warehousing systems design - isye homemgoetsch/cali/warehousing systems design... · warehousing...
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 1
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing SystemsDesign
Marc Goetschalckx, Michael Amirhosseini,Doug Bodner, T. Govindaraj,
Leon McGinnis, Gunter Sharp,Industrial and Systems Engineering
Georgia Institute of TechnologyAtlanta, GA 30332-0205
(404) 894-2317
24-May-00 Warehousing Systems Design Marc Goetschalckx
Credits
✯ Industry• M. Amirhosseini (UPS WWL)
✯ Faculty• L. McGinnis, T. Govindaraj, D. Bodner, M.
Goetschalckx, G. Sharp✯ Graduate Students
• E. Blanco, M. Insalaco, P. Bellur, A. Parfenov✯ Sponsors
• NSF, Ford Motor, UPS WWL, Keck Foundation
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 2
24-May-00 Warehousing Systems Design Marc Goetschalckx
Distribution WarehouseFunctional Areas Illustration
24-May-00 Warehousing Systems Design Marc Goetschalckx
Changing WarehousingRequirements
✯ Faster Turns, Shorter Life Cycles• Warehouse operations• Warehouse design
✯ Proliferation of InformationTechnology• WMS, tracking
✯ Design-As-Usual
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 3
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing Design Objective
The goal of warehouse design is tominimize the discounted presentvalue of the costs ofestablishing and operating thewarehouse over some horizonspecified by the decision-maker,subject to a number of resource andperformance constraints.
24-May-00 Warehousing Systems Design Marc Goetschalckx
State-of-the-Art in WarehousingDesign
✯ Reviews and Bibliography• Rouwenhorst, Goetschalckx (www)
✯ Analysis of Isolated Components• Numerous, focussed, uneven• Detailed simulation and animation• Clearly suboptimal• No impact on the practice of
warehousing design
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 4
24-May-00 Warehousing Systems Design Marc Goetschalckx
State-of-the-Art in WarehousingDesign continued
✯ No Structured, Integrated DesignMethodology• No model for warehousing operations• No explicit design theory
✯ Consulting-University Cooperativesfor DSS and Education• Twente, Dortmund, Darmstadt, Georgia
Tech
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing DesignMethodology Needs
✯ Integration of Isolated Research andMethods
✯ Rich Empirical Data Sets✯ Rigorous Mathematical Models✯ Synthesis and Design Tools
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 5
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing Design andOperations Education Status
✯ Mirrors State-of-the-Art• Focussed, uneven, analysis
✯ High Demand• Bachelors, Graduate, and Professional
✯ Few Educational Materials• MHI and CICMHE• Several books in preparation
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing Design EducationEffort at Georgia Tech
✯ Asynchronous Education• www (http://www.isye.gatech.edu
/warehousing)– standard software (html, vrml…)
• client-server architecture– common and private components
✯ Rich, Industry-Grade Case Studies
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 6
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing DesignDevelopment at Georgia Tech
✯ Functional Flow Network✯ Object Oriented Data Base✯ Mathematical Design Models✯ Visualization
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing Functions
✯ Receiving✯ Storage - Holding✯ Order Picking - Retrieval✯ Consolidation - Sorting✯ Shipping
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 7
24-May-00 Warehousing Systems Design Marc Goetschalckx
Functional Flow Network forBasic Warehousing Functions
Receiving
Shipping
Order picking
Carton storageand picking
Inspection
Bulk storage
Material flow Function-to-space mapping
Order sort/accumulate
24-May-00 Warehousing Systems Design Marc Goetschalckx
Functional Flow NetworkCharacteristics
✯ Every Warehouse Has a DifferentFunctional Flow Network
✯ Different Products Can FollowDifferent and Multiple Paths
✯ Functions are Mapped to Areas,Areas are Mapped to MaterialHandling and Storage Equipment
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 8
24-May-00 Warehousing Systems Design Marc Goetschalckx
Object Classes in WarehouseDesign
Project Object(Design Control)
WarehousingObjects
(Common BuildingBlocks)
Operation Objects(Warehouse
Configuration andState)
Functional FlowObjects
(Requirements andProducts )
24-May-00 Warehousing Systems Design Marc Goetschalckx
Object Classes
✯ Design Object• Design project status
✯ Warehousing Objects• Equipment and policies and protocols
✯ Functional Flow Objects• Products and flows requirements
✯ Operations Objects• Design specification
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 9
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehousing Objects Structure(Equipment and Personnel)
24-May-00 Warehousing Systems Design Marc Goetschalckx
Operations Object Structure(Warehouse State)
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 10
24-May-00 Warehousing Systems Design Marc Goetschalckx
Design Optimization Model
Receiving
Bulk Store
Shipping
Total Cost Function
Global Constraints: Space, Budget, etc
GlobalDecisions
ReceivingDecisions
Bulk StoreDecisions
ShippingDecisions
Con
stra
ints
24-May-00 Warehousing Systems Design Marc Goetschalckx
Optimization ModelCharacteristics
✯ Optimization Decomposed byFunctional Areas
✯ Joint Space (Area), Manpower,Budget Constraints
✯ Economic Analysis Joint ObjectiveFunction
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 11
24-May-00 Warehousing Systems Design Marc Goetschalckx
Block Stacking Example:Software Program Interactions
1. User Inputs the1. User Inputs theRegion InformationRegion Information(VISIO)(VISIO)
Unix/PostGres
2. Block Stacking 2. Block Stacking AlgorithmAlgorithm
3. Display Results3. Display Results(VISIO + VRML)(VISIO + VRML)
24-May-00 Warehousing Systems Design Marc Goetschalckx
Department Block Layout inVisio
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 12
24-May-00 Warehousing Systems Design Marc Goetschalckx
Access Tables and Relations
24-May-00 Warehousing Systems Design Marc Goetschalckx
Block Stacking Layout in Visio
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 13
24-May-00 Warehousing Systems Design Marc Goetschalckx
Block Stacking Layout in VRML
24-May-00 Warehousing Systems Design Marc Goetschalckx
Rotated Block Stacking Layoutin VRML
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 14
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Side View with Storage Systems
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Top View with Storage Systems
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 15
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Side View with Floor Stacking
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Interior View
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 16
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Inside the Aisle View
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Truck View Animation
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 17
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Top View with All Elements
24-May-00 Warehousing Systems Design Marc Goetschalckx
Warehouse VRML Visualization:Interior View without Stock
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Warehousing Systems Design 24-May-00
Copyright © 1997-2000, Marc Goetschalckx, All rights reserved. 18
24-May-00 Warehousing Systems Design Marc Goetschalckx
Thank YouCan I Answer Any Questions?