Warehouse redesign considering systematic obstructions of In-transit Goods through capacity expansion and reorganization plan

In some warehouses, the dispatch area is often one of the busiest zones, as it is a mandatory passage point for several processes. This is particularly true in warehouses like the one studied, which has a U-shaped layout where the inflow and outflow of materials converge in the same location. Consequently, any obstruction in this area can directly impact operational efficiency. The analyzed warehouse had a bottleneck in the dispatch area, worsened by high demand from in-transit orders arriving from other cities for temporary processing and shipment to their final destinations. This situation further aggravated congestion in the dispatch area, where the in-transit orders were temporarily stored, causing excessive processing times. Additionally, delivery deadlines were frequently missed, resulting in contractual penalties. The main objective of the project was to resolve this structural issue by implementing alternatives to improve inventory flow, optimize capacity, and reduce operational times. After evaluating options, the chosen solution was to add an additional level to the rack closest to the dispatch area, creating a fourth shelf to establish an exclusive zone for in-transit inventory. The methodology included diagnosing the problem, time analyses, and designing solutions. The solution had a significant impact: the average time that boxes obstructed the dispatch area decreased from nearly 3 days to 97 minutes, processing times improved by 20%, and contractual penalties were eliminated.orking conditions. In conclusion, the implemented solution improved both logistical performance and customer service, achieving the goals of reducing operational times and eliminating penalties, thereby contributing to the company’s enhanced competitiveness.

• Autores: Hernández Blanco, Daniel; Juan Palencia, Ilan Paul; Silva Ospino, Harrison David
• Fecha de publicación: 2025
• Institución: Universidad del Norte
• Repositorio: Repositorio Uninorte
• Idioma: spa
• OAI Identifier: oai:manglar.uninorte.edu.co:10584/13500
• Acceso en línea: http://hdl.handle.net/10584/13500
• Palabra clave: Bodega, Inventario, Tránsito, Congestión, Despacho, Demanda.; Warehouse, Inventory, Transit, Congestion, Dispatch, Demand.
• License: Universidad del Norte