Capacity upgrade criteria of large‐intensive material handling and storage systems: a case study

Abstract

PurposeThis paper aims to discuss some relevant issues in the design and operation of material handling and storage systems (MH&SS) characterized by complex material flows and high‐traffic intensity. The paper seeks to provide solution examples and an analysis methodology to face large increases of materials flows through a redesign of the material handling and storage system.Design/methodology/approachAt first, possible strategies to improve system performances when facing strong increments of material flows are presented and discussed. A significant case study is then analyzed in order to present a practical application of the proposed methodology. Resorting to discrete‐events simulation, the alternatives are verified, correct design choices are identified, and the resources are properly sized to develop a streamlined layout.FindingsThe paper recognises that design and upgrade of intensive material handling systems is a complex task asking for a careful study of alternatives and detailed system analysis, otherwise capacity problems and bottleneck phenomena may not be effectively solved.Research limitations/implicationsThis work focuses on a specific case study. The paper, therefore, will be of interest mainly to managers and designers of similar plants and large – intensive material handling systems.Practical implicationsThe paper shows how the correct planning and analysis of design alternatives integrated with a detailed system simulation enable a drastic reduction of bottleneck phenomena, thus meeting the required capacity improvement goals when upgrading and redesigning complex and high‐volume material handling systems.Originality/valueThe paper, while providing insights to practitioners engaged in design and management of complex MH&SS, outlines a methodological approach which can be useful when facing major capacity improvement projects.