Research on warehouse design and performance evaluation: A comprehensive review

European Journal of Operational Research

Volumn 203, Issue 3, 2010, Pages 539-549

  Gu, Jinxiang ^a   Goetschalckx, Marc ^b   McGinnis, Leon F ^b  

^a NESTLÉ RESEARCH CENTER   (Switzerland)

^b GEORGIA INSTITUTE OF TECHNOLOGY   (United States)

Author keywords

Case studies; Computational tools; Facilities design and planning; Warehouse design; Warehouse performance evaluation model

Indexed keywords

CASE STUDIES; COMPUTATIONAL TOOLS; FACILITIES DESIGN AND PLANNING; WAREHOUSE DESIGN; WAREHOUSE PERFORMANCE EVALUATION MODEL;

DESIGN; SURVEYS; WAREHOUSES;

RESEARCH;

EID: 70449529526     PISSN: 03772217     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.ejor.2009.07.031     Document Type: Review

References (130)

1. Ashayeri J., and Gelders L.F. Warehouse design optimization. European Journal of Operational Research 21 (1985) 285-294
2. Ashayeri J., Gelders L., and Wassenhove L.V. A microcomputer-based optimization model for the design of automated warehouses. International Journal of Production Research 23 4 (1985) 825-839
3. Ashayeri J., Heuts R.M., Valkenburg M.W.T., Veraart H.C., and Wilhelm M.R. A geometrical approach to computing expected cycle times for zone-based storage layouts in AS/RS. International Journal of Production Research 40 17 (2002) 4467-4483
4. Azadivar F. Maximizing of the throughput of a computerized automated warehousing system under system constraints. International Journal of Production Research 24 3 (1986) 551-566
5. Azadivar F. Optimum allocation of resources between the random access and rack storage spaces in an automated warehousing system. International Journal of Production Research 27 1 (1989) 119-131
6. Bartholdi J.J., Eisenstein D.D., and Foley R.D. Performance of bucket brigades when work is stochastic. Operations Research 49 5 (2000) 710-719
7. Bassan Y., Roll Y., and Rosenblatt M.J. Internal layout design of a warehouse. AIIE Transactions 12 4 (1980) 317-322
8. BEA, 2008. Table 5.7.5B. Private Inventories and Domestic Final Sales by Industry accessed at >http://bea.gov/national/nipaweb/TableView.asp?SelectedTable=153&FirstYear=2005&LastYear=2007&Freq=Qtr>.
9. Berry J.R. Elements of warehouse layout. International Journal of Production Research 7 2 (1968) 105-121
10. Bhaskaran K., and Malmborg C.J. Modelling the service process in a multi-address warehousing system. Applied Mathematical Modelling 13 7 (1989) 386-396
11. Bozer Y.A., and White J.A. Travel-time models for automated storage/retrieval systems. IIE Transactions 16 4 (1984) 329-338
12. Bozer Y.A., and White J.A. Design and performance models for end-of-aisle order picking systems. Management Science 36 7 (1990) 852-866
13. Bozer Y.A., and White J.A. A generalized design and performance analysis models for end-of-aisle order-picking systems. IIE Transactions 28 (1996) 271-280
14. Brynzer H., and Johansson M.I. Design and performance of kitting and order picking systems. International Journal of Production Economics 41 (1995) 115-125
15. Burkard R.E., Fruhwirth B., and Rote G. Vehicle routing in an automated warehouse: Analysis and optimization. Annals of Operations Research 57 (1995) 29-44
16. Caron F., Marchet G., and Perego A. Routing policies and COI-based storage policies in picker-to-part systems. International Journal of Production Research 36 3 (1998) 713-732
17. Caron F., Marchet G., and Perego A. Optimal layout in low-level picker-to-part systems. International Journal of Production Research 38 1 (2000) 101-117
18. Chang D.-T., and Wen U.-P. The impact of rack configuration on the speed profile of the storage and retrieval machine. IIE Transactions 29 (1997) 525-531
19. Chang D.-T., Wen U.-P., and Lin J.T. The impact of acceleration/deceleration on travel-time models for automated storage/retrieval systems. IIE Transactions 27 (1995) 108-111
20. Chew E.P., and Tang L.C. Travel time analysis for general item location assignment in a rectangular warehouse. European Journal of Operational Research 112 (1999) 582-597
21. Chow W.-M. An analysis of automated storage and retrieval systems in manufacturing assembly lines. IIE Transactions 18 2 (1986) 204-214
22. Cormier G. Operational research methods for efficient warehousing. In: Langevin A., and Riopel D. (Eds). Logistics Systems: Design and Optimization (2005), Springer, Berlin 93-122
23. Cormier G., and Gunn E.A. A review of warehouse models. European Journal of Operational Research 58 (1992) 3-13
24. Cormier G., and Gunn E.A. On coordinating warehouse sizing, leasing and inventory policy. IIE Transactions 28 (1996) 149-154
25. Cormier G., and Gunn E.A. Modelling and analysis for capacity expansion planning in warehousing. Journal of the Operational Research Society 50 1 (1999) 52-59
26. Cormier G., and Kersey D.F. Conceptual design of a warehouse for just-in-time operations in a bakery. Computers and Industrial Engineering 29 1-4 (1995) 361-365
27. Cox, B., 1986. Determining economic levels of automation by using a hierarchy of productivity ratios techniques, in: Proceedings of 7th International Conference on Automation in Warehousing.
28. Daskin M.S., Snyder L.V., and Berger R.T. Facility location in supply chain design. In: Langevin A., and Riopel D. (Eds). Logistics Systems: Design and Optimization (2005), Springer Science, Business Media, Inc., New York 39-65
29. Dekker R., de Koster M.B.M., Roodbergen K.J., and van Kalleveen H. Improving order-picking response time at Ankor's warehouse. Interfaces 34 4 (2004) 303-313
30. de Koster R. Performance approximation of pick-to-belt orderpicking systems. European Journal of Operational Research 72 3 (1994) 558-573
31. Eynan A., and Rosenblatt M.J. Establishing zones in single-command class-based rectangular AS/RS. IIE Transactions 26 1 (1994) 38-46
32. Foley R., and Frazelle E.H. Analytical results for miniload throughput and the distribution of dual command travel time. IIE Transactions 23 3 (1991) 273-281
33. Foley R., Frazelle E.H., and Park B.C. Throughput bounds for miniload automated storage/retrieval systems. IIE Transactions 34 10 (2002) 915-920
34. Francis R.L. On some problems of rectangular warehouse design and layout. The Journal of Industrial Engineering 18 (1967) 595-604
35. Goetschalckx M., and Ratliff H.D. Shared storage policies based on the duration stay of unit loads. Management Science 36 9 (1990) 1120-1132
36. Goetschalckx M., and Ratliff H.D. Optimal lane depths for single and multiple products in block stacking storage systems. IIE Transactions 23 3 (1991) 245-258
37. Goh M., Ou J., and Teo C.-P. Warehouse sizing to minimize inventory and storage costs. Naval Research Logistics 48 4 (2001) 299-312
38. Graves S.C., Hausman W.H., and Schwarz L.B. Storage-retrieval interleaving in automatic warehousing systems. Management Science 23 9 (1977) 935-945
39. Gray A.E., Karmarkar U.S., and Seidmann A. Design and operation of an order-consolidation warehouse: models and applications. European Journal of Operational Research 58 (1992) 14-36
40. Gu J.X., Goetschalckx M., and McGinnis L.F. Research on warehouse operation: A comprehensive review. European Journal of Operational Research 177 1 (2007) 1-21
41. Ha J.-W., and Hwang H. Class-based storage assignment policy in carousel system. Computers and Industrial Engineering 26 3 (1994) 489-499
42. Hackman S.T., Frazelle E.H., Griffin P.M., Griffin S.O., and Vlasta D.A. Benchmarking warehouse and distribution operations: An input-output approach. Journal of Productivity Analysis 16 (2001) 79-100
43. Hall R.W. Distance approximation for routing manual pickers in a warehouse. IIE Transactions 25 4 (1993) 76-87
44. Han M.H., and McGinnis L.F. Carousel Application for Work-in-process: Modelling and Analysis (1986), Material Handling Research Center, Georgia Institute of Technology, Atlanta, Georgia
45. Han M.H., McGinnis L.F., Shieh J.S., and White J.A. On sequencing retrievals in an automated storage/retrieval system. IIE Transactions 19 1 (1987) 56-66
46. Han M.H., McGinnis L.F., and White J.A. Analysis of rotary rack operation. Material Flow 4 (1988) 283-293
47. Hausman W.H., Schwarz L.B., and Graves S.C. Optimal storage assignment in automatic warehousing systems. Management Science 22 6 (1976) 629-638
48. Heragu S.S., Du L., Mantel R.J., and Schuur P.C. Mathematical model for warehouse design and product allocation. International Journal of Production Research 43 2 (2005) 327-338
49. Hung M.S., and Fisk C.J. Economic sizing of warehouses - A linear programming approach. Computers and Operations Research 11 1 (1984) 13-18
50. Hur S., Lee Y.H., Lim S.Y., and Lee M.H. A performance estimating model for AS/RS by M/G/1 queuing system. Computers and Industrial Engineering 46 (2004) 233-241
51. Hwang H., and Ha J.-W. Cycle time models for single/double carousel system. International Journal of Production Economics 25 (1991) 129-140
52. Hwang H., and Ko C.S. A study on multi-aisle system served by a single storage/retrieval machine. International Journal of Production Research 26 11 (1988) 1727-1737
53. Hwang H., and Lee S.B. Travel-time models considering the operating characteristics of the storage and retrieval machine. International Journal of Production Research 28 10 (1990) 1779-1789
54. Hwang H., and Song J.Y. Sequencing picking operations and travel time models for man-on-board storage and retrieval warehousing system. International Journal of Production Economics 29 (1993) 75-88
55. Hwang H., Kim C.-S., and Ko K.-H. Performance analysis of carousel systems with double shuttle. Computers and Industrial Engineering 36 (1999) 473-485
56. Hwang H., Oh Y.H., and Lee Y.K. An evaluation of routing policies for order-picking operations in low-level picker-to-part system. International Journal of Production Research 42 18 (2004) 3873-3889
57. Hwang H., Song Y.-K., and Kim K.-H. The impacts of acceleration/deceleration on travel time models for carousel systems. Computers and Industrial Engineering 46 (2004) 253-265
58. Ito T., Abadi J., and Mousavi S.M. Agent-based material handling and inventory planning in warehouse. Journal of Intelligent Manufacturing 13 3 (2002) 201-210
59. Jarvis J.M., and McDowell E.D. Optimal product layout in an order picking warehouse. IIE Transactions 23 1 (1991) 93-102
60. Johnson M.E., and Lofgren T. Model decomposition speeds distribution center design. Interfaces 24 5 (1994) 95-106
61. Johnson M.E., and Meller R.D. Performance analysis of split-case sorting systems. Manufacturing & Service Operations Management 4 4 (2002) 258-274
62. Kallina C., and Lynn J. Application of the cube-per-order index rule for stock location in a distribution warehouse. Interfaces 7 1 (1976) 37-46
63. Karasawa Y., Nakayama H., and Dohi S. Trade-off analysis for optimal design of automated warehouses. International Journal of Systems Science 11 5 (1980) 567-576
64. Kim J., and Seidmann A. A framework for the exact evaluation of expected cycle times in automated storage systems with full-turnover item allocation and random service requests. Computers and Industrial Engineering 18 4 (1990) 601-612
65. Kim B.-I., Graves R.J., Heragu S.S., and Onge A.S. Intelligent agent modeling of an industrial warehousing problem. IIE Transactions 34 7 (2002) 601-612
66. Koh S.G., Kim B.S., and Kim B.N. Travel time model for the warehousing system with a tower crane S/R machine. Computers and Industrial Engineering 43 3 (2002) 495-507
67. Kouvelis P., and Papanicolaou V. Expected travel time and optimal boundary formulas for a two-class-based automated storage/retrieval system. International Journal of Production Research 33 10 (1995) 2889-2905
68. Kulturel S., Ozdemirel N.E., Sepil C., and Bozkurt Z. Experimental investigation of shared storage assignment policies in automated storage/retrieval systems. IIE Transactions 31 8 (1999) 739-749
69. Larson N., March H., and Kusiak A. A heuristic approach to warehouse layout with class-based storage. IIE Transactions 29 (1997) 337-348
70. Lee H.S. Performance analysis for automated storage and retrieval systems. IIE Transactions 29 (1997) 15-28
71. Lee M.-K., and Hwang H. An approach in the design of a unit-load automated carousel storage system. Engineering Optimization 13 (1988) 197-210
72. Lee Y.H., Tanchoco J.M.A., and Chun S.J. Performance estimation models for AS/RS with unequal sized cells. International Journal of Production Research 37 18 (1999) 4197-4216
73. Levy J. The optimal size of a storage facility. Naval Research Logistics Quarterly 21 2 (1974) 319-326
74. Lin C.-H., and Lu I.-Y. The procedure of determining the order picking strategies in distribution center. International Journal of Production Economics (1999) 301-307
75. Linn R.J., and Wysk R.A. An expert system framework for automated storage and retrieval system control. Computers and Industrial Engineering 18 1 (1990) 37-48
76. Lowe T.J., Francis R.L., and Reinhardt E.W. A greedy network flow algorithm for a warehouse leasing problem. AIIE Transactions 11 3 (1979) 170-182
77. Luxhoj J.T., and Skarpness B.O. A manpower planning model for a distribution center: A case study. Material Flow 3 (1986) 251-261
78. Malmborg C.J. An integrated storage system evaluation model. Applied Mathematical Modelling 20 5 (1996) 359-370
79. Malmborg C.J. Interleaving models for the analysis of twin shuttle automated storage and retrieval systems. International Journal of Production Research 38 18 (2000) 4599-4610
80. Malmborg C.J. Rule of thumb heuristics for configuring storage racks in automated storage and retrieval systems design. International Journal of Production Research 39 3 (2001) 511-527
81. Malmborg C.J. Design optimization models for storage and retrieval systems using rail-guided vehicles. Applied Mathematical Modelling 27 12 (2003) 929-941
82. Malmborg C.J., and Al-Tassan K. Analysis of storage assignment policies in less than unit load warehousing systems. International Journal of Production Research 36 12 (1998) 3459-3475
83. Malmborg C.J., and Al-Tassan K. An integrated performance model for order picking systems with randomized storage. Applied Mathematical Modelling 24 2 (2000) 95-111
84. Marsh W.H. Elements of block storage design. International Journal of Production Research 17 4 (1979) 377-394
85. Marsh W.H. A comparison with Berry. International Journal of Production Research 21 2 (1983) 163-172
86. Matson J.O., and White J.A. Storage System Optimization. Production and Distribution Research Center (1981), Georgia Institute of Technology, Atlanta, Georgia
87. McGinnis, L.F., 2003. Best of breed warehouse performance assessment. In: Council on Logistics Management Annual Conference. Chicago, IL. .
88. Meller R.D., and Gau K.Y. Journal of Manufacturing Systems 15 5 (1996) 351
89. Meller R.D., and Klote J.F. A throughput model for carousel/VLM pods. IIE Transactions 36 8 (2004) 725-741
90. Meller R.D., and Mungwattana A. Multi-shuttle automated storage/retrieval systems. IIE Transactions 29 10 (1997) 925-938
91. Moder J.J., and Thornton H.M. Quantitative analysis of the factors affecting floor space utilization of palletized storage. The Journal of Industrial Engineering 16 1 (1965) 8-18
92. Pan C.-H., and Wang C.-H. A framework for the dual command cycle travel time model in automated warehousing systems. International Journal of Production Research 34 8 (1996) 2099-2117
93. Pandit R., and Palekar U.S. Response time considerations for optimal warehouse layout design. Journal of Engineering for Industry 115 (1993) 322-328
94. Park Y.H., and Webster D.B. Modelling of three-dimensional warehouse systems. International Journal of Production Research 27 6 (1989) 985-1003
95. Park B.C., Frazelle E.H., and White J.A. Buffer sizing models for end-of-aisle order picking systems. IIE Transactions 31 (1999) 31-38
96. Park B.C., Foley R.D., White J.A., and Frazelle E.H. Dual command travel times and miniload system throughput with turnover-based storage. IIE Transactions 35 4 (2003) 343-355
97. Park B.C., Park J.Y., and Foley R.D. Carousel system performance. Journal of Applied Probability 40 (2003) 602-612
98. Perlmann A.M., and Bailey M. Warehouse logistics systems - A CAD model. Engineering Costs and Production Economics 13 (1988) 229-237
99. Petersen C.G. An evaluation of order picking policies for mail order companies. Production and Operations Management 9 4 (2000) 319-335
100. Pliskin J.S., and Dori D. Ranking alternative warehouse area assignments: A multiattribute approach. IIE Transactions 14 1 (1982) 19-26
101. Potrc I., Lerher T., Kramberger J., and Sraml M. Simulation model of multi-shuttle automated storage and retrieval systems. Journal of Materials Processing Technology (2004) 236-244
102. Randhawa S.U., and Shroff R. Simulation-based design evaluation of unit load automated storage/retrieval systems. Computers and Industrial Engineering 28 1 (1995) 71-79
103. Randhawa S.U., McDowell E.D., and Wang W.-T. Evaluation of scheduling rules for single- and dual-dock automated storage/retrieval system. Computers and Industrial Engineering 20 4 (1991) 401-410
104. Rao A.K., and Rao M.R. Solution procedures for sizing of warehouses. European Journal of Operational Research 108 (1998) 16-25
105. Roberts S.D., and Reed R. Optimal warehouse bay configurations. AIIE Transactions 4 3 (1972) 178-185
106. Roll Y., Rosenblatt M.J., and Kadosh D. Determining the size of a warehouse container. International Journal of Production Research 27 10 (1989) 1693-1704
107. Roodbergen K.J., and Vis I.F.A. A model for warehouse layout. IIE Transactions 38 10 (2006) 799-811
108. Rosenblatt M.J., and Eynan A. Deriving the optimal boundaries for class-based automatic storage/retrieval systems. Management Science 35 12 (1989) 1519-1524
109. Roll, Y., Rosenblatt, M.J., 1983. Random versus grouped storage policies and their effect on warehouse capacity. Material Flow 1, 199-205.
110. Rosenblatt M.J., and Roll Y. Warehouse design with storage policy considerations. International Journal of Production Research 22 5 (1984) 809-821
111. Rosenblatt M.J., and Roll Y. Warehouse capacity in a stochastic environment. International Journal of Production Research 26 12 (1988) 1847-1851
112. Rosenblatt M.J., Roll Y., and Zyser V. A combined optimization and simulation approach for designing automated storage/retrieval systems. IIE Transactions 25 1 (1993) 40-50
113. Ross A., and Droge C. An integrated benchmarking approach to distribution center performance using DEA modeling. Journal of Operations Management 20 (2002) 19-32
114. Rowenhorst B., Reuter B., Stockrahm V., van Houtum G.J., Mantel R.J., and Zijm W.H.M. Warehouse design and control: Framework and literature review. European Journal of Operational Research 122 (2000) 515-533
115. Russell M.L., and Meller R.D. Cost and throughput modeling of manual and automated order fulfillment systems. IIE Transactions 35 (2003) 589-603
116. Schefczyk M. Industrial benchmarking: A case study of performance analysis techniques. International Journal of Production Economics 32 (1993) 1-11
117. Schwarz L.B., Graves S.C., and Hausman W.H. Scheduling policies for automatic warehousing systems: Simulation results. AIIE Transactions 10 3 (1978) 260-270
118. Sharp G.P., Vlasta D.A., and Houmas C.G. Economics of storage/retrieval systems for item picking (1994), Material Handling Research Center, Georgia Institute of Technology, Atlanta, Georgia
119. Su C.-T. Performance evaluation of carousel operation. Production Planning and Control 9 5 (1998) 477-488
120. Thonemann U.W., and Brandeau M.L. Optimal storage assignment policies for automated storage and retrieval systems with stochastic demands. Management Science 44 1 (1998) 142-148
121. Trunick, P.A., 2005. Can we hold the line on logistics costs? Logistics Today. .
122. van den Berg J.P. A literature survey on planning and control of warehousing systems. IIE Transactions 31 (1999) 751-762
123. van Oudheusden D.L., Tzen Y.-J., and Ko H.-T. Improving storage and order picking in a person-on-board AS/R system: A case study. Engineering Costs and Production Economics 13 (1988) 273-283
124. Wang J.-Y., and Yih Y. Using neural networks to select a control strategy for automated storage and retrieval systems (AS/RS). International Journal of Computer Integrated Manufacturing 10 6 (1997) 487-495
125. White J.A., and Francis R.L. Normative models for some warehouse sizing problems. AIIE Transactions 9 3 (1971) 185-190
126. White, J.A., DeMars, N.A., Matson, J.O., 1981. Optimizing storage system selection, in: Proceedings of the 4th International Conference on Automation in Warehousing, Tokyo, Japan.
127. Yoon C.S., and Sharp G.P. Example application of the cognitive design procedure for an order pick system: Case study. European Journal of Operational Research 87 (1995) 223-246
128. Yoon C.S., and Sharp G.P. A structured procedure for analysis and design of order pick systems. IIE Transactions 28 (1996) 379-389
129. Zeng A.Z., Mahan M., and Fluet N. Designing an efficient warehouse layout to facilitate the order-filling process: An industrial distributor's experience. Production and Inventory Management Journal 43 3-4 (2002) 83-88
130. Zollinger, H.A., 1996. Expanded methodology to concept horizontal transportation problem solutions. In: Graves, R.J., McGinnis, L.F., Medeiros, D.J., Ward, R.E., Wilhelm, M.R. (Eds.), Progress in Material Handling Research, pp. 651-663.