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Warehouse Zoning

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Times New Roman Symbol Default Design Warehouse Zoning & Bucket Brigades The two main concepts of zoning in contemporary warehousing Zone-based order picking The ... – PowerPoint PPT presentation

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Title: Warehouse Zoning


1
Warehouse Zoning Bucket Brigades
  • (Chpt. 9 in Bartholdi Hackman
  • also see
  • http//www.isye.gatech.edu/jjb/bucket-brigades.ht
    ml)

2
The two main concepts of zoning in contemporary
warehousing
  • Warehouse zoning The physical and/or logical
    segmentation of the warehouse / picking area,
    through
  • the employment of different storage modes and
    practices due to the product differentiation
    w.r.t.
  • dimensions,
  • physical characteristics
  • storage and material handling requirements
  • throughput,
  • etc.
  • the parallelization of the order-picking
    activity.

3
Zone-based order picking
Progressive Zoning / Order assembly
Parallel/Simultaneous Zoning (typically organized
in pick-waves with downstream sortation)
To sorting and consolidation
Z1
Z2
Z3
Z4
Z5
Order (Batch)
4
The problem and the problems of establishing
effective logical zones in Warehouse operations
  • The problem Try to achieve maximum utilization
    of the picking resources, by distributing
    equally the total (picking) workload among the
    defined zones.
  • The problems
  • The warehouse picking environment usually is a
    very dynamic environment workload profiles are
    constantly changing.
  • Existing zoning systems seek to balance the
    average workloads across zones, based on some
    hypothetical order work-content and worker
    behavioral models.
  • Furthermore, constant zone redefinition requires
    a lot of effort from, both, the warehouse
    management (who must keep track of all the
    workload changes and re-establish the zones) and
    the warehouse pickers (who must adjust to the new
    policies).
  • The results Very limited scientific literature.

5
Bucket Brigades( c.f. Bartholdi Hackman, Chpt.
10)
  • A dynamic self-balancing scheme for progressive
    zoning.
  • The three main requirements of bucket brigades
  • Carry work forward, from station to station,
    until someone takes over your work.
  • If a worker catches up to his successor, he
    remains idle until the station is available
    (i.e., no overpassing is allowed)
  • Workers are sequenced from slowest to fastest.

6
The self-balancing property of bucket brigades
  • Theorem Letting v_i denote the working rate of
    the i-th worker,
  • the line operation under the three main
    requirements of bucket
  • brigades, converges to a balanced partition of
    the effort, wherein
  • the fraction of work performed by the i-th
    worker is equal to
  • v_i / ?_j1n v_j
  • and the line production rate is equal to
  • ?_j1n v_j
  • items per unit time.
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