A support-design tool for block-stacking storage system layout

In warehousing system, block stacking is one of the most common storage mode to guarantee high storage density in case of large quantities and limited product variety. Most common applications for block stacking storage are end-of-line warehouses at manufacturing facilities in processing industry (e.g., beverage, bakery, tissue industries). These storage systems put-Away the incoming pallets into deep lanes of homogeneous products and take advantage of vertical space through high stacks. Although the design of the optimal lane depth is widely debated in the extant literature through analytical modelling, the lack of support-design methodologies able to tackle the proper design of high-Turnover warehouses that experience high variability on inbound and outbound flows is even stated. Therefore, the aim of this paper is to illustrate a decision-support tool that implements and incorporates some existing and original models and uses a simulation approach to aid the design of a block-stacking storage system layout.