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     

Design and control of agile automated CONWIP production lines

In this article, we study the design and control of manufacturing cells with a mix of manual and automated equipment, operating under a CONWIP pull protocol, and staffed by a single agile (cross‐trained) worker. For a three‐station line with one automated station, we fully characterize the structure of the optimal control policy for the worker and show that it is a static priority policy. Using analytical models and extensive simulation experiments, we also evaluate the effectiveness of practical heuristic control policies and provide managerial insights on automation configuration design of the line. This characterization of the worker control policy enables us to develop managerial insights into the design issues of how best to locate and concentrate automation in the line. Finally, we show that, in addition to ease of control and greater design flexibility, the CONWIP protocol also offers higher efficiency and robustness than does the push protocol. © 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Interactive optimization methodology for fleet scheduling

This article addresses the problem of scheduling the United States Navy's Atlantic Fleet to satisfy overseas strategic requirements. An integer programming formulation is developed but results in a model with prohibitive size. This fact and the qualitative nature of additional secondary objectives and constraints suggest an interactive optimization approach. A system that solves a natural relaxation of the integer program within an interactive environment is discussed.     

Facility location when demand is time dependent

In this article we investigate the problem of locating a facility among a given set of demand points when the weights associated with each demand point change in time in a known way. It is assumed that the location of the facility can be changed one or more times during the time horizon. We need to find the time “breaks” when the location of the facility is to be changed, and the location of the facility during each time segment between breaks. We investigate the minisum Weber problem and also minimax facility location. For the former we show how to calculate the objective function for given time breaks and optimally solve the rectilinear distance problem with one time break and linear change of weights over time. Location of multiple time breaks is also discussed. For minimax location problems we devise two algorithms that solve the problem optimally for any number of time breaks and any distance metric. These algorithms are also applicable to network location problems.     

Use of a classifier in a knowledge-based simulation optimization system

This article defines and develops a simulation optimization system based upon response surface classification and the integration of multiple search strategies. Response surfaces are classified according to characteristics that indicate which search technique will be most successful. Typical surface characteristics include statistical measures and topological features, while search techniques encompass response surface methodology, simulated annealing, random search, etc. The classify-then-search process flow and a knowledge-based architecture are developed and then demonstrated with a detailed computer example. The system is useful not only as an approach to optimizing simulations, but also as a means for integrating search techniques and thereby providing the user with the most promising path toward an optimal solution. © 1995 John Wiley & Sons, Inc.     

Some comments on the optimal assembly problem

It is shown that two recent results of Baxter and Harche [1] on monotone and balanced optimal assemblies hold only under conditions that are more restrictive than those originally proposed by the authors. We describe such additional conditions, illustrate why they are needed, and establish their sufficiency. We also consider a recent result by Malon [11] and demonstrate that, while the result itself is correct, its two proofs were incomplete. A complete proof of an extension of the result is then suggested. © 1995 John Wiley & Sons, Inc.     

An inventory model of incentives for on-time delivery in just-in-time purchasing contracts

This article formulates an analytic model of just-in-time purchasing contracts and compares the minimum cost solution with the cost attainable through vertical integration. The models use standard inventory theory cost parameters and decision variables. The results quantify the increase in cost of buying an item rather than making it. Optimal incentives are characterized when JIT purchasing contracts are used. When JIT purchasing is implemented, buffer inventories are typically reduced. This inventory reduction makes on-time delivery critical to the buyer; yet timeliness is controlled by the supplier. As an incentive to provide on-time delivery, the buyer offers the supplier a bonus for on-time delivery. The supplier chooses a flow time allowance based upon the bonus offered. First- and second-order conditions are characterized in general, and examples are provided for exponentially and uniformly distributed flow times. The delivery timeliness obtainable in a vertically integrated firm is determined and compared with timeliness obtainable between separate firms. This comparison indicates that buyers who choose to purchase materials from a separate firm are more likely to experience late deliveries. The relationship between the value of the bonus and the proportion of on-time deliveries is also considered. The bonus required to achieve the same probability of on-time delivery as under vertical integration is also determined. © 1993 John Wiley & Sons, Inc.     

Exploiting self‐canceling demand point aggregation error for some planar rectilinear median location problems

When solving location problems in practice it is quite common to aggregate demand points into centroids. Solving a location problem with aggregated demand data is computationally easier, but the aggregation process introduces error. We develop theory and algorithms for certain types of centroid aggregations for rectilinear 1‐median problems. The objective is to construct an aggregation that minimizes the maximum aggregation error. We focus on row‐column aggregations, and make use of aggregation results for 1‐median problems on the line to do aggregation for 1‐median problems in the plane. The aggregations developed for the 1‐median problem are then used to construct approximate n‐median problems. We test the theory computationally on n‐median problems (n ≥ 1) using both randomly generated, as well as real, data. Every error measure we consider can be well approximated by some power function in the number of aggregate demand points. Each such function exhibits decreasing returns to scale. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 614–637, 2003.     

Scheduling with parallel processors and linear delay costs

This paper deals with the sequencing problem of minimizing linear delay costs with parallel identical processors. The theoretical properties of this m-machine problem are explored, and the problem of determining an optimum scheduling procedure is examined. Properties of the optimum schedule are given as well as the corresponding reductions in the number of schedules that must be evaluated in the search for an optimum. An experimental comparison of scheduling rules is reported; this indicates that although a class of effective heuristics can be identified, their relative behavior is difficult to characterize.