Abstract:

This study focuses on improving warehouse operations through the optimization of deep-lane storage systems, where storage racks are densely compacted, and access is limited to the front and/or rear of the lanes. In such systems, retrieving a product located deeper in the lane requires removing the items in front, which must then be returned, creating inefficiencies known as “blocks.” These blocks significantly increase retrieval time and reduce overall efficiency. To address this, a mathematical model is proposed to minimize blocking during retrieval, developed and solved. The model’s effectiveness is validated through a real-world case application, and a sensitivity analysis is conducted to evaluate its reliability under varying conditions.