Optimizing dock configuration and staffing in decentralized receiving

In manufacturing facilities, shipping and receiving traditionally have been concentrated in one or two areas of the building. The widespread introduction of just-in-time shipping policies in US manufacturing companies during the past 15 years, as well as the common use of decentralized receiving in the Japanese automobile industry, has motivated the consideration (and occasionally the adoption) of dock configurations to support decentralized receiving (also known as perimeter receiving). By providing multiple access points along the perimeter of the building, decentralized receiving generally reduces the time and cost associated with moving purchased parts to the locations within the facility where they are used, but also results in increased cost of construction, maintenance, and operation for docks and associated truck access/egress, as well as additional interior floorspace requirements. We develop an optimization-based procedure to determine which of several possible dock areas to construct, how many doors or gates each should have, how many unloading and internal material handling staff should be assigned to each group, and which inbound materials each group should handle. We consider the amortized cost of constructing and equipping the docks, the amortized cost of material handling equipment to support the unloaders and material handlers, the cost of operating the material handling equipment, and labor costs for both unloading and internal material handling.