Reliability of evaluations for the choice of system solutions at the example of automated order-picking systems for bagged goods

There is a steadily increasing pressure on cost-savings and productivity growth in sectors of order-picking such that the wish for rationalization by automation is rising. Special problems are faced trying to automatize handling operations of order-picking articles packed in bags. The mechanical properties of the objects and their hard-to-predict shape and position represent obstacles and are complicating handling operations. A systematic approach in system design is required. This article deals with the properties of such products under aspects of difficulties arising in automated handling and points out a useful system development methodology.

Performance Evaluation of Material Flow Systems in Discrete Time

Im folgenden Beitrag werden zeitdiskrete analytische Methoden vorgestellt, mit Hilfe derer Informations- und Materialflüsse in logistischen Systemen analysiert und bewertet werden können. Bestehende zeitdiskrete Verfahren sind jedoch auf die Bearbeitung und Weitergabe in immer gleichen Mengen („One Piece Flow“) beschränkt. Vor allem in Materialflusssystemen kommt es, bedingt durch die Zusammenfassung von Aufträgen, durch Transporte und durch Sortiervorgänge, zur Bildung von Batches. Daher wurden analytische Methoden entwickelt, die es ermöglichen, verschiedene Sammelprozesse, Batchankünfte an Ressourcen, Batchbearbeitung und Sortieren von Batches analytisch abzubilden und Leistungskenngrößen zu deren Bewertung zu bestimmen. Die im Rahmen der Entwicklungsarbeiten entstandene Software-Lösung „Logistic Analyzer“ ermöglicht eine einfache Modellierung und Analyse von praktischen Problemen. Der Beitrag schließt mit einem numerischen Beispiel.

Control concept for autonomous changeable material flow systems

Today’s material flow systems for mass customization or dynamic productions are usually realized with manual transportation systems. However new concepts in the domain of material flow and device control like function-oriented modularization and intelligent multi-agent-systems offer the possibility to employ changeable and automated material flow systems in dynamic production structures. These systems need the ability to react on unplanned and unexpected events autonomously.

Technical throughput of material flow systems required to achieve design flow – determined by simulation with aniteration algorithm

This article deals with complex material flow systems and series connections of conveyor and op-erating elements. These can be characterised by a specific availability. The thus resultant overall availabil-ity of necessary “technical throughput” of the individual elements for the achievement of a specified throughput. When the conveyor and operating elements are subjected to a stochastic distribution, the interposition of buffers is necessary but these can also lead to a reduction of the necessary throughput due faults. The system behaviour of complex installations can only be investigated by simulation. The parame-ter changes required in order to achieve specific target values can also be determined by simulation runs in iteration loops.

Utilizing the full Capacity of Sorting Systems with new Infeed Technology

Utilisation of sorting systems’ maximum performance demands continuous conveying of goods by infeed lines to sorters. This is the case especially for sorters with one single infeed line, because the sorters’ performance is limited by the performance of the infeed line. Within this paper different infeed line constructions at the Rotary Sorter with diverse performances will be presented. The focus lies on a specific conveying system to synchronise the goods with the sorter by a performance of 6000 pieces per hour with one dynamic infeed line. By this means there is no extensive adjustment control of serial conveyors in the infeed line any longer.

Energy and weight reduction in hoisting systems with magnetic traction sheaves

At the Chair of Logistics Engineering, TU Dresden, a particular focus is research and development of magnetic traction sheaves. Therein the main fundamentals of these special sheaves are determined for applications in different fields such as elevators, several kinds of winches, hoists and cranes. In the current research project “energy balance of magnetic traction sheaves”, the dynamic behaviour of systems with magnetic traction sheaves was investigated. The research focused on theoretical and practical examinations of energy balance. Moreover, a new approach for dimensioning magnetic traction sheave systems is presented. It is a project of the Research Foundation Intralogistics / Material Handling and Logistics (IFL), which is funded through the AiF under the program of Industrial Collective Research for SMEs (IGF) by the Federal Ministry of Economics and Technology (BMWi).

Comparison of performance measurement-systems used for order-picking

In consequence of rapidly changing market demands companies are permanently encouraged to review their own processes and structures and to modify them. Being one of these developments, order-picking is involved as part of an intra-logistics system. But to take appropriate actions, system performance and system costs have to be measured permanently. Concerning this the use of performance measurement-systems as further development of traditional systems of key figures is suitable. In this paper various performance measurement-systems are compared and their suitability for an implementation in order-picking systems is estimated. On the basis of the result of the evaluation a first concept of a performance measurement-system for order-picking will be developed by using typical key figures that are mentioned in academic literature. Finally, hints for a necessary detailed implementation and evaluation in practice will be given.

Novel calculation method for chain conveyor systems

Sidexflexing plastic chains are used increasingly in material handling due to their highly flexible conveying design and layout options. These systems are often equipped with so called modular belts. Due to their specific force transmission, detailed calculation methods are not yet available. In the following, a generally valid calculation approach is derived and its difference to existing solutions shown by examples.

Meta-model for calculating the mean energy demand of automated storage and retrieval systems

Energy efficiency has become an important research topic in intralogistics. Especially in this field the focus is placed on automated storage and retrieval systems (AS/RS) utilizing stacker cranes as these systems are widespread and consume a significant portion of the total energy demand of intralogistical systems. Numerical simulation models were developed to calculate the energy demand rather precisely for discrete single and dual command cycles. Unfortunately these simulation models are not suitable to perform fast calculations to determine a mean energy demand value of a complete storage aisle. For this purpose analytical approaches would be more convenient but until now analytical approaches only deliver results for certain configurations. In particular, for commonly used stacker cranes equipped with an intermediate circuit connection within their drive configuration there is no analytical approach available to calculate the mean energy demand. This article should address this research gap and present a calculation approach which enables planners to quickly calculate the energy demand of these systems.

Performance Availability and Anticipatory Change Planning of Intralogistics Systems: A Simulation-Based Approach

In recent years, the ability to respond to real time changes in operations and reconfigurability in equipment are likely to become essential characteristics for next generation intralogistics systems as well as the level of automation, cost effectiveness and maximum throughput. In order to cope with turbulences and the increasing level of dynamic conditions, future intralogistics systems have to feature short reaction times, high flexibility in processes and the ability to adapt to frequent changes. The increasing autonomy and complexity in processes of today’s intralogistics systems requires new and innovative management approaches, which allow a fast response to (un)anticipated events and adaptation to changing environment in order to reduce the negative consequences of these events. The ability of a system to respond effectively a disruption depends more on the decisions taken before the event than those taken during or after. In this context, anticipatory change planning can be a usable approach for managers to make contingency plans for intralogistics systems to deal with the rapidly changing marketplace. This paper proposes a simulation-based decision making framework for the anticipatory change planning of intralogistics systems. This approach includes the quantitative assessments based on the simulation in defined scenarios as well as the analysis of performance availability that combines the flexibility corridors of different performance dimensions. The implementation of the approach is illustrated on a new intralogistics technology called the Cellular Transport System.

Robustness and Recoverability in Transport Logistics

Abstract Transport is the foundation of any economy: it boosts economic growth, creates wealth, enhances trade, geographical accessibility and the mobility of people. Transport is also a key ingredient for a high quality of life, making places accessible and bringing people together. The future prosperity of our world will depend on the ability of all of its regions to remain fully and competitively integrated in the world economy. Efficient transport is vital in making this happen. Operations research can help in efficiently planning the design and operating transport systems. Planning and operational processes are fields that are rich in combinatorial optimization problems. These problems can be analyzed and solved through the application of mathematical models and optimization techniques, which may lead to an improvement in the performance of the transport system, as well as to a reduction in the time required for solving these problems. The latter aspect is important, because it increases the flexibility of the system: the system can adapt in a faster way to changes in the environment (i.e.: weather conditions, crew illness, failures, etc.). These disturbing changes (called disruptions) often enforce the schedule to be adapted. The direct consequences are delays and cancellations, implying many schedule adjustments and huge costs. Consequently, robust schedules and recovery plans must be developed in order to fight against disruptions. This dissertation makes contributions to two different fields: rail and air applications. Robust planning and recovery methods are presented. In the field of railway transport we develop several mathematical models which answer to RENFE’s (the major railway operator in Spain) needs: 1. We study the rolling stock assignment problem: here, we introduce some robust aspects in order to ameliorate some operations which are likely to fail. Once the rolling stock assignment is known, we propose a robust routing model which aims at identifying the train units’ sequences while minimizing the expected delays and human resources needed to perform the sequences. 2. It is widely accepted that the sequential solving approach produces solutions that are not global optima. Therefore, we develop an integrated and robust model to determine the train schedule and rolling stock assignment. We also propose an integrated model to study the rolling stock circulations. Circulations are determined by the rolling stock assignment and routing of the train units. 3. Although our aim is to develop robust plans, disruptions will be likely to occur and recovery methods will be needed. Therefore, we propose a recovery method which aims to recover the train schedule and rolling stock assignment in an integrated fashion all while considering the passenger demand. In the field of air transport we develop several mathematical models which answer to IBERIA’s (the major airline in Spain) needs: 1. We look at the airline-scheduling problem and develop an integrated approach that optimizes schedule design, fleet assignment and passenger use so as to reduce costs and create fewer incompatibilities between decisions. Robust itineraries are created to ameliorate misconnected passengers. 2. Air transport operators are continuously facing competition from other air operators and different modes of transport (e.g., High Speed Rail). Consequently, airline profitability is critically influenced by the airline’s ability to estimate passenger demands and construct profitable flight schedules. We consider multi-modal competition including airline and rail, and develop a new approach that estimates the demand associated with a given schedule; and generates airline schedules and fleet assignments using an integrated schedule design and fleet assignment optimization model that captures the impacts of schedule decisions on passenger demand.

Controlling systems with a single actuator

In this paper the problem of designing a single actuator control for a class of systems is addressed. The existence of such control is studied and several ways for designing such control are provided. The results depend either on the rational canonical form or on the Jordan structure associated with the matrix which characterizes the system dynamics. The constructed control laws can be employed in the design of minimum cost controllers for a large variety of systems.