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Information System Proposal to Improve Warehouse Operations in a Production System

Year 2022, Volume: 15 Issue: 4, 413 - 426, 31.10.2022
https://doi.org/10.17671/gazibtd.1079208

Abstract

The purpose of lean thinking is to get rid of as much waste as possible. Eliminating wasteful activities such as transport, overproduction, waiting, defects, overprocessing, inventory and movement is one of the most important prerequisites in a successful company. This concept is an integral part of lean thinking, and it helps increase profitability. Material picking costs constitute approximately 55%-60% of the total costs related to warehouse operations [1]. The purpose of this article is to develop an information system that finds the shortest path for the responsible personnel to collect the materials required for production from the stock addresses in the warehouse, determines the number of picking boxes required for these materials, and provides the material sequences within the box (in-box sequences). With this developed information system, it will be possible to reduce material picking costs by eliminating wasteful activities such as transport, waiting and movement. The implementation of the developed information system is carried out in a company that produces electromechanical products in Ankara. With the Material Picking Information Systems (MPIS) presented in this article, up to 50% improvement has been achieved in terms of the distance and time spent by the personnel and the model has been validated.

References

  • C. Theys, O. Braysy, W. Dullaert and B. Raa, “Using a TSP Heuristic for Routing Order Pickers in Warehouses”, European Journal of Operational Research, 200(3), 755–763, 2010.
  • N. D. K. Al-Shakarchy, “Warehouse Management System”, International Journal of Science and Research (IJSR), 4(10), 1253-1260, 2015.
  • Internet: G. Erdoğan, CLP Spreadsheet Solver, Released on 07.09.2017, https://researchportal.bath.ac.uk/en/publications/clp-spreadsheet-solver, 31.05.2021.
  • J. Gu, M. Goetschalckx, and L.F. McGinnis, “Research on Warehouse Operation: A Comprehensive Review”, European Journal of Operational Research, 177(1), 1–21, 2007.
  • F. Yener and H. R. Yazgan, “Optimal Warehouse Design: Literature Review and Case Study Application”, Computers & Industrial Engineering, 129(March), 1-13, 2019.
  • R. D. Armstrong, W. D. Cook and A.L. Saipe, “Optimal Batching in a Semi-Automated Order Picking System”, Journal of the Operational Research Society, 30(8), 711–720, 1979.
  • E. A. Elsayed, “Algorithms for Optimal Material Handling in Automatic Warehousing Systems”, International Journal of Production Research, 19(5), 525–535, 1981.
  • G. R. Stern and E. A. Elsayed, “Computerized Algorithms for Order Processing in Automated Warehousing Systems”, International Journal of Production Research, 21(4), 1983.
  • E. A. Elsayed and O. Unal, “Order Batching Algorithms and Travel-Time Estimation for Automated Storage/Retrieval Systems”, International Journal of Production Research, 27(7), 1097-1114, 1989.
  • H. D. Ratliff and A. S. Rosenthal, “Order-picking in a Rectangular Warehouse: A Solvable Case of the Traveling Salesman Problem”, International Journal of Operations Research, 31(3), 507–521, 1983.
  • R. L. Daniels, J. L. Rummel and R. Schantz, "A Model for Warehouse Order Picking," European Journal of Operational Research, 105(1), 1-17, 1998.
  • R. De Koster, T. Le-Duc and K. J. Roodbergen, “Design and Control of Warehouse Order Picking: A Literature R eview”, European Journal of Operational Research, 182(2), 481-50, 2007.
  • C. Y. Tsai, J. J. H. Liou and T. M. Huang, “Using a Multiple-GA Method to Solve the Batch Picking Problem: Considering Travel Distance and Order Due Time”, International Journal of Production Research, 46(22), 6533–6555, 2008.
  • C. C. Lin, J. R. Kang, C. Y. Cheng, “Joint Order Batching and Picker Manhattan Routing Problem”, Computers and Industrial Engineering, 95, 164–174, 2016.
  • M. Masae, C. H. Glock, ve E. H. Grosse, “Order Picker Routing in Warehouses: A Systematic Literature Review”, International Journal of Production Economics, 224, 2-22, 2020.
  • H. Gökçen, Yönetim Bilgi Sistemleri: Analiz ve Tasarım, Afşar Matbaacılık, Ankara, 2011.
  • C. E. Miller, A. W. Tucker, R. A. Zemlin, “Integer Programming Formulation of Traveling Salesman Problems”, Journal of the ACM, 7(4), 326–329, 1960.
  • G. Dantzig, R. Fulkerson, S. Johnson, “Solution of a Large-Scale Traveling-Salesman Problem”, Journal of the Operations Research Society of America, 2(4), 1954.
  • R. Matai, S. Singh, M. L. Mittal, Traveling Salesman Problem: An Overview of Applications, Formulations, and Solution Approaches, Traveling Salesman Problem, Theory and Applications, Editor: D. Davendra, 2010.
  • F. Valdez, F. Moreno, P. Melin, Hybrid Intelligent Systems in Control, Pattern Recognition and Medicine, A Comparison of ACO, GA and SA for Solving the TSP Problem, Editors: O. Castillo, P. Melin, 181-189, Springer, 2020.
  • C. Theys, O. Bräysy, W. Dullaert, W., B. Raa, “Using a TSP Heuristic for Routing Order Pickers in Warehouses”, European Journal of Operational Research, 200(3), 755-763, 2010.
  • V. Raman, N. S. Gill, “Review of Different Heuristic Algorithms for Solving Travelling Salesman Problem”, International Journal of Advanced Research in Computer Science, 8(5), 423-425, 2017.
  • C. Chen, S. M. Lee, Q. Shen, “An Analytical Model for the Container Loading Problem”, European Journal of Operational Research, 80(1), 68-76, 1995.
  • H. Gehring, A. Bortfeldt, “A Genetic Algorithm for Solving the Container Loading Problem”, International Transactions in Operational Research, 4(5-6), 401-418, 1997.
  • A. Bortfeldt, H. Gehring, “A Hybrid Genetic Algorithm for the Container Loading Problem”, European Journal of Operational Research, 131(1), 143-161, 2001.
  • D. Pisinger, “Heuristics for the Container Loading Problem”, European Journal of Operational Research, 141(2), 382–392, 2002.
  • M. Hifi, “Exact Algorithms for Unconstrained Three-Dimensional Cutting Problems: A Comparative Study”, Computers & Operational Resource, 31(5), 657-674, 2004.
  • J. Liu, Y. Yue, Z. Dong, C. Maple, M. Keech, “A Novel Hybrid Tabu Search Approach to Container Loading”, Computer Operations Research, 38(4), 797-807, 2011.
  • M. M. Baldi, G. Perboli, R. Tadei, “The Three-Dimensional Knapsack Problem with Balancing Constraints”, Applied Mathematics and Computation, 218(19), 9802-9818, 2012.
  • A. Bortfeldt, G. Wäscher, “Constraints in Container Loading–A State-of-the-Art Review”, European Journal of Operational Research, 229(1), 1-20, 2013.
  • H. M. Ghomi, B. G. S. Amour, W. Abdul-Kader, “Three-dimensional container loading: a simulated annealing approach”, International Journal of Applied Engineering Research, 12(7), 1290-1304, 2017.
  • B. Özoğlu, E. Çakmak, T. Koç, “Clarke & Wright's Savings Algorithm and Genetic Algorithms Based Hybrid Approach for Flying Sidekick Traveling Salesman Problem”, European Journal of Science and Technology, Special Issue, 185- 192, 2019.

Bir Üretim Sisteminde Depo Operasyonlarını İyileştirmeye Yönelik Bilgi Sistemi Önerisi

Year 2022, Volume: 15 Issue: 4, 413 - 426, 31.10.2022
https://doi.org/10.17671/gazibtd.1079208

Abstract

Yalın düşüncenin amacı, mümkün olduğunca fazla israftan kurtulmaktır. Taşıma, aşırı üretim, bekleme, uygunsuz malzemeler, aşırı işleme, envanter ve hareket gibi katma değeri olmayan faaliyetleri ortadan kaldırmak, başarılı bir şirketin en önemli ön koşullarından biridir. Bu kavram, yalın düşüncenin ayrılmaz bir parçasıdır ve karlılığı artırmaya yardımcı olur. Malzeme toplama maliyetleri, depo operasyonları ile ilgili toplam maliyetlerin yaklaşık %55-60'ını oluşturmaktadır [1]. Bu makalenin amacı, sorumlu personelin üretim için gerekli malzemeleri depodaki stok adreslerinden toplaması için en kısa yolu bulan, bu malzemeler için gerekli olan toplama kutusu sayısını belirleyen ve kutu içindeki malzeme dizilimlerini sağlayan bir bilgi sistemi geliştirmektir. Geliştirilen bu bilgi sistemi ile taşıma, bekleme ve hareket gibi israflı faaliyetler ortadan kaldırılarak malzeme toplama maliyetlerinin düşürülmesi mümkün olacaktır. Geliştirilen bilgi sisteminin uygulaması Ankara'da elektromekanik ürünler üreten bir firmada gerçekleştirilmiştir. Bu yazıda sunulan Malzeme Toplama Bilgi Sistemleri (MPIS) ile personelin harcadığı mesafe ve zaman açısından %50'ye varan iyileştirme sağlanmış ve model valide edilmiştir.

References

  • C. Theys, O. Braysy, W. Dullaert and B. Raa, “Using a TSP Heuristic for Routing Order Pickers in Warehouses”, European Journal of Operational Research, 200(3), 755–763, 2010.
  • N. D. K. Al-Shakarchy, “Warehouse Management System”, International Journal of Science and Research (IJSR), 4(10), 1253-1260, 2015.
  • Internet: G. Erdoğan, CLP Spreadsheet Solver, Released on 07.09.2017, https://researchportal.bath.ac.uk/en/publications/clp-spreadsheet-solver, 31.05.2021.
  • J. Gu, M. Goetschalckx, and L.F. McGinnis, “Research on Warehouse Operation: A Comprehensive Review”, European Journal of Operational Research, 177(1), 1–21, 2007.
  • F. Yener and H. R. Yazgan, “Optimal Warehouse Design: Literature Review and Case Study Application”, Computers & Industrial Engineering, 129(March), 1-13, 2019.
  • R. D. Armstrong, W. D. Cook and A.L. Saipe, “Optimal Batching in a Semi-Automated Order Picking System”, Journal of the Operational Research Society, 30(8), 711–720, 1979.
  • E. A. Elsayed, “Algorithms for Optimal Material Handling in Automatic Warehousing Systems”, International Journal of Production Research, 19(5), 525–535, 1981.
  • G. R. Stern and E. A. Elsayed, “Computerized Algorithms for Order Processing in Automated Warehousing Systems”, International Journal of Production Research, 21(4), 1983.
  • E. A. Elsayed and O. Unal, “Order Batching Algorithms and Travel-Time Estimation for Automated Storage/Retrieval Systems”, International Journal of Production Research, 27(7), 1097-1114, 1989.
  • H. D. Ratliff and A. S. Rosenthal, “Order-picking in a Rectangular Warehouse: A Solvable Case of the Traveling Salesman Problem”, International Journal of Operations Research, 31(3), 507–521, 1983.
  • R. L. Daniels, J. L. Rummel and R. Schantz, "A Model for Warehouse Order Picking," European Journal of Operational Research, 105(1), 1-17, 1998.
  • R. De Koster, T. Le-Duc and K. J. Roodbergen, “Design and Control of Warehouse Order Picking: A Literature R eview”, European Journal of Operational Research, 182(2), 481-50, 2007.
  • C. Y. Tsai, J. J. H. Liou and T. M. Huang, “Using a Multiple-GA Method to Solve the Batch Picking Problem: Considering Travel Distance and Order Due Time”, International Journal of Production Research, 46(22), 6533–6555, 2008.
  • C. C. Lin, J. R. Kang, C. Y. Cheng, “Joint Order Batching and Picker Manhattan Routing Problem”, Computers and Industrial Engineering, 95, 164–174, 2016.
  • M. Masae, C. H. Glock, ve E. H. Grosse, “Order Picker Routing in Warehouses: A Systematic Literature Review”, International Journal of Production Economics, 224, 2-22, 2020.
  • H. Gökçen, Yönetim Bilgi Sistemleri: Analiz ve Tasarım, Afşar Matbaacılık, Ankara, 2011.
  • C. E. Miller, A. W. Tucker, R. A. Zemlin, “Integer Programming Formulation of Traveling Salesman Problems”, Journal of the ACM, 7(4), 326–329, 1960.
  • G. Dantzig, R. Fulkerson, S. Johnson, “Solution of a Large-Scale Traveling-Salesman Problem”, Journal of the Operations Research Society of America, 2(4), 1954.
  • R. Matai, S. Singh, M. L. Mittal, Traveling Salesman Problem: An Overview of Applications, Formulations, and Solution Approaches, Traveling Salesman Problem, Theory and Applications, Editor: D. Davendra, 2010.
  • F. Valdez, F. Moreno, P. Melin, Hybrid Intelligent Systems in Control, Pattern Recognition and Medicine, A Comparison of ACO, GA and SA for Solving the TSP Problem, Editors: O. Castillo, P. Melin, 181-189, Springer, 2020.
  • C. Theys, O. Bräysy, W. Dullaert, W., B. Raa, “Using a TSP Heuristic for Routing Order Pickers in Warehouses”, European Journal of Operational Research, 200(3), 755-763, 2010.
  • V. Raman, N. S. Gill, “Review of Different Heuristic Algorithms for Solving Travelling Salesman Problem”, International Journal of Advanced Research in Computer Science, 8(5), 423-425, 2017.
  • C. Chen, S. M. Lee, Q. Shen, “An Analytical Model for the Container Loading Problem”, European Journal of Operational Research, 80(1), 68-76, 1995.
  • H. Gehring, A. Bortfeldt, “A Genetic Algorithm for Solving the Container Loading Problem”, International Transactions in Operational Research, 4(5-6), 401-418, 1997.
  • A. Bortfeldt, H. Gehring, “A Hybrid Genetic Algorithm for the Container Loading Problem”, European Journal of Operational Research, 131(1), 143-161, 2001.
  • D. Pisinger, “Heuristics for the Container Loading Problem”, European Journal of Operational Research, 141(2), 382–392, 2002.
  • M. Hifi, “Exact Algorithms for Unconstrained Three-Dimensional Cutting Problems: A Comparative Study”, Computers & Operational Resource, 31(5), 657-674, 2004.
  • J. Liu, Y. Yue, Z. Dong, C. Maple, M. Keech, “A Novel Hybrid Tabu Search Approach to Container Loading”, Computer Operations Research, 38(4), 797-807, 2011.
  • M. M. Baldi, G. Perboli, R. Tadei, “The Three-Dimensional Knapsack Problem with Balancing Constraints”, Applied Mathematics and Computation, 218(19), 9802-9818, 2012.
  • A. Bortfeldt, G. Wäscher, “Constraints in Container Loading–A State-of-the-Art Review”, European Journal of Operational Research, 229(1), 1-20, 2013.
  • H. M. Ghomi, B. G. S. Amour, W. Abdul-Kader, “Three-dimensional container loading: a simulated annealing approach”, International Journal of Applied Engineering Research, 12(7), 1290-1304, 2017.
  • B. Özoğlu, E. Çakmak, T. Koç, “Clarke & Wright's Savings Algorithm and Genetic Algorithms Based Hybrid Approach for Flying Sidekick Traveling Salesman Problem”, European Journal of Science and Technology, Special Issue, 185- 192, 2019.
There are 32 citations in total.

Details

Primary Language English
Subjects Computer Software
Journal Section Articles
Authors

Volkan Çetin 0000-0003-3131-5403

Başak Gök 0000-0002-8687-5961

Hadi Gökçen 0000-0002-5163-0008

Publication Date October 31, 2022
Submission Date February 25, 2022
Published in Issue Year 2022 Volume: 15 Issue: 4

Cite

APA Çetin, V., Gök, B., & Gökçen, H. (2022). Information System Proposal to Improve Warehouse Operations in a Production System. Bilişim Teknolojileri Dergisi, 15(4), 413-426. https://doi.org/10.17671/gazibtd.1079208