An integrated design approach for class-based block stacked warehouse

Purpose This paper aims to develop an approach to design a warehouse that uses class-based storage policy in a way that minimizes both space cost and material handling cost. Design/methodology/approach The authors argue for and develop an optimization model for joint determination of lane depth, lateral width and product partitions for minimizing the sum of handling and space costs. In doing so, the assumption of perfect sharing is also relaxed. Using computational experiments, the authors characterize the operating conditions based on pick density and cost ratio. The authors further outline an approach to decide the conditions under which it is advantageous to implement multiple classes. Findings More classes are preferred when both the pick density and cost ratio are higher and vice versa. Factors such as demand skewness, lane depth and stacking height affect the space-sharing dynamics. Originality/value Very few studies have seen class-based storage policy in the context of block stacked warehouse layout. Further, block stacking designs have mostly been approached with the objective of minimizing just the space cost. This study contributes to the literature by developing an integrated model, which has the practical utility.