配送中心分拣系统设计方法研究
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摘要
分拣系统运作是否有效将对整个物流系统的运作有着至关重要的作用。虽然当前有配送中心成功地运用自动分拣系统,但由于自动分拣系统不仅成本高而且灵活性低,手动分拣系统仍然具有一定的实际意义。本文选择人工分拣系统设计为研究问题。
首先,本文以系统整体论和还原论相结合的方法论为基本理论,分析了分拣系统的整体性和设计内容的之间层次关系,提出了两阶段设计思路：第一阶段,解决布局、存储设备选择、空间分配的设计问题,建立基于运作要素作为假设条件的分拣系统总成本优化模型；在第二阶段,解决分拣系统运作组合策略的问题,建立以存储设备和布局为假设条件的仿真模型。基于两阶段设计思路,并借鉴以往文献,整理分拣系统设计流程,采用深度访谈的方法针对该流程进行调研。最终根据企业人士的反馈,构建出理论与实践相结合的分拣系统设计流程。
其次,本文基于优化理论建立了分拣系统全局数学优化模型,为分拣系统选择存储设备并进行空间分配。本文以人工分拣系统为例,建立了以最小化年总成本为目标的数学模型,总成本包括储设备成本、空间成本、分拣运作成本、补货成本,为每个品项选择合适的存储设备和分配合理的空间。鉴于求解的复杂性,本文采用启发式思想,为模型设计求解过程。本文以小件人工分拣系统改造为例,运用MATLAB程序实现求解。
最后,针对分拣系统的路径策略和储位分配原则进行了仿真实验研究,运用蒙特卡罗软件实现仿真程序,对影响拣货行走距离的路径策略和储位分配策略在不同订单特点下进行实验,通过对仿真结果的对比分析,最终确定最佳组合策略。
The operation of order picking system plays an extremely important role for the effectiveness of the overall logistics system. Although there are automated orders picking system being used by some distribution centers, due to the high investment and low flexibility of automated order picking system, manual order picking is still meaningful for some industries. This paper will solve the problem of manual order picking system design.
Firstly, based on the theory of reductionism and wholism, this paper raises a two-stage design method:(1) to solve the design problems of layout, storage equipment selection and space assignment, a optimal total cost model should be built on the assumption of fixed order picking operation elements; (2) to solve the order picking operation decisions, a simulation model should be built with known layout out and storage equipment. According to the two-stage design methodology, an order picking system design process is configured after drawing good ideas from literature and suggestions from field interview.
Secondly, a global optimal total order picking cost model is built to evaluate storage equipment and space assignment alternatives and this model is used for manual picking system, including storage equipment cost, space cost, picking cost and replenishment cost. And a huristic algorithm is designed to solve the model and an example of manual small part picking system is given to apply the solving algorithm.
Finally, a simulation model of pick routing and storage rules is built and Mont-Carlo software is utilized to realize the simulation program to analyze the impacts of routing strategies and storage rules on walking distance during picking under different sizes of orders. And the optimal hybrid strategy is identified according to the simulation result analysis.
首先,本文以系统整体论和还原论相结合的方法论为基本理论,分析了分拣系统的整体性和设计内容的之间层次关系,提出了两阶段设计思路：第一阶段,解决布局、存储设备选择、空间分配的设计问题,建立基于运作要素作为假设条件的分拣系统总成本优化模型；在第二阶段,解决分拣系统运作组合策略的问题,建立以存储设备和布局为假设条件的仿真模型。基于两阶段设计思路,并借鉴以往文献,整理分拣系统设计流程,采用深度访谈的方法针对该流程进行调研。最终根据企业人士的反馈,构建出理论与实践相结合的分拣系统设计流程。
其次,本文基于优化理论建立了分拣系统全局数学优化模型,为分拣系统选择存储设备并进行空间分配。本文以人工分拣系统为例,建立了以最小化年总成本为目标的数学模型,总成本包括储设备成本、空间成本、分拣运作成本、补货成本,为每个品项选择合适的存储设备和分配合理的空间。鉴于求解的复杂性,本文采用启发式思想,为模型设计求解过程。本文以小件人工分拣系统改造为例,运用MATLAB程序实现求解。
最后,针对分拣系统的路径策略和储位分配原则进行了仿真实验研究,运用蒙特卡罗软件实现仿真程序,对影响拣货行走距离的路径策略和储位分配策略在不同订单特点下进行实验,通过对仿真结果的对比分析,最终确定最佳组合策略。
The operation of order picking system plays an extremely important role for the effectiveness of the overall logistics system. Although there are automated orders picking system being used by some distribution centers, due to the high investment and low flexibility of automated order picking system, manual order picking is still meaningful for some industries. This paper will solve the problem of manual order picking system design.
Firstly, based on the theory of reductionism and wholism, this paper raises a two-stage design method:(1) to solve the design problems of layout, storage equipment selection and space assignment, a optimal total cost model should be built on the assumption of fixed order picking operation elements; (2) to solve the order picking operation decisions, a simulation model should be built with known layout out and storage equipment. According to the two-stage design methodology, an order picking system design process is configured after drawing good ideas from literature and suggestions from field interview.
Secondly, a global optimal total order picking cost model is built to evaluate storage equipment and space assignment alternatives and this model is used for manual picking system, including storage equipment cost, space cost, picking cost and replenishment cost. And a huristic algorithm is designed to solve the model and an example of manual small part picking system is given to apply the solving algorithm.
Finally, a simulation model of pick routing and storage rules is built and Mont-Carlo software is utilized to realize the simulation program to analyze the impacts of routing strategies and storage rules on walking distance during picking under different sizes of orders. And the optimal hybrid strategy is identified according to the simulation result analysis.
引文
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[4]Dekker R., de Koster R., Roodbergen K.J., et al. Improving order-picking response time at Ankor's warehouse. Interfaces.2004,34 (4):303-313.
[5]Heskett, J.L. Putting the cube-per-order index to work in warehouse layout, Transportation and Distribution Management.1964,4(8):23-30.
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[17]Baker P., Canessa M. Warehouse design:A structured approach, European Journal of Operational Research.2009,193:425-436.
[18]Ashayeri J., Gelders L.F. Warehouse design optimization. European Journal of Operational Research.1985,21 (3):285-294.
[19]Rouwenhorst B., Reuter B., Stockrahm V., et al. Warehouse design and control:Framework and literature review. European Journal of Operational Research.2000,122:515-533.
[20]Goetschalckx M., McGinnis L., Bodner D., et al. A systematic design procedure for small parts warehousing systems using modular drawer and bin shelving systems. IMHRC proceedings,2002.
[21]De Koster R., Le-Duc T., Roodbergen K.J. Design and control of warehouse order picking:A literature review.European Journal of Operational Researeh.2007,182(2):481-501.
[22]Goetschalckx M., Ashayeri J. Classification and design of order picking systems. Logistics World.1989:99-106.
[23]Yoon C.S., Sharp G.P. A cognitive design procedure for an order pick system. Transactions on Systems, Man, and Cybernetics.1992.
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