Modeling, Analysis, and Design Insights for Shuttle-Based Compact Storage Systems

54 Pages Posted: 15 Jul 2015

See all articles by Elena Tappia

Elena Tappia

Erasmus Research Institute of Management (ERIM)

Debjit Roy

Indian Institute of Management (IIM), Ahmedabad

M. B. M. de Koster

Erasmus University Rotterdam (EUR) - Department of Technology and Operations Management

Marco Melacini

Polytechnic University of Milan

Date Written: July 15, 2015

Abstract

Shuttle-based compact systems are new automated multi-deep unit-load storage systems with lifts that promise both low operational cost and large volume flexibility. In this paper, we develop novel queuing network models to estimate the performance of both single-tier and multi-tier shuttle-based compact systems. Each tier is modeled as a multi-class semiopen queuing network, whereas the vertical transfer is modeled using an open queue. For a multi-tier system, the models corresponding to tiers and vertical transfer are linked together using the first and second moment information of the queue departure processes. The models can handle both specialized and generic shuttles, and both continuous and discrete lifts. The accuracy of the models is validated through both simulation and a real case. Errors are acceptable for conceptualizing initial designs. Numerical studies provide new design insights. Results show that the best way to minimize expected throughput time in single-tier systems is to have a depth/width ratio around 1.25. Moreover, specialized shuttles are recommended for multi-tier systems because the higher cost of generic shuttles is not balanced by savings in reduced throughput time and equipment needs.

Keywords: material handling; compact storage systems; semi-open queuing networks; warehouse design trade-offs

Suggested Citation

Tappia, Elena and Roy, Debjit and de Koster, M.B.M. René and Melacini, Marco, Modeling, Analysis, and Design Insights for Shuttle-Based Compact Storage Systems (July 15, 2015). ERIM Report Series Reference No. ERS-2015-010-LIS. Available at SSRN: https://ssrn.com/abstract=2631137 or http://dx.doi.org/10.2139/ssrn.2631137

Elena Tappia (Contact Author)

Erasmus Research Institute of Management (ERIM) ( email )

P.O. Box 1738
3000 DR Rotterdam
Netherlands

Debjit Roy

Indian Institute of Management (IIM), Ahmedabad ( email )

Vastrapur
Ahmedabad, Gujarat 380 015
India

M.B.M. René De Koster

Erasmus University Rotterdam (EUR) - Department of Technology and Operations Management ( email )

RSM Erasmus University
PO Box 1738
3000 DR Rotterdam
Netherlands
+31 10 408 1719 (Phone)
+31 10 408 9014 (Fax)

HOME PAGE: http://www.rsm.nl/rdekoster

Marco Melacini

Polytechnic University of Milan ( email )

Piazza Leonardo da Vinci
Milan, Milano 20100
Italy

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