to be transported to a ship or to trucks in a predefined sequence as fast as possible. Generally, this sequence does not match the stacking order within the yard. Therefore, a sequence of retrieval and relocation ...


Toward Sustainability, High Density And Short Response Time By Live-Cube Storage Systems, Nima Zaerpour, Yugang Yu, René De Koster Jan 2012

Toward Sustainability, High Density And Short Response Time By Live-Cube Storage Systems, Nima Zaerpour, Yugang Yu, René De Koster

12th IMHRC Proceedings (Gardanne, France – 2012)

This paper studies random storage in a live-cube storage system where loads are stored multi-deep. Although such storage systems are still rare, they are increasingly used, for example in automated car parking systems. Each load is accessible individually and can be moved to a lift on every level of the system in x- and y-directions by a shuttle as long as an open slot is available next to it, comparable to Sam Loyd’s sliding puzzles. A lift moves the loads across different levels in z-direction. We derive the expected travel time of a random load from its storage location ...


A Study On Storage Allocation In An Automated Semiconductor Manufacturing Facility, St´Ephane Dauz`Ere-P´Er`Es, Claude Yugma, Ahmed Ben Chaabane, Ahmed Ben Chaabane, Lionel Rulli`Ere, Gilles Lamiable Jan 2012

A Study On Storage Allocation In An Automated Semiconductor Manufacturing Facility, St´Ephane Dauz`Ere-P´Er`Es, Claude Yugma, Ahmed Ben Chaabane, Ahmed Ben Chaabane, Lionel Rulli`Ere, Gilles Lamiable

12th IMHRC Proceedings (Gardanne, France – 2012)

This paper deals with the allocation of storage capacity in the automated material handling environment of a semiconductor wafer manufacturing facility. The impact of the allocation of stokers to machines in semiconductor fabrication facilities (fabs) is very little studied, although it significantly impacts the efficiency of the Automated Material Handling System (AMHS). After motivating and describing the problem of allocating unitary stokers to machines, a first local approach is discussed. We then propose a Mixed Integer linear Programming model to solve the global problem with two objectives: Minimizing the total maximum travel distance of vehicles and balancing the utilization of ...


Open Location Management In Automated Warehousing Systems, Yugang Yu, René De Koster Jan 2012

Open Location Management In Automated Warehousing Systems, Yugang Yu, René De Koster

12th IMHRC Proceedings (Gardanne, France – 2012)

A warehouse needs to have sufficient open locations to be able to deal with the change of item inventory levels, but due to ongoing storage and retrieval processes, open locations usually spread over storage areas. Unfavorable positions of open locations negatively impact the average load retrieval times. This paper presents a new method to manage these open locations such that the average system travel time for processing a block of storage and retrieval jobs in an automated warehousing system is minimized. We introduce the effective storage area (ESA), a well-defined part of the locations closest to the depot; where only ...


Dynamic Slotting Optimization Based On Skus Correlations In A Zone-Based Wave-Picking System, Li Yingde, Jeffery S. Smith Jan 2012

Dynamic Slotting Optimization Based On Skus Correlations In A Zone-Based Wave-Picking System, Li Yingde, Jeffery S. Smith

12th IMHRC Proceedings (Gardanne, France – 2012)

Many exiting slotting methods ignore the picking correlations between Stock Keeping Units (SKUs). In a previous paper, a mix integer program model for dynamic slotting to minimize the pick-wave makespan among all zones under some load balancing constraints was developed. In this paper, we develop an ant colony optimization with slot-exchange policy (ACO-SE) based on SKU correlation to assign the correlated SKUs to the adjacent slots in the same zone. The ACO-SE deposits pheromones between SKUs, uses local and global pheromone trail updates, and controls pheromone accumulation using the Max-Min rule. The main heuristic information is set to the correlation ...


Hybrid Heuristics For Infinite Period Inventory Routing Problem, Ronald Askin, Mingjun Xia Jan 2012

Hybrid Heuristics For Infinite Period Inventory Routing Problem, Ronald Askin, Mingjun Xia

12th IMHRC Proceedings (Gardanne, France – 2012)

In this paper, we address a one-to-many distribution network inventory routing problem over an infinite planning horizon. Each retailer has an independent, random demand, and the distribution center uses capacitated vehicles for routing delivery. The demand at each retailer is relatively small compared to the vehicle capacity. A novel mathematical model is given to simultaneously decide the optimal routing tours to retailers and routing frequencies of each route. Several heuristics are developed to solve large scale instances of the problem.


Robust Design Of Public Storage Warehouses, Yeming Yale Gong, Rene De Koster Jan 2012

Robust Design Of Public Storage Warehouses, Yeming Yale Gong, Rene De Koster

12th IMHRC Proceedings (Gardanne, France – 2012)

We apply robust optimization and revenue management in public storage warehouses. We optimize the expected revenue of public storage warehouses against the worst cases with a max-min revenue objective, and the decision variables are mainly the number of storage units for each storage type. With the robust design, we can observe worst-case revenue improvement.


Robust Material Handling System Design Based On The Risk Versus Cost Tradeoff, Marc Goetschalckx, Edward Huang, Pratik Mital Jan 2012

Robust Material Handling System Design Based On The Risk Versus Cost Tradeoff, Marc Goetschalckx, Edward Huang, Pratik Mital

12th IMHRC Proceedings (Gardanne, France – 2012)

The design and planning of major material handling systems belongs to the class of systems design problems under uncertainty. The overall structure of the system is decided during the current design stage, while the values of the future conditions and the future planning decisions are not known with certainty. Typically the future uncertainty is modeled through a number of scenarios and each scenario has an individual timediscounted total system cost. The overall performance of the material handling system is characterized by the distribution of these scenario costs. The central tendency of the cost distribution is almost always computed as the ...


A Yard Crane Scheduling Problem With Practical Constraints, Amin Hossein Gharehgozli, Yugang Yu, Rene De Koster, Gilbert Laporte Jan 2012

A Yard Crane Scheduling Problem With Practical Constraints, Amin Hossein Gharehgozli, Yugang Yu, Rene De Koster, Gilbert Laporte

12th IMHRC Proceedings (Gardanne, France – 2012)

The problem considered in this paper is to locate storage containers while a set of container storage and retrieval requests are sequenced. Two automated cranes stack and retrieve containers in a single block of a yard. The cranes cannot pass each other and must be separated by a safety distance. Storage containers are initially located at the seaside and land side input/output (I/O) points of the block. Each must be stacked in a specific location of the block, selected from a set of open locations suitable for stacking the storage container. Retrieval containers are initially located in the ...


Analysis Of Material Handling Systems Based On Discrete Time Design Modules, Furmans Kai, Ozden Eda, Stoll Judith, Epp Martin, Schmidt Thorsten, Meinhardt Ingolf, Schulze Frank Jan 2012

Analysis Of Material Handling Systems Based On Discrete Time Design Modules, Furmans Kai, Ozden Eda, Stoll Judith, Epp Martin, Schmidt Thorsten, Meinhardt Ingolf, Schulze Frank

12th IMHRC Proceedings (Gardanne, France – 2012)

In this paper, we present a method for the performance evaluation of material handling systems in an early planning stage. We are mapping typical material handling elements onto stochastic analytical models. Our intention is to build a toolbox of material handling modules that allows a fast analysis of typical continuous conveying systems. The tool should enable the identification of bottlenecks and the computation of lead time distributions for intra-logistic systems.


Humanitarian Logistics – The First Week, Selina Begum, Bill Ferrell Jan 2012

Humanitarian Logistics – The First Week, Selina Begum, Bill Ferrell

12th IMHRC Proceedings (Gardanne, France – 2012)

Decisions made on material flow during the first week of a natural disaster are critical for victims. Currently, decision makers appears to be making important choices based on experience and intuition with little or no support from quantitative approaches because they do not exist. This research proposes a paradigm and offers two supporting models that will assist decision makers regarding the routing of materials during the first week of a disaster. It explicitly includes information regarding the victims’ needs and the degree to which routes are available in a quantitative way that allows updating as information improves. The paradigm involves ...


Collaborative Freight Transportation To Improve Efficiency And Sustainability, Kimberly P. Ellis, Steven Roesch, Russell D. Meller Jan 2012

Collaborative Freight Transportation To Improve Efficiency And Sustainability, Kimberly P. Ellis, Steven Roesch, Russell D. Meller

12th IMHRC Proceedings (Gardanne, France – 2012)

Collaborative distribution offers the potential for substantial improvements in freight transportation. As collaboration increases, more loads are available for sharing among transportation service providers, leading to more fully loaded trailers that travel fewer miles and reduce the cost per load on average. In this study, we develop approaches to analyze improvements in key performance measures as collaboration increases in freight transportation. For the data sets analyzed, improvements include a 34% increase in trailer fullness, a 29% reduction in average costs per load, and a 25% decrease in average miles per load. Based on this analysis, collaboration provides substantial improvements for ...