Design and Control of Warehouse Order Picking: a literature review

Order picking has long been identified as the most labour-intensive and costly activity for almost every warehouse; the cost of order picking is estimated to be as much as 55% of the total warehouse operating expense. Any underperformance in order picking can lead to unsatisfactory service and high operational cost for its warehouse, and consequently for the whole supply chain. In order to operate efficiently, the orderpicking process needs to be robustly designed and optimally controlled. This paper gives a literature overview on typical decision problems in design and control of manual order-picking processes. We focus on optimal (internal) layout design, storage assignment methods, routing methods, order batching and zoning. The research in this area has grown rapidly recently. Still, combinations of the above areas have hardly been explored. Order-picking system developments in practice lead to promising new research directions.Order picking;Logistics;Warehouse Management

Order batching in multi-server pick-and-sort warehouses.

In many warehouses, customer orders are batched to profit from a reduction in the order picking effort. This reduction has to be offset against an increase in sorting effort. This paper studies the impact of the order batching policy on average customer order throughput time, in warehouses where the picking and sorting functions are executed separately by either a single operator or multiple parallel operators. We present a throughput time estimation model based on Whitt's queuing network approach, assuming that the number of order lines per customer order follows a discrete probability distribution and that the warehouse uses a random storage strategy. We show that the model is adequate in approximating the optimal pick batch size, minimizing average customer order throughput time. Next, we use the model to explore the different factors influencing optimal batch size, the optimal allocation of workers to picking and sorting, and the impact of different order picking strategies such as sort-while-pick (SWP) versus pick-and-sort (PAS)Order batching; Order picking and sorting; Queueing; Warehousing;

Performance Approximation and Design of Pick-and-Pass Order Picking Systems

In this paper, we discuss an approximation method based on G/G/m queuing network modeling using Whitt’s (1983) queuing network analyzer to analyze pick-and-pass order picking systems. The objective of this approximation method is to provide an instrument for obtaining rapid performance estimates (such as order lead time and station utilization) of the order picking system. The pick-and-pass system is decomposed into conveyor pieces and pick stations. Conveyor pieces have a constant processing time, whereas the service times at a pick station depend on the number of order lines in the order to be picked at the station, the storage policy at the station, and the working methods. Our approximation method appears to be sufficiently accurate for practical purposes. It can be used to rapidly evaluate the effects of the storage methods in pick stations, the number of order pickers at stations, the size of pick stations, the arrival process of customer orders, and the impact of batching and splitting orders on system performance.simulation;warehousing;order picking;queuing network;pick-and-pass

Design and Control of Warehouse Order Picking: a literature review

Order picking has long been identified as the most labour-intensive and costly activity for almost every warehouse; the cost of order picking is estimated to be as much as 55% of the total warehouse operating expense. Any underperformance in order picking can lead to unsatisfactory service and high operational cost for its warehouse, and consequently for the whole supply chain. In order to operate efficiently, the orderpicking process needs to be robustly designed and optimally controlled. This paper gives a literature overview on typical decision problems in design and control of manual order-picking processes. We focus on optimal (internal) layout design, storage assignment methods, routing methods, order batching and zoning. The research in this area has grown rapidly recently. Still, combinations of the above areas have hardly been explored. Order-picking system developments in practice lead to promising new research directions

Performance Approximation and Design of Pick-and-Pass Order Picking Systems

In this paper, we discuss an approximation method based on G/G/m queuing network modeling using Whitt’s (1983) queuing network analyzer to analyze pick-and-pass order picking systems. The objective of this approximation method is to provide an instrument for obt

Order batching and picking in a synchronized zone order picking system

Order picking has been considered as one of the most critical operations in warehouse. In this study, we propose an analytical approximation model based on probability and queueing network theory to analyze order batching and picking area zoning on the mean order throughput time in a synchronized zone picker-to-part order picking system. The resulting model can be easily applied in the design and selection process of order picking systems. © 2011 IEEE.published_or_final_versionThe IEEE International Conference on Industrial Engineering and Engineering Management (IEEM 2011), Singapore, 6-9 December 2011. In Proceedings of the IEEE IEEM, 2011, p. 156-16

Determining Number of Zones in a Pick-and-pack Orderpicking System

In this study we consider a pick-to-pack orderpicking system, in which batches of orders are picked simultaneously from different(work) zones by a group of order pickers. After picking, the orders are transported by a conveyor to the next station for packing. Our aim is to determine the optimal number of zones such that the overall (picking and packing) time to finish a batch is minimized. We solve this problem by optimally assigning items to pick routes in each zone. We illustrate the method with data taken from a distribution center of one of the largest online retailers in the Netherlands

Product Return Handling

In this article we focus on product return handling and warehousingissues. In some businesses return rates can be well over 20% andreturns can be especially costly when not handled properly. In spiteof this, many managers have handled returns extemporarily. The factthat quantitative methods barely exist to support return handlingdecisions adds to this. In this article we bridge those issues by 1)going over the key decisions related with return handling; 2)identifying quantitative models to support those decisions.Furthermore, we provide insights on directions for future research.reverse logistics;decision-making;quantitative models;retailing and warehousing

Integrated Models and Tools for Design and Management of Global Supply Chain

In modern and global supply chain, the increasing trend toward product variety, level of service, short delivery delay and response time to consumers, highlight the importance to set and configure smooth and efficient logistic processes and operations. In order to comply such purposes the supply chain management (SCM) theory entails a wide set of models, algorithms, procedure, tools and best practices for the design, the management and control of articulated supply chain networks and logistics nodes. The purpose of this Ph.D. dissertation is going in detail on the principle aspects and concerns of supply chain network and warehousing systems, by proposing and illustrating useful methods, procedures and support-decision tools for the design and management of real instance applications, such those currently face by enterprises. In particular, after a comprehensive literature review of the principal warehousing issues and entities, the manuscript focuses on design top-down procedure for both less-than-unit-load OPS and unit-load storage systems. For both, decision-support software platforms are illustrated as useful tools to address the optimization of the warehousing performances and efficiency metrics. The development of such interfaces enables to test the effectiveness of the proposed hierarchical top-down procedure with huge real case studies, taken by industry applications. Whether the large part of the manuscript deals with micro concerns of warehousing nodes, also macro issues and aspects related to the planning, design, and management of the whole supply chain are enquired and discussed. The integration of macro criticalities, such as the design of the supply chain infrastructure and the placement of the logistic nodes, with micro concerns, such the design of warehousing nodes and the management of material handling, is addressed through the definition of integrated models and procedures, involving the overall supply chain and the whole product life cycle. A new integrated perspective should be applied in study and planning of global supply chains. Each aspect of the reality influences the others. Each product consumed by a customer tells a story, made by activities, transformations, handling, processes, traveling around the world. Each step of this story accounts costs, time, resources exploitation, labor, waste, pollution. The economical and environmental sustainability of the modern global supply chain is the challenge to face