Journal
IIE TRANSACTIONS
Volume 45, Issue 12, Pages 1309-1321Publisher
TAYLOR & FRANCIS INC
DOI: 10.1080/0740817X.2013.772691
Keywords
Warehouse design; low-level order picking system; storage classes; class-based storage; optimal partitions; sorting and assembling; multi-item order picking; pick list size; warehouse layout; two-block warehouse layout
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This article considers a two-block warehouse with low-level aisles having dedicated pickers who follow a return routing policy within the aisle. Travel distance models are formulated assuming a given product density distribution in aisles for multi-item picks. An analytical recursive procedure is developed to find optimal n-class partitions of each warehouse aisle. A range on the number of classes and number of picks for which class-based storage is an attractive option over the random storage policy is determined through a computational study. The article also presents an iterative hierarchical framework to simultaneously obtain pick list size, number of aisles, and class storage boundaries. A sensitivity analysis of optimal pick travel distance against important warehouse design parameters is presented.
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