An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programming
Warehouses are vital in linking production to consumption, often using a forward–reserve layout to balance picking efficiency and bulk storage. However, replenishing the forward area from reserve storage is prone to delays and congestion, especially during high-demand periods. This study investigate...
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| Format: | Article |
| Language: | English |
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MDPI AG
2025-07-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/15/14/7767 |
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| author | İrem Kalafat Mustafa Hekimoğlu Ahmet Deniz Yücekaya Gökhan Kirkil Volkan Ş. Ediger Şenda Yıldırım |
| author_facet | İrem Kalafat Mustafa Hekimoğlu Ahmet Deniz Yücekaya Gökhan Kirkil Volkan Ş. Ediger Şenda Yıldırım |
| author_sort | İrem Kalafat |
| collection | DOAJ |
| description | Warehouses are vital in linking production to consumption, often using a forward–reserve layout to balance picking efficiency and bulk storage. However, replenishing the forward area from reserve storage is prone to delays and congestion, especially during high-demand periods. This study investigates the strategic use of buffer areas—intermediate zones between forward and reserve locations—to enhance flexibility and reduce bottlenecks. Although buffer zones are common in practice, they often lack a structured decision-making framework. We address this gap by developing an optimization model that integrates demand forecasts to guide daily replenishment decisions. To handle the computational complexity arising from large state and action spaces, we implement an approximate dynamic programming (ADP) approach using certainty-equivalent control within a rolling-horizon framework. A real-world case study from an automotive spare parts warehouse demonstrates the model’s effectiveness. Results show that strategically integrating buffer zones with an ADP model significantly improves replenishment timing, reduces direct picking by up to 90%, minimizes congestion, and enhances overall flow of intra-warehouse inventory management. |
| format | Article |
| id | doaj-art-1640f0f2e70b4d6c80dfc77ce26d4024 |
| institution | Matheson Library |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj-art-1640f0f2e70b4d6c80dfc77ce26d40242025-07-25T13:12:18ZengMDPI AGApplied Sciences2076-34172025-07-011514776710.3390/app15147767An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programmingİrem Kalafat0Mustafa Hekimoğlu1Ahmet Deniz Yücekaya2Gökhan Kirkil3Volkan Ş. Ediger4Şenda Yıldırım5Department of Industrial Engineering, Faculty of Engineering and Natural Sciences, Kadir Has University, 34083 Istanbul, TürkiyeDepartment of Industrial Engineering, Faculty of Engineering and Natural Sciences, Kadir Has University, 34083 Istanbul, TürkiyeDepartment of Industrial Engineering, Faculty of Engineering and Natural Sciences, Kadir Has University, 34083 Istanbul, TürkiyeDepartment of Industrial Engineering, Faculty of Engineering and Natural Sciences, Kadir Has University, 34083 Istanbul, TürkiyeDepartment of Industrial Engineering, Faculty of Engineering and Natural Sciences, Kadir Has University, 34083 Istanbul, TürkiyeDepartment of Industrial Engineering, Faculty of Engineering and Natural Sciences, Kadir Has University, 34083 Istanbul, TürkiyeWarehouses are vital in linking production to consumption, often using a forward–reserve layout to balance picking efficiency and bulk storage. However, replenishing the forward area from reserve storage is prone to delays and congestion, especially during high-demand periods. This study investigates the strategic use of buffer areas—intermediate zones between forward and reserve locations—to enhance flexibility and reduce bottlenecks. Although buffer zones are common in practice, they often lack a structured decision-making framework. We address this gap by developing an optimization model that integrates demand forecasts to guide daily replenishment decisions. To handle the computational complexity arising from large state and action spaces, we implement an approximate dynamic programming (ADP) approach using certainty-equivalent control within a rolling-horizon framework. A real-world case study from an automotive spare parts warehouse demonstrates the model’s effectiveness. Results show that strategically integrating buffer zones with an ADP model significantly improves replenishment timing, reduces direct picking by up to 90%, minimizes congestion, and enhances overall flow of intra-warehouse inventory management.https://www.mdpi.com/2076-3417/15/14/7767forward–reserveinventory managementADPreplenishmentspare parts warehouse |
| spellingShingle | İrem Kalafat Mustafa Hekimoğlu Ahmet Deniz Yücekaya Gökhan Kirkil Volkan Ş. Ediger Şenda Yıldırım An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programming Applied Sciences forward–reserve inventory management ADP replenishment spare parts warehouse |
| title | An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programming |
| title_full | An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programming |
| title_fullStr | An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programming |
| title_full_unstemmed | An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programming |
| title_short | An Integrated Framework for Internal Replenishment Processes of Warehouses Using Approximate Dynamic Programming |
| title_sort | integrated framework for internal replenishment processes of warehouses using approximate dynamic programming |
| topic | forward–reserve inventory management ADP replenishment spare parts warehouse |
| url | https://www.mdpi.com/2076-3417/15/14/7767 |
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