Capacity analysis of sequential zone picking systems

Jelmer van der Gaast, M.B.M. de Koster, I.J.B.F. Adan, J.A.C. Resing

Onderzoeksoutput: Bijdrage aan tijdschriftTijdschriftartikelAcademicpeer review

Uittreksel

This paper develops a capacity model for sequential zone picking
systems. These systems are popular internal transport and order
picking systems, due to their scalability, flexibility, high-throughput ability,
and fit-for-use for a wide range of products and order profiles. The major disadvantage of such systems is congestion and blocking under heavy use, leading to long order throughput times. To reduce blocking and congestion, most systems use the block-and-recirculate protocol to dynamically manage workload. In this paper, the various elements of the system, such as conveyor lanes and pick zones, are modeled as a multi-class block-and-recirculate queueing network with capacity constraints on subnetworks. Due to this blocking protocol, the stationary distribution of the queueing network is highly intractable.
We propose an approximation method based on jump-over blocking. Multi-class
jump-over queueing networks admit a product-form stationary distribution
and can be efficiently evaluated by Mean Value Analysis (MVA)
and Norton's theorem. This method can be applied during the design phase
of sequential zone picking systems to determine the number of segments, number and length of zones, buffer capacities, and storage allocation of
products to zones, to meet performance targets.
For a wide range of parameters, the results show that the relative error in the system throughput is typically less than 1% compared to simulation.
Originele taal-2Engels
TijdschriftOperations Research
StatusGeaccepteerd/In druk - 2018

Vingerafdruk

Queueing networks
Throughput
Value engineering
Scalability
Capacity analysis

Citeer dit

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title = "Capacity analysis of sequential zone picking systems",
abstract = "This paper develops a capacity model for sequential zone pickingsystems. These systems are popular internal transport and orderpicking systems, due to their scalability, flexibility, high-throughput ability,and fit-for-use for a wide range of products and order profiles. The major disadvantage of such systems is congestion and blocking under heavy use, leading to long order throughput times. To reduce blocking and congestion, most systems use the block-and-recirculate protocol to dynamically manage workload. In this paper, the various elements of the system, such as conveyor lanes and pick zones, are modeled as a multi-class block-and-recirculate queueing network with capacity constraints on subnetworks. Due to this blocking protocol, the stationary distribution of the queueing network is highly intractable.We propose an approximation method based on jump-over blocking. Multi-classjump-over queueing networks admit a product-form stationary distributionand can be efficiently evaluated by Mean Value Analysis (MVA)and Norton's theorem. This method can be applied during the design phaseof sequential zone picking systems to determine the number of segments, number and length of zones, buffer capacities, and storage allocation ofproducts to zones, to meet performance targets.For a wide range of parameters, the results show that the relative error in the system throughput is typically less than 1{\%} compared to simulation.",
author = "{van der Gaast}, Jelmer and {de Koster}, M.B.M. and I.J.B.F. Adan and J.A.C. Resing",
year = "2018",
language = "English",
journal = "Operations Research",
issn = "0030-364X",
publisher = "INFORMS Institute for Operations Research and the Management Sciences",

}

Capacity analysis of sequential zone picking systems. / van der Gaast, Jelmer; de Koster, M.B.M.; Adan, I.J.B.F.; Resing, J.A.C.

In: Operations Research, 2018.

Onderzoeksoutput: Bijdrage aan tijdschriftTijdschriftartikelAcademicpeer review

TY - JOUR

T1 - Capacity analysis of sequential zone picking systems

AU - van der Gaast, Jelmer

AU - de Koster, M.B.M.

AU - Adan, I.J.B.F.

AU - Resing, J.A.C.

PY - 2018

Y1 - 2018

N2 - This paper develops a capacity model for sequential zone pickingsystems. These systems are popular internal transport and orderpicking systems, due to their scalability, flexibility, high-throughput ability,and fit-for-use for a wide range of products and order profiles. The major disadvantage of such systems is congestion and blocking under heavy use, leading to long order throughput times. To reduce blocking and congestion, most systems use the block-and-recirculate protocol to dynamically manage workload. In this paper, the various elements of the system, such as conveyor lanes and pick zones, are modeled as a multi-class block-and-recirculate queueing network with capacity constraints on subnetworks. Due to this blocking protocol, the stationary distribution of the queueing network is highly intractable.We propose an approximation method based on jump-over blocking. Multi-classjump-over queueing networks admit a product-form stationary distributionand can be efficiently evaluated by Mean Value Analysis (MVA)and Norton's theorem. This method can be applied during the design phaseof sequential zone picking systems to determine the number of segments, number and length of zones, buffer capacities, and storage allocation ofproducts to zones, to meet performance targets.For a wide range of parameters, the results show that the relative error in the system throughput is typically less than 1% compared to simulation.

AB - This paper develops a capacity model for sequential zone pickingsystems. These systems are popular internal transport and orderpicking systems, due to their scalability, flexibility, high-throughput ability,and fit-for-use for a wide range of products and order profiles. The major disadvantage of such systems is congestion and blocking under heavy use, leading to long order throughput times. To reduce blocking and congestion, most systems use the block-and-recirculate protocol to dynamically manage workload. In this paper, the various elements of the system, such as conveyor lanes and pick zones, are modeled as a multi-class block-and-recirculate queueing network with capacity constraints on subnetworks. Due to this blocking protocol, the stationary distribution of the queueing network is highly intractable.We propose an approximation method based on jump-over blocking. Multi-classjump-over queueing networks admit a product-form stationary distributionand can be efficiently evaluated by Mean Value Analysis (MVA)and Norton's theorem. This method can be applied during the design phaseof sequential zone picking systems to determine the number of segments, number and length of zones, buffer capacities, and storage allocation ofproducts to zones, to meet performance targets.For a wide range of parameters, the results show that the relative error in the system throughput is typically less than 1% compared to simulation.

M3 - Article

JO - Operations Research

JF - Operations Research

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