CPU-Based Layout Design for Picker-to-Parts Pallet Warehouses
Timo Looms, Lin Xie
TL;DR
The paper tackles high order-picking costs in picker-to-parts pallet warehouses by introducing a CPU-inspired layout that partitions space into tri-zones: $P$ (Performance), $E$ (Efficiency), and $S$ (Shared). It evaluates this design via discrete-event simulation against conventional rectangular, random/ABC, and Flying-V layouts, using real-world data and takt-based outbound dynamics. A key contribution is the integration of zone-based, class-aware storage directly into the physical layout, aligning access priority with SKU turnover to improve throughput and on-time fulfillment, with only a modest area increase. The findings suggest substantial practical impact for high-throughput warehouses, offering a modular, scalable approach that can adapt to demand shifts and support takt-driven operations, while outlining future work on adaptive zone sizing and multi-story or automated implementations.
Abstract
Picker-to-parts pallet warehouses often face inefficiencies due to conventional layouts causing excessive travel distances and high labor requirements. This study introduces a novel layout design inspired by CPU architecture, partitioning warehouse space into specialized zones, namely Performance (P), Efficiency (E), and Shared (S). Discrete-event simulation is used to evaluate this design against traditional rectangular (random and ABC storage) and Flying-V layouts. Results demonstrate significant improvements in throughput time and reduced labor requirements, highlighting the potential for CPU-based layouts in optimizing warehouse operations.