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(1)
(2)
(3)
(4)
(5)
(6)
(7)

26,

24

26,

49

30,

87

29,

87

30,

49

30,75

31,

84

31,

72

31,

69

36,

28

27,

07

27,

44

31,

23

31,

20

30,

83

32,

76

31,

90

31,

90

35,

96

36,59

27,

45

28,

06

29,

31

31,

66

31,

54

33,05

31,

60

31,

93

36,

27

36,

51

22,

93

22,

79

29,

75

29,

58

30,

35

33,

8

32,

53

36,

1

37,08

20

22

24

26

28

30

32

34

36

38

B A S E L A Y O U T B A S E L A Y O U T + B A L A N C IN G B A S E L A Y O U T + B A L A N C IN G + A U T O M A T E D P A C K IN G D IS T A N C E M IN IM IZ A T IO N L A Y O U T D IS T A N C E M IN IM IZ A T IO N L A Y O U T + B A L A N C IN G D IS T A N C E M IN IM IZ A T IO N L A Y O U T + O N L IN E B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T C E L L U L A R M A N U F A C T U R IN G L A Y O U T + B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T + O N L IN E B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T + O N L IN E B A L A N C IN G + A U T O M A T E D P A C K IN G

Pr

o

d

u

ctiv

ity (o

rd

e

rs/m

an

h

o

u

(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)

(21)

(22)
(23)

Phase 1 Identification of the problem

Phase 2 Formulation of

problem approach

Phase 3 Analysis of the

problem

Phase 4 Generation of

alternative solutions Phase 5

Choice of the best alternative Phase 6

Implementation of the chosen

solution Phase 7 Evaluation of

(24)

Effects for storage allocation/operations

Creating an implementation model that determines which orders should be processed by the autostore, in which sequence and using which

machines or processing paths

Selection of the best solution

Weighing of different KPIs and adressing pros and cons of the alternatives

Layout evaluation

Simulation study

Productivity evaluation for all alternatives

New layout design

Elaborated versions of the alternatives generated in the previous phase

Generation of alternatives

Using internal and external ideas for new layout designs

Current situation analysis

Requirements for product

families

Requirements for the processing

line

Customer requirements

(25)

2

Literature research - Which relevant theory can be found in literature?

1

Current situation analysis - What does the current system look like in detail?

Model design - How can we model the AutoStore order processing line?

3

Generated alternatives - Which promising alternatives should be investigated?

4, 5

Evaluation of alternatives - What will be the effects of the various new layouts?

(26)
(27)

(28)

(29)

(30)
(31)

𝑚𝑖𝑛 ∑ ∑(𝑐

𝑖𝑗𝐻

𝑑

𝑖𝑗𝐻

+ 𝑐

𝑖𝑗𝑉

𝑑

𝑖𝑗𝑉

)𝑓

𝑖𝑗 𝑁

𝑗=1 𝑁 𝑖=1

𝑐

𝑖𝑗𝐻

𝑑

𝑖𝑗𝐻

𝑐

𝑖𝑗𝑉

𝑑

𝑖𝑗𝑉

(32)
(33)
(34)

𝑎

𝑖𝑗

= 1 𝑖𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑖 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑠 𝑎𝑛 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑎𝑡 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑗 , 0 𝑜𝑡ℎ𝑒𝑟𝑤𝑖𝑠𝑒

𝑆

𝑖𝑗𝑚

=

∑𝑝𝑘=1𝑎𝑖𝑘𝑎𝑗𝑘 ∑𝑝𝑘=1(𝑎𝑖𝑘+𝑎𝑗𝑘−𝑎𝑖𝑘𝑎𝑗𝑘)

𝑆

𝑖𝑗𝑚

𝑎

𝑖𝑘

𝑆

𝑖𝑗𝑝

=

∑𝑚𝑘=1𝑎𝑘𝑖𝑎𝑘𝑗

(35)

𝑀𝑎𝑥𝑖𝑚𝑖𝑧𝑒 ∑ ∑ 𝑆

𝑖𝑗𝑝

𝑥

𝑖𝑗 𝑝 𝑗=1 𝑝 𝑖=1

𝑠𝑢𝑏𝑗𝑒𝑐𝑡 𝑡𝑜:

∑ 𝑥

𝑖𝑗

= 1,

𝑝

𝑗=1

𝑖 = 1,2, … , 𝑝

∑ 𝑥

𝑗𝑗

= 𝑛

𝑝

𝑗=1

,

𝑥

𝑖𝑗

≤ 𝑥

𝑗𝑗,

𝑖, 𝑗 = 1,2, … , 𝑝,

𝑥

𝑖𝑗

∈ {0,1}, 𝑖, 𝑗 = 1,2, … , 𝑝,

𝑆

𝑖𝑗𝑝

𝑥

𝑖𝑗

(36)

𝑊𝑜𝑟𝑘 𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠 𝑘 = 1, … , 𝑚

𝑇𝑎𝑠𝑘 𝑠𝑒𝑡 𝑉 = {1 … 𝑛}

𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑙𝑜𝑎𝑑 𝑓𝑜𝑟 𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑖𝑛𝑔 𝑜𝑛𝑒 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒 = 𝑡

𝑠𝑢𝑚

𝑆𝑒𝑡 𝑜𝑓 𝑡𝑎𝑠𝑘𝑠 𝑎𝑠𝑠𝑖𝑔𝑛𝑒𝑑 𝑡𝑜 𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛 𝑘 = 𝑆𝑘 (𝑘 = 1, … , 𝑚)

(37)

𝑀𝑖𝑛 ∑ ∑ |𝑇(𝑆

𝑥

) − 𝑇(𝑆

𝑦

)|

𝑦

𝑥

𝑇(𝑆

𝑥

) = ∑

𝑗𝜖𝑆𝑥

𝑡

𝑗

(38)

(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)

39%

36%

67%

77%

75%

75%

0%

20%

40%

60%

80%

100%

(48)

(49)
(50)

Order

Orderline (T-shirt)

Item

Item

Item

Orderline

(Socks)

Item

Item

Orderline

(Glasses)

(51)

0

200

400

600

800

1000

1200

1400

1600

1800

2000

Monday

Tuesday Wednesday Thursday

Friday

Saturday

Sunday

Orders

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

0

10

20

30

40

50

60

70

00:00

-01:59

02:00

-03:59

04:00

-05:59

06:00

-07:59

08:00

-09:59

10:00

-11:59

12:00

-13:59

14:00

-15:59

16:00

-17:59

18:00

-19:59

20:00

-21:59

22:00

-23:59

Ord

er

in

flow

p

er

h

o

u

r

Timeframe

(52)
(53)

0

5

10

15

20

25

30

0

5

10

15

20

25

30

ma

di

wo

do

vr

za

zo

Pro

d

u

ctiv

(54)
(55)
(56)
(57)

(58)
(59)
(60)

β

(61)

(62)
(63)

(64)

(65)
(66)
(67)
(68)

𝛼 = (

𝜇

𝑠

)

2

𝛽 =

𝑠

2

𝜇

𝜇

𝑠

𝑠

2

0

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

1

3

5

7

9

11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

Gamma distribution fit

(69)

219 220

=

λ

𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 =

𝑀𝑇𝑇𝐹

(70)
(71)
(72)
(73)
(74)
(75)

(76)
(77)
(78)
(79)

𝑚𝑖𝑛 ∑ ∑(𝑐

𝑖𝑗𝐻

𝑑

𝑖𝑗𝐻

+ 𝑐

𝑖𝑗𝑉

𝑑

𝑖𝑗𝑉

)𝑓

𝑖𝑗 𝑁

𝑗=1 𝑁 𝑖=1

𝑚𝑖𝑛 ∑ ∑(𝑐

𝑖𝑗

𝑑

𝑖𝑗

)𝑓

𝑖𝑗 𝑁

𝑗=1 𝑁 𝑖=1

𝑓

𝑖𝑗

𝑐

𝑖𝑗

𝑑

𝑖𝑗

𝑐

𝑖𝑗

𝑓

𝑖𝑗

(80)
(81)
(82)
(83)

𝑆

𝑖𝑗𝑚

=

∑𝑝𝑘=1𝑎𝑖𝑘𝑎𝑗𝑘 ∑𝑝𝑘=1(𝑎𝑖𝑘+𝑎𝑗𝑘−𝑎𝑖𝑘𝑎𝑗𝑘)

(84)
(85)
(86)
(87)
(88)
(89)
(90)
(91)
(92)
(93)
(94)
(95)
(96)
(97)
(98)

26,

24

29,

87

31,

84

27,

07

31,

20

31,

90

27,45

31,

66

31,

60

22,

93

29,

58

20

22

24

26

28

30

32

34

B A S E L A Y O U T

D I S T A N C E

M I N I M I Z A T I O N L A Y O U T

C E L L U L A R

M A N U F A C T U R I N G

L A Y O U T

Pr

o

d

u

ctiv

ity

(99)

26,

24

26,

49

30,

87

27,

07

27,44

31,

23

27,

45

28,

06

29,

31

22,

93

22,

79

29,

75

20

22

24

26

28

30

32

B A S E L A Y O U T

B A S E L A Y O U T B A L A N C E D

B A S E L A Y O U T B A L A N C E D

A U T O M A T E D P A C K I N G

Pr

o

d

u

ctiv

ity

(100)

29,87

30,

49

30,

75

31,

20

30,

83

32,76

31,

66

31,

54

33,

05

29,

58

30,

35

33,

8

27

28

29

30

31

32

33

34

35

D I S T A N C E M I N I M I Z A T I O N

L A Y O U T

D I S T A N C E M I N I M I Z A T I O N

L A Y O U T B A L A N C E D

D I S T A N C E M I N I M I Z A T I O N

L A Y O U T B A L A N C E D O N L I N E

PR

O

DU

CT

IV

IT

Y

(101)

31,

84

31,

72

31,

69

36,

28

31,

90

31,

90

35,

96

59

36,

31,

60

31,

93

36,

27

36,

51

32,

53

36,

1

37,08

30

31

32

33

34

35

36

37

38

C E L L U L A R

M A N U F A C T U R I N G

L A Y O U T

C E L L U L A R

M A N U F A C T U R I N G

L A Y O U T B A L A N C E D

C E L L U L A R

M A N U F A C T U R I N G

L A Y O U T B A L A N C E D

O N L I N E

C E L L U L A R

M A N U F A C T U R I N G

L A Y O U T B A L A N C E D

O N L I N E A U T O M A T E D

P A C K I N G

Pr

o

d

u

ctiv

ity

(102)
(103)

€0,00

€0,20

€0,40

€0,60

€0,80

€1,00

€1,20

€1,40

20

25

30

35

40

La

b

o

u

r

cos

ts

p

er

o

rd

er

(€)

(104)
(105)
(106)
(107)
(108)
(109)

(110)

(111)
(112)
(113)
(114)

26,

24

26,

49

30,

87

29,

87

30,

49

30,

75

31,

84

31,

72

31,

69

36,

28

27,

07

27,

44

31,

23

31,

20

30,

83

32,

76

31,

90

31,

90

35,

96

36,

59

27,

45

28,

06

29,

31

31,

66

31,

54

33,

05

31,

60

31,

93

36,

27

36,

51

22,

93

22,

79

29,

75

29,

58

30,

35

33,

8

32,

53

36,

1

37,

08

20

22

24

26

28

30

32

34

36

38

B A S E L A Y O U T B A S E L A Y O U T + B A L A N C IN G B A S E L A Y O U T + B A L A N C IN G + A U T O M A T E D P A C K IN G D IS T A N C E M IN IM IZ A T IO N L A Y O U T D IS T A N C E M IN IM IZ A T IO N L A Y O U T + B A L A N C IN G D IS T A N C E M IN IM IZ A T IO N L A Y O U T + O N L IN E B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T C E L L U L A R M A N U F A C T U R IN G L A Y O U T + B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T + O N L IN E B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T + O N L IN E B A L A N C IN G + A U T O M A T E D P A C K IN G

Pr

o

d

u

ctiv

ity

(115)
(116)
(117)

Base Layout

Base Layout + Balancing

Base Layout + Balancing + Automated Packing

Distance Minimization Layout

Distance Minimization Layout + Balancing

Distance Minimization Layout + Online Balancing

Cellular Manufacturing Layout

Cellular Manufacturing Layout + Balancing

Cellular Manufacturing Layout + Online Balancing

Cellular Manufacturing Layout + Online Balancing + Automated Packing

26,

24

26,

49

30,

87

29,

87

30,

49

30,

75

31,

84

31,

72

31,

69

36,

28

27,

07

27,

44

31,

23

31,

20

30,

83

32,

76

31,

90

31,

90

35,

96

36,

59

27,

45

28,

06

29,

31

31,

66

31,

54

33,

05

31,

60

31,

93

36,

27

36,

51

22,

93

22,

79

29,

75

29,

58

30,

35

33,

8

32,

53

36,

1

37,

08

20

22

24

26

28

30

32

34

36

38

B A S E L A Y O U T B A S E L A Y O U T + B A L A N C IN G B A S E L A Y O U T + B A L A N C IN G + A U T O M A T E D P A C K IN G D IS T A N C E M IN IM IZ A T IO N L A Y O U T D IS T A N C E M IN IM IZ A T IO N L A Y O U T + B A L A N C IN G D IS T A N C E M IN IM IZ A T IO N L A Y O U T + O N L IN E B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T C E L L U L A R M A N U F A C T U R IN G L A Y O U T + B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T + O N L IN E B A L A N C IN G C E L L U L A R M A N U F A C T U R IN G L A Y O U T + O N L IN E B A L A N C IN G + A U T O M A T E D P A C K IN G

Pr

o

d

u

ctiv

ity

(118)
(119)
(120)
(121)
(122)
(123)
(124)

Final amount of entries : 17

amount of entries : 322

Exclude (-305) Filtering based on title and abstract and removing overlap

amount of entries: 1055

Exclude (- 733 ) Articles with < 10 citations

amount of entries: 1536

Refine (-73) Only articles in the "Business, management and accounting" and the

(125)

Final amount of entries : 4

amount of entries : 45

Exclusion (-41)

Inspection of title and thereafter the abstract

amount of entries: 57

Refine (-12)

Subject area: Business AND Engineering

amount of entries: 158

(126)

Final amount of entries : 12

amount of entries :152

Exclude (-140)

Inspection of title and thereafter the abstract

amount of entries: 594

Exclude (-442)

Only article with > 10 citations

amount of entries: 807

(127)
(128)
(129)
(130)
(131)
(132)
(133)
(134)
(135)
(136)

0

5

10

15

20

25

30

35

40

45

50

Fr

e

q

u

e

n

cy

Bin

Frequency

(137)

0

5

10

15

20

25

30

0

5

10

15

20

25

30

Th

eo

re

tical

q

u

ar

tile

s

Sample quartiles

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

0

0,2

0,4

0,6

0,8

1

Exp

ected

cu

m

u

lat

iv

e

p

ro

b

ab

ili

ty

(138)
(139)
(140)
(141)
(142)

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