Simulation and Optimization of a Crossdocking Operation in a Just-in-Time Environment

In an ideal Just-in-Time (JIT) production environment, parts should be deli-vered to the workstations at the exact time they are needed and in the exact quantity required. In reality, for most component and subassemblies this is neither practical nor economical. In this study, the material flow of the crossdocking operation at the Toyota Motor Manufacturing plant in Georgetown, KY is simulated, analyzed and optimized. The objective is twofold. The first objective is to gain insight into the dynamic behaviour and the material flow of different crossdocking lay-outs and incoming material levels. The second objective is to reduce the travel distances in the crossdocking area; which in turn reduce the workload of the team members and ultimately decrease the lead time from unloading of the truck to delivery to the assembly line. Starting with the best layouts from the simulation results, the lanes will be rearranged using a genetic algorithm to allow the lanes with the most crossdocking traffic to be closest together. The book is addressed to professionals and researchers in the logistics area.