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Detailed design of fishbone warehouse layouts with vertical travel

Author

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  • Cardona, Luis F.
  • Soto, Diego F.
  • Rivera, Leonardo
  • Martínez, Hector J.

Abstract

In this paper, we provide a method to generate a three-dimensional detailed design of fishbone layouts. This method takes the desired storage capacity and returns the location (x,y,z) of each opening of the warehouse in such a way that the total operational cost – area cost and material handling cost – of the warehouse is minimal. We model the arrangement of the openings using mathematical finite sequences and represent a fishbone layout in terms of four primary characteristics. Next, we develop an algorithm that generates a detailed design of a fishbone layout given values of its four primary characteristics. Then, we present an optimization model that finds the values for the four primary characteristics that minimize the total operational cost of the warehouse. Finally, we solve the optimization model using a genetic algorithm. Our results suggest that in 91.74% of the cases, our optimization procedure reaches a near optimum point – deviated only by 0.587% – in a reasonable computational time (maximum 4.5min). This paper aims to diminish dependence upon experts and human decision making in the process of implementing a fishbone layout on greenfield projects, and fulfills an identified need of warehouse practitioners by integrating the most recent advances on non-traditional layouts and detailed warehouse design.

Suggested Citation

  • Cardona, Luis F. & Soto, Diego F. & Rivera, Leonardo & Martínez, Hector J., 2015. "Detailed design of fishbone warehouse layouts with vertical travel," International Journal of Production Economics, Elsevier, vol. 170(PC), pages 825-837.
    • Handle: RePEc:eee:proeco:v:170:y:2015:i:pc:p:825-837
    DOI: 10.1016/j.ijpe.2015.03.006
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    References listed on IDEAS

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    1. Kevin Gue & Russell Meller, 2009. "Aisle configurations for unit-load warehouses," IISE Transactions, Taylor & Francis Journals, vol. 41(3), pages 171-182.
    2. Gue, Kevin R. & Ivanović, Goran & Meller, Russell D., 2012. "A unit-load warehouse with multiple pickup and deposit points and non-traditional aisles," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 48(4), pages 795-806.
    3. Kirby Clark & Russell Meller, 2013. "Incorporating vertical travel into non-traditional cross aisles for unit-load warehouse designs," IISE Transactions, Taylor & Francis Journals, vol. 45(12), pages 1322-1331.
    4. Ömer Öztürkoğlu & Kevin Gue & Russell Meller, 2012. "Optimal unit-load warehouse designs for single-command operations," IISE Transactions, Taylor & Francis Journals, vol. 44(6), pages 459-475.
    5. Rouwenhorst, B. & Reuter, B. & Stockrahm, V. & van Houtum, G. J. & Mantel, R. J. & Zijm, W. H. M., 2000. "Warehouse design and control: Framework and literature review," European Journal of Operational Research, Elsevier, vol. 122(3), pages 515-533, May.
    6. Letitia Pohl & Russell Meller & Kevin Gue, 2011. "Turnover-based storage in non-traditional unit-load warehouse designs," IISE Transactions, Taylor & Francis Journals, vol. 43(10), pages 703-720.
    7. Parikh, Pratik J. & Meller, Russell D., 2010. "A travel-time model for a person-onboard order picking system," European Journal of Operational Research, Elsevier, vol. 200(2), pages 385-394, January.
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    Cited by:

    1. Li Zhou & Huwei Liu & Junhui Zhao & Fan Wang & Jianglong Yang, 2022. "Performance Analysis of Picking Routing Strategies in the Leaf Layout Warehouse," Mathematics, MDPI, vol. 10(17), pages 1-28, September.
    2. Rakesh Venkitasubramony & Gajendra K. Adil, 2016. "Analytical models for pick distances in fishbone warehouse based on exact distance contour," International Journal of Production Research, Taylor & Francis Journals, vol. 54(14), pages 4305-4326, July.
    3. Ivan Derpich & Juan M. Sepúlveda & Rodrigo Barraza & Fernanda Castro, 2022. "Warehouse Optimization: Energy Efficient Layout and Design," Mathematics, MDPI, vol. 10(10), pages 1-17, May.
    4. Bo Yan & Chang Yan & Feng Long & Xing-Chao Tan, 2018. "Multi-objective optimization of electronic product goods location assignment in stereoscopic warehouse based on adaptive genetic algorithm," Journal of Intelligent Manufacturing, Springer, vol. 29(6), pages 1273-1285, August.
    5. Xuan Zhang & Tiantian Mo & Yougong Zhang, 2023. "Optimization of Storage Location Assignment for Non-Traditional Layout Warehouses Based on the Firework Algorithm," Sustainability, MDPI, vol. 15(13), pages 1-21, June.
    6. Derhami, Shahab & Smith, Jeffrey S. & Gue, Kevin R., 2020. "A simulation-based optimization approach to design optimal layouts for block stacking warehouses," International Journal of Production Economics, Elsevier, vol. 223(C).
    7. Li Zhou & Zhaochan Li & Ning Shi & Shaohua Liu & Ke Xiong, 2019. "Performance Analysis of Three Intelligent Algorithms on Route Selection of Fishbone Layout," Sustainability, MDPI, vol. 11(4), pages 1-17, February.

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