This 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.
At 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.
The 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.
This 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.
The 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.
The 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.
