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Impact of required storage space on storage policy performance in a unit-load warehouse

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  • Xiaolong Guo
  • Yugang Yu
  • René B.M. De Koster

Abstract

The performance of a storage policy in a warehouse is usually evaluated on the basis of the average one-way travel distance/time needed to store/retrieve a load. Dividing the storage space into zones based on item turnover frequency can reduce the travel distance. However, for a given number of stored items, a larger number of storage zones also requires more storage space, because of reduced space sharing between the items, which increases travel time. This study considers the required space consumption by storage zoning in comparing the performance of random, full turnover-based and class-based storage policies for a unit-load warehouse operated by a forklift in single-command mode. A generalised travel distance model that considers the required space consumption is developed to compare the performance of these policies. Results show that the one-way travel distance of a random policy decreases with the increase in skewness of the demand curve. By considering the required space consumption, a class-based storage policy performs generally better than a full turnover-based policy. In addition, the optimal warehouse shape factor (ratio of warehouse width to depth) appears to decrease with the skewness of the demand curve. Warehouse managers are advised to adopt a wide-shallow warehouse layout when the item demands are approximately equal, whereas a narrow-deep layout is preferred when the demand curves are steep.

Suggested Citation

  • Xiaolong Guo & Yugang Yu & René B.M. De Koster, 2016. "Impact of required storage space on storage policy performance in a unit-load warehouse," International Journal of Production Research, Taylor & Francis Journals, vol. 54(8), pages 2405-2418, April.
    • Handle: RePEc:taf:tprsxx:v:54:y:2016:i:8:p:2405-2418
    DOI: 10.1080/00207543.2015.1083624
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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. Ang, Marcus & Lim, Yun Fong, 2019. "How to optimize storage classes in a unit-load warehouse," European Journal of Operational Research, Elsevier, vol. 278(1), pages 186-201.
    3. Zhang, Guoqing & Nishi, Tatsushi & Turner, Sarina D.O. & Oga, Keisuke & Li, Xindan, 2017. "An integrated strategy for a production planning and warehouse layout problem: Modeling and solution approaches," Omega, Elsevier, vol. 68(C), pages 85-94.
    4. Pawel Zajac & Egidijus Dragasius & Tetiana Roik, 2021. "Energy Consumption When Transporting Pallet Loads Using a Forklift with an Anti Slip Pad Preventing Damage," Energies, MDPI, vol. 14(24), pages 1-20, December.
    5. Zhang, Jingran & Onal, Sevilay & Das, Sanchoy, 2020. "The dynamic stocking location problem – Dispersing inventory in fulfillment warehouses with explosive storage," International Journal of Production Economics, Elsevier, vol. 224(C).
    6. Silva, Allyson & Roodbergen, Kees Jan & Coelho, Leandro C. & Darvish, Maryam, 2022. "Estimating optimal ABC zone sizes in manual warehouses," International Journal of Production Economics, Elsevier, vol. 252(C).
    7. van Gils, Teun & Ramaekers, Katrien & Braekers, Kris & Depaire, Benoît & Caris, An, 2018. "Increasing order picking efficiency by integrating storage, batching, zone picking, and routing policy decisions," International Journal of Production Economics, Elsevier, vol. 197(C), pages 243-261.
    8. Zhang, Guoqing & Shang, Xiaoting & Alawneh, Fawzat & Yang, Yiqin & Nishi, Tatsushi, 2021. "Integrated production planning and warehouse storage assignment problem: An IoT assisted case," International Journal of Production Economics, Elsevier, vol. 234(C).
    9. Guo, Xiaolong & Chen, Ran & Du, Shaofu & Yu, Yugang, 2021. "Storage assignment for newly arrived items in forward picking areas with limited open locations," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 151(C).
    10. van Gils, Teun & Ramaekers, Katrien & Caris, An & de Koster, René B.M., 2018. "Designing efficient order picking systems by combining planning problems: State-of-the-art classification and review," European Journal of Operational Research, Elsevier, vol. 267(1), pages 1-15.
    11. Tutam, Mahmut & White, John A., 2019. "Multi-dock unit-load warehouse designs with a cross-aisle," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 129(C), pages 247-262.
    12. 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).

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