An Efficient Approach to Investigate the Tradeoff between Double Handling and Needed Capacity in Automated Distribution Centers

Mohammed Alnahhal, Bashir Salah and Mohammed Ruzayqat
Additional contact information
Mohammed Alnahhal: Mechanical and Industrial Engineering Department, American University of Ras Al Khaimah, Ras Al Khaimah P.O. Box 10021, United Arab Emirates
Bashir Salah: Department of Industrial Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia
Mohammed Ruzayqat: Transport Systems and Logistics, Department of Mechanical and Process Engineering, University of Duisburg-Essen, Keetmanstraße 3-9, 47058 Duisburg, Germany

Sustainability, 2022, vol. 14, issue 13, 1-25

Abstract: Sustainable techniques in distribution centers, such as automation that reduces the land area needed, can be utilized. Automated Storage and Retrieval Systems (AS/RS) are used to efficiently manage the flow of pallets and carton cases in distribution centers. There are two types of AS/RS: one for pallets and another type for cases that are depalletized from pallets. Further enhancements on the system are obtained by investigating both warehouses together. This paper investigates an efficient approach that directly affects the conceptual design of automated distribution centers for the purpose of reducing the total costs. The tradeoff between the throughput (defined by the level of double handling) and warehouse capacity is investigated in this study by finding the best lot sizing rules for different classes of products (A, B, and C). These rules are to determine the method of moving carton cases from the first warehouse to the second one. The number of stacker cranes is determined based on the found throughput. The effect of double handling of pallets on the design is considered for the first time in this study. Analytical formulas and simulation were used to find the throughput and capacity based on the mentioned lot sizing rules. Then, an integer nonlinear model was developed to optimize the system. According to the results of the assumed data, the model can save up to 19.5%. The costs of stacker cranes were found to account for approximately 78.7% of the total costs in the best solution found. A decision support system has been developed to help decision makers find an efficient design of distribution center.

Keywords: Automated Storage and Retrieval System; material flow; warehouses; throughput; conceptual design; double handling; ABC analysis (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2022
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (2)

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