•
•
•
•
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 GPr
o
d
u
ctiv
ity (o
rd
e
rs/m
an
h
o
u
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
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
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
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?
•
•
•
•
•
•
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
✅
𝑚𝑖𝑛 ∑ ∑(𝑐
𝑖𝑗𝐻𝑑
𝑖𝑗𝐻+ 𝑐
𝑖𝑗𝑉𝑑
𝑖𝑗𝑉)𝑓
𝑖𝑗 𝑁𝑗=1 𝑁 𝑖=1
𝑐
𝑖𝑗𝐻𝑑
𝑖𝑗𝐻𝑐
𝑖𝑗𝑉𝑑
𝑖𝑗𝑉𝑎
𝑖𝑗= 1 𝑖𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑖 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑠 𝑎𝑛 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑎𝑡 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑗 , 0 𝑜𝑡ℎ𝑒𝑟𝑤𝑖𝑠𝑒
𝑆
𝑖𝑗𝑚=
∑𝑝𝑘=1𝑎𝑖𝑘𝑎𝑗𝑘 ∑𝑝𝑘=1(𝑎𝑖𝑘+𝑎𝑗𝑘−𝑎𝑖𝑘𝑎𝑗𝑘)
𝑆
𝑖𝑗𝑚𝑎
𝑖𝑘𝑆
𝑖𝑗𝑝=
∑𝑚𝑘=1𝑎𝑘𝑖𝑎𝑘𝑗𝑀𝑎𝑥𝑖𝑚𝑖𝑧𝑒 ∑ ∑ 𝑆
𝑖𝑗𝑝𝑥
𝑖𝑗 𝑝 𝑗=1 𝑝 𝑖=1𝑠𝑢𝑏𝑗𝑒𝑐𝑡 𝑡𝑜:
∑ 𝑥
𝑖𝑗= 1,
𝑝𝑗=1
𝑖 = 1,2, … , 𝑝
∑ 𝑥
𝑗𝑗= 𝑛
𝑝𝑗=1
,
𝑥
𝑖𝑗≤ 𝑥
𝑗𝑗,𝑖, 𝑗 = 1,2, … , 𝑝,
𝑥
𝑖𝑗∈ {0,1}, 𝑖, 𝑗 = 1,2, … , 𝑝,
𝑆
𝑖𝑗𝑝𝑥
𝑖𝑗𝑊𝑜𝑟𝑘 𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠 𝑘 = 1, … , 𝑚
𝑇𝑎𝑠𝑘 𝑠𝑒𝑡 𝑉 = {1 … 𝑛}
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑙𝑜𝑎𝑑 𝑓𝑜𝑟 𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑖𝑛𝑔 𝑜𝑛𝑒 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒 = 𝑡
𝑠𝑢𝑚𝑆𝑒𝑡 𝑜𝑓 𝑡𝑎𝑠𝑘𝑠 𝑎𝑠𝑠𝑖𝑔𝑛𝑒𝑑 𝑡𝑜 𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛 𝑘 = 𝑆𝑘 (𝑘 = 1, … , 𝑚)
𝑀𝑖𝑛 ∑ ∑ |𝑇(𝑆
𝑥) − 𝑇(𝑆
𝑦)|
𝑦𝑥
𝑇(𝑆
𝑥) = ∑
𝑗𝜖𝑆𝑥𝑡
𝑗•
•
39%
36%
67%
77%
75%
75%
0%
20%
40%
60%
80%
100%
•
•
•
•
Order
Orderline (T-shirt)
Item
Item
Item
Orderline
(Socks)
Item
Item
Orderline
(Glasses)
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
•
•
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
•
•
•
•
•
•
•
•
β
•
•
•
•
•
•
•
•
•
•
•
•
•
•
𝛼 = (
𝜇
𝑠
)
2
𝛽 =
𝑠
2𝜇
𝜇
𝑠
𝑠
20
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
219 220
=
λ
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 =
𝑀𝑇𝑇𝐹•
•
•
•
•
𝑚𝑖𝑛 ∑ ∑(𝑐
𝑖𝑗𝐻𝑑
𝑖𝑗𝐻+ 𝑐
𝑖𝑗𝑉𝑑
𝑖𝑗𝑉)𝑓
𝑖𝑗 𝑁𝑗=1 𝑁 𝑖=1
𝑚𝑖𝑛 ∑ ∑(𝑐
𝑖𝑗𝑑
𝑖𝑗)𝑓
𝑖𝑗 𝑁𝑗=1 𝑁 𝑖=1
𝑓
𝑖𝑗𝑐
𝑖𝑗𝑑
𝑖𝑗𝑐
𝑖𝑗𝑓
𝑖𝑗𝑆
𝑖𝑗𝑚=
∑𝑝𝑘=1𝑎𝑖𝑘𝑎𝑗𝑘 ∑𝑝𝑘=1(𝑎𝑖𝑘+𝑎𝑗𝑘−𝑎𝑖𝑘𝑎𝑗𝑘)
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
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
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
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
€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
(€)
•
•
•
•
•
•
•
•
•
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 GPr
o
d
u
ctiv
ity
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 GPr
o
d
u
ctiv
ity
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amount of entries : 322
Exclude (-305) Filtering based on title and abstract and removing overlap
amount of entries: 1055
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