Industrial Engineering Commons^™

Simulation-Based Energy And Cycle Time Analysis Of Shuttle-Based Storage And Retrieval System, Tone Lerher, Banu Yetkin Ekren, Anil Akpunar

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

This study explores the best warehouse design for shuttle-based storage and retrieval system (SBS/RS) minimizing average energy consumption per transaction and average cycle time per transaction, simultaneously. For that we provided average energy consumption per transaction versus average cycle time per transaction graphs, for different design scenarios of the studied SBS/RS warehouse. In the design concept, we considered, rack design in terms of number of bays, number of tiers, number of aisles, as well as velocity profiles of lifts in the system. We completed 144 number of experiments by simulation to see the trade-offs based on the design scenarios and …

Non-Traditional Aisle Design For A Manufacturing Facility Layout, Dale T. Masel, Dean Marinchek

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Methods for designing a facility layout typically assume that the aisles for interdepartmental travel will be parallel to the exterior walls of the facility. However, by putting aisles at an angle to the exterior walls, more direct routes between departments can be created, reducing travel distance. This paper describes a method to create a facility layout that does not have orthogonal aisles and testing of the resulting layouts shows that travel distance is reduced.

Operational-Level Optimization Of Inbound Intralogistics, Hector J. Carlo, Yeiram Martinez

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

This study is concerned with optimizing inbound operations at distribution centers (DCs), warehouses, and cross-docks with staging areas. The objective of the problem is to minimize the makespan required to move all unit loads from the trailers to the flow racks, and from the flow racks to their respective storage locations. It is assumed that a set of inbound trailers with known composition have been assigned and sequenced to inbound dock doors. The following three inbound logistics decisions are simultaneously considered: i) unloaders’ assignment and scheduling, ii) loads-to-flow rack assignment, and iii) assignment and haulers’ scheduling. In this study we …

Understanding Worker Blocking And The Design Process, Russell D. Meller, Lisa M. Thomas

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Designing a distribution center (DC) is a complex process that consists of answering dozens of interrelated questions. From our perspective, the penultimate question is one of which picking methodology is optimal. To answer this question requires a full evaluation of picking methodologies in terms of their ability to meet the expected throughput requirements of the system. In manual picking systems, as throughput requirements increase, worker interaction and blocking increase as well. This implies that being able to estimate the amount of worker blocking in a system is critical to a design effort. Most of the prior research in this area …

Introducing The Concept Of Hyperconnected Mobile Production, Suzanne Marcotte, Benoit Montreuil

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Many globalized businesses are trying to cope with growing competition by strategically expanding their dedicated network of production facilities so as to be able to offer and to deliver time and price competitive offers to their clients across the world. In this paper, exploiting Physical Internet principles, we introduce the concept of hyperconnected mobile production that can alternatively enable businesses to dynamically expand and contract as necessary their production capacity in regions worldwide. First, hyperconnected mobile production exploits open fabs from multiple parties readily available in those regions. Second, these fabs are to rely on plug-and-play production modules. These modules …

A High-Density, Puzzle-Based System For Rail-Rail Container Transfers, Kevin Gue

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

We describe a high-density, puzzle-based storage and transfer system for containers in a rail-to-rail hub for the Physical Internet. The system uses a new algorithm called GridHub, which is able to transfer items in all four cardinal directions simultaneously within a grid. We show how the GridHub system might be used in a rail-rail transfer hub to transfer containers between one side of the grid and a train.

Logistics Models To Support Order-Fulfillment From The Sea, Jennifer Pazour, Ian Shin

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Sea based logistics use maritime platforms to transfer cargo stored on vessels and delivers them ashore. This chapter describes the motivations and logistical requirements of seabasing. The sea base’s organizational structure, its material handling environment, and the internal cargo flow processes of the T-AKE vessel are described. Three seabasing distribution network scenarios -- Iron Mountain, Skin-to-Skin Replenishment, and Tailored Resupply Packages -- are described and mapped to warehousing and distribution networks, characteristics, and decision problems. Finally, related literature is reviewed and open areas for logistics research to support order fulfillment from the sea are identified.

Omnichannel Business-­‐To-­‐Consumer Logistics And Supply Chains: Towards Hyperconnected Networks And Facilities, Benoit Montreuil

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

This paper deals with omnichannel business-­‐to-­‐consumer logistics and supply chains. Its key contribution is the conceptualization of hyperconnected network and facility design options for enabling to meet the challenges toward achieving omnichannel logistics efficiently and sustainably while meeting the timely expectations of clients. These design options exploit key Physical Internet concepts. They encompass the transportation, pickup and delivery of ordered goods, the deployment of products across territories to enable fast response to orders, as well as on-­‐demand production of products across networks of facilities while engaging multiple parties. The options range from current practice to prospective ones that are associated …

Maritime Location Decisions For Lng Bunkering Facilities, Reinier C. Schneider, Iris F.A. Vis

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Liquefied natural gas (LNG) is one of the upcoming fuels to be used for more sustainable shipping activities in the maritime sector. For a widespread adoption by end-users, a refuelling network requiring capital intensive investments, needs to be in place. From a macro perspective of suppliers of LNG, it makes sense to develop the infrastructure at strategic locations that capture as many vessels and ships as possible. The goal of this research is to develop a facility location model that can contribute to the location selection of LNG facilities in a new fuelling network. The new model will fit the …

Methodology For Choosing An Appropriate Inland Vessels As A Floating Distribution Centers, Andrea Seidlova, David Sourek

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

The primary goal of this paper is to propose a methodology for the choice of an appropriate vessel type under the specific condition of floating distribution center. The right choice of the appropriate type of vessel has a fundamental influence on the long-term success of city logistic projects with water transport. In this paper, we propose a methodology for vessel choice according to its inner layout and technology of handling. The possibility of an application in practice will be defined for each option.

Integrated Versus Sequential Scheduling And Assignment At A Unit Load Cross-Dock, Arpan Rijal, Marco Bijvank, Rene De Koster

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Within a cross-dock, the assignment of trucks to dock-doors and the scheduling of trucks to be processed are two major operational decisions. Conventionally, assignment and scheduling decisions are made sequentially. However, solving the two problems sequentially can lead to sub-optimal solutions because the objectives of the two problems are in conflict with each other. To gain further insights, we create an integrated model which is capable of simultaneously scheduling and assigning trucks at cross-docks. We contrast the integrated model with a sequential model which first schedules trucks for processing and then assigns them to dock-doors. Experiments demonstrate that the integrated …

A Heuristic Approach To Storage System Design With Simultaneous Assignment Of Goods, Tobias Staab, Willibad A. Gunthner

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

In the paper at hand, we analyze the planning of manually operated storage systems consisting of different storage areas. When solving design problems like dimensioning or equipment selection, the assignment of goods to storage areas has to be considered. Based on a general model to describe the geometry and performance calculation of a warehouse, we present a heuristic approach to assign goods to storage areas while simultaneously determining the design of the storage areas in a way that generates the lowest running costs. Our approach aims to support planners during the rough planning stage by providing a quick overview of …

Intermodal Hubs In The Physical Internet, Nadeepa Wickramage, Bill Ferrell

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Distribution of finished goods is currently an effective but inefficient process that consumes significant quantities of fossil fuel to move empty assets. This results in increased costs that are passed to the consumer and unnecessarily increased carbon emissions. The Physical Internet (PI) is focused on shared logistics that could prove to be an important element of next-generation logistics systems. The idea is to store and transport goods in anonymous standard-sized containers so that transportation and warehousing can be efficiently shared by many companies including competitors. If implemented, this idea has the potential of dramatically increasing efficiency thereby reducing fuel consumption …

Analyzing Order Throughput Times In A Milkrun Picking System, J. P. Van Der Gaast, M.B. M. De Koster, Ivo J.B.F. Adan

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

E-commerce fulfillment competition evolves around cheap, speedy, and time-definite delivery. Milkrun order picking systems have proven to be very successful in providing handling speed for a large, but highly variable, number of orders. In this system, an order picker picks orders that arrive in real time during the picking process; by dynamically changing the stops on the picker’s current picking route. The advantage of milkrun picking is that it reduces order picking set-up time and worker travel time compared to conventional batch picking systems. This paper is the first in studying order throughput times of multi-line orders in a milkrun …

A Lagrangian Relaxation For Capacitated Single Allocation P-Hub Median Problem With Multiple Capacity Levels, Ching-Jung Ting, Kuo-Rui Lu

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

In this paper we consider a capacitated single allocation p-hub median problem with multiple capacity levels (CSApHMPMC) in which the decisions are to determine the location of p hubs and their capacity levels, the single allocation of non-hub nodes to hubs in the logistics network. This problem is formulated as an integer programming model with the objective of minimizing the sum of total transportation cost and fixed cost of the selected p hubs with established capacity levels. A Lagrangian relaxation (LR) approach is proposed to solve the CSApHMPMC. The Lagrangian function that we formulated decomposed the original problem into smaller …

การลดของเสียในกระบวนการผลิตอุปกรณ์ส่งและรับสัญญาณ, กนกวรรณ บุญฤทธิ์ศักดิ์

Chulalongkorn University Theses and Dissertations (Chula ETD)

งานวิจัยนี้มีวัตถุประสงค์เพื่อลดปริมาณของเสียอุปกรณ์ส่งและรับสัญญาณทางแสงที่เกิดจากค่าแรงเฉือนของการยึดติดระหว่างชิ้นส่วนเลนส์บนแผ่นประกอบวงจรไฟฟ้าชนิดยืดหยุ่น (FPCBA: Flexible Printed Circuit Board Assembly) ซึ่งมีกระบวนการผลิตเริ่มจาก (1) นำแผ่นประกอบวงจรไฟฟ้าชนิดยืดหยุ่น (FPCBA) ที่ผ่านการประกอบวงจรอิเล็กทรอนิกส์แล้วมาทำความสะอาด (2) หยอดกาวชนิด Urethane Acrylate (UA) จำนวน 8 ตำแหน่งบนแผ่น FPCBA (3) ยิงและอบด้วยแสงยูวี (4) หยอดกาวชนิดEpoxyสีดำ (5) อบด้วยความร้อน ดำเนินการวิเคราะห์หาสาเหตุโดย (1) ศึกษาความสัมพันธ์ระหว่างค่าแรงเฉือนที่ได้กับจำนวนการเกิดสีขาวขุ่นของกาวUA บนแผ่น FPCBA (2) ตรวจสอบลักษณะข้อบกพร่องของการยึดติดกาวด้วยกล้องจุลทรรศน์เล็กตรอนแบบส่องกราด (3) วิเคราะห์องค์ประกอบของชนิดคราบกาวและตรวจหาหมู่ฟังก์ชันด้วยเครื่อง FTIR (Fourier Transform Infrared Spectrometer) (4) วิเคราะห์หาขั้นตอนที่ทำให้เกิดของเสีย โดยพิจารณาจากขั้นตอนท้ายไปหน้า (5) ดำเนินการปรับปรุง ผลการศึกษาพบว่า 1) ค่าแรงเฉือนมีค่าลดลงเมื่อมีจำนวนตำแหน่งของกาวUA เปลี่ยนสีจากใสเป็นขาวขุ่นมากขึ้น 2) ลักษณะของเสียกาวUAขาวขุ่นเกิดขึ้นที่ขั้นตอนการทำความสะอาด โดยวิธีทำความสะอาดของพนักงานมีอิทธิพลมากที่สุด ซึ่งลักษณะของเสียกาวUA ขาวขุ่นเกิดจากกาวUA ที่ไม่ยึดติดบน FPCBA ซึ่งเกิดจากการทำความสะอาดที่ไม่เพียงพอ 3) ระยะทางในการทำความสะอาดต่อก้านสำลีและการทำซ้ำที่ใช้เช็ดทำความสะอาด ส่งผลต่อการเกิดกาวUAขาวขุ่น 4) การใช้สารระเหยทำความสะอาดชิ้นงานชนิด IPA (Isopropyl Alcohol) ที่มีจุดเดือด 82.6°C ซึ่งใกล้เคียงกับอุณหภูมิที่ใช้ในขั้นตอนการอบชิ้นงานเท่ากับ90±5°C ซึ่งเป็นขั้นตอนสุดท้าย เป็นสาเหตุให้กาวUA เปลี่ยนสีจากใสเป็นขาวขุ่น เนื่องจากไอระเหยที่ไล่ออกไม่หมด 5) การใช้สารระเหยชนิดเมธนอล (Methanol) ที่มีจุดเดือด 64.7°C ทดแทน IPA พบว่าของเสียจากกาวUA ขาวขุ่นลดลงจากเดิมก่อนศึกษา 33% เป็น 7% และไม่เกิดกาวขาวขุ่นอีกเลย ตามลำดับ

การปรับปรุงกระบวนการออกแบบชุดสายไฟในรถยนต์, ทิวารัตน์ สวัสดี

Chulalongkorn University Theses and Dissertations (Chula ETD)

งานวิจัยฉบับนี้ ทำการศึกษาเกี่ยวกับบริษัท ออกแบบสายไฟในรถยนต์ที่ให้ความสำคัญในเรื่องความพึงพอใจของลูกค้า ซึ่งเป็นหนึ่งในปัจจัยที่สำคัญที่สุดในการออกแบบผลิตภัณฑ์ ด้วยเหตุนี้บริษัท จึงใช้วิธีการทั้งหมดในการออกแบบกระบวนการออกแบบผลิตภัณฑ์ตามความต้องการที่หลากหลายของลูกค้า จึงทำให้มีการเปลี่ยนแปลงการออกแบบเป็นจำนวนมาก งานวิจัยนี้มีวัตถุประสงค์เพื่อปรับปรุงกระบวนการออกแบบชุดสายไฟในรถยนต์ที่มีผลต่อกำหนดการผลิตโดยใช้การวิเคราะห์ Fault Tree และ Failure Mode and Effect Analysis (FMEA) เป็นเครื่องมือหลัก FTA ใช้สำหรับการวิเคราะห์สาเหตุหลักและใช้ FMEA เพื่อจัดลำดับความสำคัญสูง (RPN) ซึ่งแสดงให้เห็นถึงความสำคัญของปัจจัยต่างๆในชุดสายไฟในรถยนต์ที่มีผลกระทบสูงต่อการออกแบบชุดสายไฟในรถยนต์ และหลังจากมีการปรับปรุงกระบวนการออกแบบและควบคุมปัจจัยที่ส่งผลเสียต่อกระบวนการออกแบบจะพบการขอเปลี่ยนแปลงการออกแบบที่ลดลงจาก 0.26 ครั้ง ต่อการออกแบบ 1 ครั้ง เป็น 0.06 ครั้ง ต่อการออกแบบ 1 ครั้ง แสดงถึงกระบวนการออกแบบที่ถูกปรับปรุงให้สามารถสร้างความพึงพอใจแก่ลูกค้าที่มีต่อผลิตภัณฑ์มากขึ้น

The Reconfigurable Machinery Efficient Workspace Analysis Based On The Twist Angles, Ana M. Djuric, Vukica Jovanovic, Mirjana Filipovic, Ljubinko Kevac

Engineering Technology Faculty Publications

A novel methodology for the calculation, visualisation and analysis of the Reconfigurable Machinery Efficient Workspace (RMEW), based on the twist angles, is presented in this paper. The machinery's kinematic parameters are used for calculating the workspace, while the efficient workspace is associated with the machinery's path and includes the end-effector position and orientation. To analyse and visualise many different machinery efficient workspaces at the same time, the calculation is based on the previously developed and validated complex reconfigurable machinery's kinematic structure named n-DOF Global Kinematic Model (n-GKM). An industrial robot is used as an example to demonstrate …

Toward An Engineering Discipline Of Warehouse Design, Leon Mcginnis, Timothy Sprock

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Warehouses today are complex dynamic engineered systems, incorporating automation, mechanization, equipment, fixtures, computers, networks, products and people, and they can support the flow of tens or hundreds of thousands of different items to enable fulfilling thousands or tens of thousands of orders daily. In that sense, they represent a design challenge that is not terribly different from the design of other complex dynamic engineered systems, such as a modern passenger airplane, an automobile, or a unique building. What is different is that the design of these other complex dynamic engineered systems typically follows some engineering design discipline. Here, we argue …

Monte Carlo Algorithm To Study Performance Parameters Of Shuttle Systems, Wolfgang Trummer, Dirk Jodin

14th IMHRC Proceedings (Karlsruhe, Germany – 2016)

Shuttle systems provide alternative solutions in storage technology. Ma-terial flow analyses of these systems are extensive due to complex interac-tion of several shuttles and lift elements. Besides classic cycle time calcu-lation, it also requires advanced analyzing methods. At the Institute of Logistics Engineering (ITL), Graz University of Technology, an innovative, software-based approach has been developed to investigate the performance of shuttle systems. This approach is based on the Monte Carlo method. The software tool takes into account a variety of different systems and operating parameters to reflect operative behavior of shuttle systems.

Modeling Information Reliability And Maintenance: A Systematic Literature Review, Daysi A. Guerra Garcia

Industrial Engineering Undergraduate Honors Theses

Operating a business efficiently depends on effective everyday decision-making. In turn, those decisions are influenced by the quality of data used in the decision-making process, and maintaining good data quality becomes more challenging as a business expands. Protecting the quality of the data and the information it generates is a challenge faced by many companies across all industrial sectors. As companies begin to use data from these large data bases they will need to begin to develop strategies for maintaining and assessing the reliability of the information they generate using this data. A considerable amount of literature exists on data …

Spare Parts On Demand Using Additive Manufacturing : A Simulation Model For Cost Evaluation., Stefan Jedeck

Electronic Theses and Dissertations

Little is known about the impact of additive manufacturing in the spare part supply chain. A few studies are available, but they focus on specific parts and their applications only. A general model, which can be adapted to different applications, is nonexistent. This dissertation proposes a decision making framework that enables an interested practitioner/manager to decide whether using additive manufacturing to make spare parts on demand is economical when compared to conventional warehousing strategy. The framework consists of two major components: a general discrete event simulation model and a process of designing a wide range of simulation scenarios. The goal …

Systems Theory-Based Construct For Identifying Metasystem Pathologies For Complex System Governance, Polinpapilinho F. Katina

Engineering Management & Systems Engineering Theses & Dissertations

The purpose of this research was to develop a systems theory-based construct for metasystem pathologies identification in support of the problem formulation phase of systems-based methodologies using an inductive research design. Problem formulation has been identified as one of the most critical stages in complex system development since it influences later stages in complex system understanding. In modern society where the operating landscape is characteristically ambiguous, mired by complexity, emergence. interdependence, and uncertainty, the concept of problem formulation is used to ensure right issues affecting complex systems surface and addressed to meet expected system performance and viability. In this research, …

An Adaptive Large Neighborhood Search Heuristic For The Inventory Routing Problem With Time Windows, Mina Hadianniasar

Graduate Theses and Dissertations

This research addresses an integrated distribution and inventory control problem which is faced by a large retail chain in the United States. In their current distribution network, a direct shipping policy is used to keep stores stocked with products. The shipping policy specifies that a dedicated trailer should be sent from the warehouse to a store when the trailer is full or after five business days, whichever comes first. Stores can only receive deliveries during a window of time (6 am to 6 pm). The retail chain is seeking more efficient alternatives to this policy, as measured by total transportation, …

Inventory Management And Control "For A Cause", John Michael Miller

Graduate Theses and Dissertations

Companies today are changing the culture of business and beginning to involve more than just labor and money in overall decisions. Just as sustainability issues and humanitarian logistics are gaining popularity, so is the idea of using business to make a difference on society in addition to making a profit. As companies position themselves across the globe to make an impact, they employ people in third-world environments that create uncertainties on both the supply and demand sides. Also, the idea of strategically planning work with the goal of minimizing costs has been replaced by companies wanting to give more work …

Using The Triple Bottom Line To Select Sustainable Suppliers For A Major Oil And Gas Company, Pandarinath Adarsh Sunkari

Graduate Theses and Dissertations

Companies have primarily been focusing on the financial bottom line i.e., on increasing profits by increasing revenues and reducing costs. With high energy usage and environmental change posing threats to the environment and business operations, companies are now considering sustainability. Since some global suppliers have low cost labor, Social well-being and human development has also emerged as major goals of a company performing global operations. Focusing on these three goals is termed the "Triple Bottom Line" (TBL). We study and explore the TBL benefits that could be realized by an oil and gas company by focusing on sustainable suppliers. A …

Design, Programming, And User-Experience, Kaila G. Manca

Honors Scholar Theses

This thesis is a culmination of my individualized major in Human-Computer Interaction. As such, it showcases my knowledge of design, computer engineering, user-experience research, and puts into practice my background in psychology, com- munications, and neuroscience.

I provided full-service design and development for a web application to be used by the Digital Media and Design Department and their students.This process involved several iterations of user-experience research, testing, concepting, branding and strategy, ideation, and design. It lead to two products.

The first product is full-scale development and optimization of the web appli- cation.The web application adheres to best practices. It was …

Modeling Expected Travel Distances For A Common Warehouse Design With Multiple Docks, Mahmut Tutam

Graduate Theses and Dissertations

This thesis develops expected travel distance expressions for both single- and dual-command operations in a unit-load warehouse design with multiple docks. Storage racks are aligned perpendicular to the wall containing docks. Results are presented for continuous and discrete formulations. Because of the importance of how docks are located on a wall, different dock locations are investigated, including uniformly distributed docks along one wall, specified distances between adjacent docks located symmetrically about the mid-point of a warehouse wall, and any distribution of locations along one wall. Among the results obtained, we find that the width-to-depth ratio of the storage area (commonly …

Creating A User-Friendly Personal Wine Collection Inventory Management System, Peter Loddengaard

Industrial and Manufacturing Engineering

This project set out to create a user-friendly wine collection management software. Existing systems were reviewed and discussions with collectors took place to establish the user requirements for this type of inventory management system. This led to the scope of the project being narrowed to making a wine bottle entry form that was quick and easy to use. The programming language, Ruby on Rails, was used to design this system, and learning the software was a large part of the project itself. It was established that four forms would be designed using combinations of two ergonomic factors: an “F” shaped …

Frito-Lay - Supply Chain Impact Analysis, Kerri Blosch, Vincent Phua, Jeffrey Silva

Industrial and Manufacturing Engineering

The snack food company Frito-Lay relies on Route Sales Representatives (RSRs) to stock and maintain shelves of snack foods in every store. Frito-Lay currently does not have a system which can accurately predict cannibalization, or the effects of a store opening or closing on other stores of the same chain in the area. The goal is to sort through 1900 stores in a given metropolitan area to see the effects of cannibalization. In order to tackle the problem, a Microsoft Access program was created to filter stores based on location or whether the store was open for the full three-year …