Optimizing fishbone aisles for dual‐command operations in a warehouse

Unit‐load warehouses store and retrieve unit‐loads, typically pallets. When storage and retrieval operations are not coordinated, travel is from a pickup and deposit (P&D) point to a pallet location and back again. In some facilities, workers interleave storage and retrieval operations to form a dual‐command cycle. Two new aisle designs proposed by Gue and Meller (“Improving the unit‐load warehouse.” In Progress in Material Handling Research: 2006. Material Handling Industry of America, Charlotte, NC, 2006) use diagonal aisles to reduce the travel distance to a single pallet location by approximately 10 and 20[percnt] for the two designs, respectively. We develop analytical expressions for travel between pallet locations for one of these—the fishbone design. We then compare fishbone warehouses that have been optimized for dual‐command to traditional warehouses that have been optimized in the same manner, and show that an optimal fishbone design reduces dual‐command travel by 10–15%. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 54: 389–403, 2009     

Dynamic signatures and their use in comparing the reliability of new and used systems

The signature of a system with independent and identically distributed (i.i.d.) component lifetimes is a vector whose ith element is the probability that the ith component failure is fatal to the system. System signatures have been found to be quite useful tools in the study and comparison of engineered systems. In this article, the theory of system signatures is extended to versions of signatures applicable in dynamic reliability settings. It is shown that, when a working used system is inspected at time t and it is noted that precisely k failures have occurred, the vector s [0,1]^n‐k whose jth element is the probability that the (k + j)th component failure is fatal to the system, for j = 1,2,2026;,n ‐ k, is a distribution‐free measure of the design of the residual system. Next, known representation and preservation theorems for system signatures are generalized to dynamic versions. Two additional applications of dynamic signatures are studied in detail. The well‐known “new better than used” (NBU) property of aging systems is extended to a uniform (UNBU) version, which compares systems when new and when used, conditional on the known number of failures. Sufficient conditions are given for a system to have the UNBU property. The application of dynamic signatures to the engineering practice of “burn‐in” is also treated. Specifically, we consider the comparison of new systems with working used systems burned‐in to a given ordered component failure time. In a reliability economics framework, we illustrate how one might compare a new system to one successfully burned‐in to the kth component failure, and we identify circumstances in which burn‐in is inferior (or is superior) to the fielding of a new system. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2009     

Simultaneous determination of production and maintenance schedules using in‐line equipment condition and yield information

In many manufacturing environments, equipment condition has a significant impact on product quality, or yield. This paper presents a semi‐Markov decision process model of a single‐stage production system with multiple products and multiple maintenance actions. The model simultaneously determines maintenance and production schedules, accounting for the fact that equipment condition affects the yield of each product differently. It extends earlier work by allowing the expected time between decision epochs to vary by both action and machine state, by allowing multiple maintenance actions, and by treating the outcome of maintenance as less than certain. Sufficient conditions are developed that ensure the monotonicity of both the optimal production and maintenance actions. While the maintenance conditions closely resemble previously studied conditions for this type of problem, the production conditions represent a significant departure from earlier results. The simultaneous solution method is compared to an approach commonly used in industry, where the maintenance and production problems are treated independently. Solving more than one thousand test problems confirms that the combination of both features of the model—accounting for product differences and solving the problems simultaneously—has a significant impact on performance. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Dynamic evacuation routes for personnel on a naval ship

We propose a dynamic escape route system for emergency evacuation of a naval ship. The system employs signals that adapt to the causative contingency and the crew's physical distribution about the ship. A mixed‐integer nonlinear programming model, with underlying network structure, optimizes the evacuation process. The network's nodes represent compartments, closures (e.g., doors and hatches) and intersections, while arcs represent various types of passageways. The objective function integrates two potentially conflicting factors: average evacuation time and the watertight and airtight integrity of the ship after evacuation. A heuristic solves the model approximately using a sequence of mixed‐integer linear approximating problems. Using data for a Spanish frigate, with standard static routes specified by the ship's designers, computational tests show that the dynamic system can reduce average evacuation times, nearly 23%, and can improve a combined measure of ship integrity by up to 50%. In addition, plausible design changes to the frigate yield further, substantial improvements. Published 2008 Wiley Periodicals, Inc. Naval Research Logistics 2008     

Delivery‐date and capacity management in a decentralized internal market

We study competitive due‐date and capacity management between the marketing and engineering divisions within an engineer‐to‐order (ETO) firm. Marketing interacts directly with the customers and quotes due‐dates for their orders. Engineering is primarily concerned with the efficient utilization of resources and is willing to increase capacity if the cost is compensated. The two divisions share the responsibility for timely delivery of the jobs. We model the interaction between marketing and engineering as a Nash game and investigate the effect of internal competition on the equilibrium decisions. We observe that the internal competition not only degrades the firm's overall profitability but also the serviceability. Finally, we extend our analysis to multiple‐job settings that consider both flexible and inflexible capacity. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008