A real-time warehouse operations planning system for small batch replenishment problems in production environment

Authors:
T. C. Poon;K. L. Choy;F. T. S. Chan;G. T. S. Ho;A. Gunasekaran;H. C. W. Lau;H. K. H. Chow
Affiliations:
Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong;Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong;Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong;Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong;Department of Decision and Information Sciences, The Charlton College of Business, University of Massachusetts, Dartmouth, United States;Logistics and Supply Chain School of Management, University of Western Sydney, Sydney, Australia;Faculty of Management and Administration, Macau University of Science and Technology, Macau
Venue:
Expert Systems with Applications: An International Journal
Year:
2011

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Abstract

A factory consists of numerous production workstations, multiple production lines and many production floors. Due to the characteristics of just-in-time and make-to-order mode manufacturing, small batches of production materials are required for production lines within a short period of time in order to facilitate daily production operations. In this paper, a real-time warehouse operation planning system (R-WOPS) for solving small batch replenishment problems is described. Through using R-WOPS, real-time production and warehouse operations are monitored by radio frequency identification (RFID) technology, and a genetic algorithm (GA) technique is applied to formulate feasible small batch replenishment solutions. Simulation tests show that R-WOPS generates pick-up and delivery route plans for small batch replenishment orders very efficiently.