Advertisement

Performance assessment in order picking systems: a visual double cross-analysis

  • Riccardo ManziniEmail author
  • Riccardo Accorsi
  • Giulia Baruffaldi
  • Daniele Santi
  • Alessandro Tufano
ORIGINAL ARTICLE
  • 42 Downloads

Abstract

The aim of this paper is to introduce a practice-ready systematic methodology for the management of storage assignments and allocation decisions as well as an assessment of the resulting performance in an order picking system (OPS). Built on extant and well-known metrics of performance this method implements a double cross-analysis through an original visual tool that is easy to understand by warehousing managers and practitioners. This tool is organized in two main steps. The first step is a cross-analysis that combines multiple performance indicators to help the decision-maker understand whether an OPS provides the scope for performance improvement. A comparison with potential storage configurations is then conducted in the second step through a tailored multi-scenario cross-analysis, which attempts to identify the best combination of allocation and assignment policies capable of minimizing the overall traveling performance. The proposed methodology is applied to a significant real-world OPS. The selected case study represents a reference framework for decision-makers and practitioners.

Keywords

Picking Order picking system (OPS) Storage allocation Storage assignment Case study Picker-to-part System performance 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Acknowledgments

The authors would like to heartily thank the company Fercam S.p.a. involved in this study. Especially in the name of Eng. Luca Mezzaro, for his support and his willingness to cooperate to this project.

References

  1. 1.
    Bartholdi JJ, Hackman ST (2017) Warehouse & distribution science. IIE Trans. http://www.warehouse-science.com/. Accessed 12 Nov 2018
  2. 2.
    Heragu SS, Du L, Mantel RJ, Schuur PC (2005) Mathematical model for warehouse design and product allocation. Int J Prod Res 43(2):327–338.  https://doi.org/10.1080/00207540412331285841 CrossRefzbMATHGoogle Scholar
  3. 3.
    Tompkins JA, White JA, Bozer YA, Tanchoco JMA (2003) In: Tompkins JA, White JA, Bozer YA, Tanchoco JMA (eds) Facilities planning, 4th edn. Wiley, Hoboken.  https://doi.org/10.1080/00207543.2011.563164 Google Scholar
  4. 4.
    Rouwenhorst B, van den Berg J, Mantel R, Zijm H (1999) UnitLoad, a decision support system for warehouse design. Int J Flex Autom Integr Manuf 7:115–127Google Scholar
  5. 5.
    Dallari F, Marchet G, Melacini M (2009) Design of order picking system. Int J Adv Manuf Technol 42:1–2): 1–12.  https://doi.org/10.1007/s00170-008-1571-9 CrossRefGoogle Scholar
  6. 6.
    De Koster R, Le-duc T, Roodbergen KJ (2007) Design and control of warehouse order picking: a literature review. Eur J Oper Res 182(2006):481–501CrossRefzbMATHGoogle Scholar
  7. 7.
    Gu J, Goetschalckx M, McGinnis LF (2010) Research on warehouse design and performance evaluation: a comprehensive review. Eur J Oper Res 203(3). Elsevier):539–549.  https://doi.org/10.1016/j.ejor.2009.07.031 CrossRefzbMATHGoogle Scholar
  8. 8.
    Bartholdi JJ, Hackman ST (2008) Allocating space in a forward pick area of a distribution center for small parts. IIE Transactions (Institute of Industrial Engineers) 40(11):1046–1053.  https://doi.org/10.1080/07408170802167662 Google Scholar
  9. 9.
    Hackman ST, Rosenblatt MJ, Olin JM (1990) Allocating items to an automated storage and retrieval system. IIE Trans 22:7–14.  https://doi.org/10.1080/07408179008964152 CrossRefGoogle Scholar
  10. 10.
    Accorsi R, Manzini R, Bortolini M (2012) A hierarchical procedure for storage allocation and assignment within an order-picking system. A case study. Int J Log Res Appl 15(6):351–364.  https://doi.org/10.1080/13675567.2012.742877 CrossRefGoogle Scholar
  11. 11.
    Manzini R, Gamberi M, Persona A, Regattieri A (2007) Design of a class based storage picker to product order picking system. Int J Adv Manuf Technol 32(7–8):811–821.  https://doi.org/10.1007/s00170-005-0377-2 CrossRefGoogle Scholar
  12. 12.
    Kofler M, Beham A, Wagner S, Affenzeller M (2011) Re-warehousing vs. healing: strategies for warehouse storage location assignment. In 3rd IEEE International Symposium on Logistics and Industrial Informatics (LINDI), pp 77–82.  https://doi.org/10.1109/LINDI.2011.6031124
  13. 13.
    Gu J, Goetschalckx M, McGinnis LF (2007) Research on warehouse operation: a comprehensive review. Eur J Oper Res 177(1):1–21.  https://doi.org/10.1016/j.ejor.2006.02.025 CrossRefzbMATHGoogle Scholar
  14. 14.
    Manzini R, Accorsi R, Gamberi M, Penazzi S (2015a) Modeling class-based storage assignment over life cycle picking patterns. Int J Prod Econ 170. Elsevier:790–800.  https://doi.org/10.1016/j.ijpe.2015.06.026. CrossRefGoogle Scholar
  15. 15.
    Accorsi R, Manzini R, Maranesi F (2014) A decision-support system for the design and management of warehousing systems. Comput Ind 65(1). Elsevier B.V.):175–186.  https://doi.org/10.1016/j.compind.2013.08.007 CrossRefGoogle Scholar
  16. 16.
    Manzini R, Bozer Y, Heragu S (2015b) Decision models for the design, optimization and management of warehousing and material handling systems. Int J Prod Econ 170:711–716.  https://doi.org/10.1016/j.ijpe.2015.08.007 CrossRefGoogle Scholar
  17. 17.
    Malmborg CJ, Krishnakumar B (1989) Optimal storage assignment policies for multiaddress warehousing systems. IEEE Trans Syst Man Cybern 19:197–204CrossRefGoogle Scholar
  18. 18.
    Hackman ST, Rosenblatt MJ, Olin JM (1990) Allocating items to an automated storage and retrieval system. IIE Trans 22(1):7–14.  https://doi.org/10.1080/07408179008964152 CrossRefGoogle Scholar
  19. 19.
    Larson TN, March H, Kusiak A (1997) A heuristic approach to warehouse layout with class-based storage. IIE Trans. 29(4):337–348.  https://doi.org/10.1080/07408179708966339 Google Scholar
  20. 20.
    Bartholdi JJ, Hackman ST (2008) Allocating space in a forward pick area of a distribution center for small parts. IIE Trans 40:1046–1053.  https://doi.org/10.1080/07408170802167662 CrossRefGoogle Scholar
  21. 21.
    Hassini E (2008) Storage space allocation to maximize inter-replenishment times 35: 2162–2174.  https://doi.org/10.1016/j.cor.2006.09.023.
  22. 22.
    Walter R, Boysen N, Scholl A (2013) The discrete forward-reserve problem - allocating space, selecting products, and area sizing in forward order picking. Eur J Oper Res 229:585–594.  https://doi.org/10.1016/j.ejor.2013.02.047 CrossRefzbMATHGoogle Scholar
  23. 23.
    Yu Y, De Koster RBM, Guo X (2015) Class-based storage with a finite number of items: using more classes is not always better. Prod Oper Manag 24(8):1235–1247.  https://doi.org/10.1111/poms.12334 CrossRefGoogle Scholar
  24. 24.
    Heskett J (1963) Cube-per-order index a key to warehouse stock location. Transp Distrib Manag 3:27–31Google Scholar
  25. 25.
    Mallette AJ, Francis RL (1972) A generalized assignment approach to optimal facility layout. AIIE Trans 4(2):144–147.  https://doi.org/10.1080/05695557208974841 CrossRefGoogle Scholar
  26. 26.
    Kallina C, Lynn J (1976) Application of the Cube-Per-Order Index Rule for Stock Location in a Distribution Warehouse. Interfaces (Providence) 7:37–46.  https://doi.org/10.1287/inte.7.1.37 CrossRefGoogle Scholar
  27. 27.
    Malmborg CJ, Bhaskaran K (1990) A revised proof of optimality for the cube-per-order index rule for stored item location. Appl Math Model 14:87–95.  https://doi.org/10.1016/0307-904X(90)90076-H MathSciNetCrossRefzbMATHGoogle Scholar
  28. 28.
    Brynzèr H, Johansson MI (1996) Storage location assignment : Using the product structure to reduce order picking times. Int J Prod Econ 46–47:595–603CrossRefGoogle Scholar
  29. 29.
    Van Den Berg, Jeroen P, Sharp GP, Gademann AJRM, Pochet Y (1998) Forward-reserve allocation in a warehouse with unit-load replenishments. Eur J Oper Res 111(1):98–113.  https://doi.org/10.1016/S0377-2217(98)80013-1 CrossRefzbMATHGoogle Scholar
  30. 30.
    Liu C (1999) Clustering techniques for stock location and order-picking in a distribution center. Comput Oper Res 26:989–1002CrossRefzbMATHGoogle Scholar
  31. 31.
    Zhang GQ, Xue J, Lai KK (2002) A class of genetic algorithms for multiple-level warehouse layout problems. Int J Prod Res 40(3):731–744.  https://doi.org/10.1080/00207540110093909 CrossRefzbMATHGoogle Scholar
  32. 32.
    Muppani M, Reddy V, Adil GK (2008) Efficient formation of storage classes for warehouse storage location assignment: a simulated annealing approach. Omega 36(4):609–618.  https://doi.org/10.1016/j.omega.2007.01.006 CrossRefGoogle Scholar
  33. 33.
    Chen L, Langevin A, Riopel D (2011) A tabu search algorithm for the relocation problem in a warehousing system. Int J Prod Econ 129(1):147–156.  https://doi.org/10.1016/j.ijpe.2010.09.012 CrossRefGoogle Scholar
  34. 34.
    Ang M, Lim YF, Sim M (2012) Robust storage assignment in unit-load warehouses. Manag Sci 58(11):2114–2130.  https://doi.org/10.1287/mnsc.1120.1543 CrossRefGoogle Scholar
  35. 35.
    Ene S, Ozturk N (2012) Storage location assignment and order picking optimization in the automotive industry. Int J Adv Manuf Technol 60(5–8):787–797.  https://doi.org/10.1007/s00170-011-3593-y CrossRefGoogle Scholar
  36. 36.
    Smith JS, Yingde L (2012) Dynamic slotting optimization based on skus correlations in a zone-based wave-picking system. http://www.mhi.org/downloads/learning/cicmhe/colloquium/2012/yingde.pdf. Accessed 12 Nov 2018
  37. 37.
    Xiao J, Zheng L (2012) Correlated storage assignment to minimize zone visits for BOM picking. Int J Adv Manuf Technol 61(5–8):797–807.  https://doi.org/10.1007/s00170-011-3740-5 CrossRefGoogle Scholar
  38. 38.
    Chiang M-h, David C-p L, Chen M-c (2013, 2011) The adaptive approach for storage assignment by mining data of warehouse management system for distribution centres. Enterp Inf Syst:37–41.  https://doi.org/10.1080/17517575.2010.537784
  39. 39.
    Guerriero F, Musmanno R, Pisacane O, Rende F (2013) A mathematical model for the multi-levels product allocation problem in a warehouse with compatibility constraints. Appl Math Model 37(6). Elsevier Inc.):4385–4398.  https://doi.org/10.1016/j.apm.2012.09.015 MathSciNetCrossRefGoogle Scholar
  40. 40.
    Battista C, Fumi A, Laura L, M. Schiraldi M (2014) Multiproduct slot allocation heuristic to minimize storage space. Int J Retail Distrib Manag 42(3):172–186.  https://doi.org/10.1108/IJRDM-03-2012-0024 CrossRefGoogle Scholar
  41. 41.
    Fontana ME, Cavalcante CAV (2014) Use of Promethee method to determine the best alternative for warehouse storage location assignment. Int J Adv Manuf Technol 70:1615–1624.  https://doi.org/10.1007/s00170-013-5405-z CrossRefGoogle Scholar
  42. 42.
    Rao SS, Adil GK (2014) Class-Based Storage Assignment in a Unit-Load Warehouse Employing AS/RS with Inventory Space Allocation Considering Product Specific Setup to Holding Cost Ratio. Asia-Pacific J Oper Res 31:1450034.  https://doi.org/10.1142/S0217595914500341 MathSciNetCrossRefzbMATHGoogle Scholar
  43. 43.
    Bortolini M, Botti L, Cascini A, Gamberi M, Mora C, Pilati F (2015) Unit-load storage assignment strategy for warehouses in seismic areas. Comput Ind Eng 87. Elsevier Ltd:481–490.  https://doi.org/10.1016/j.cie.2015.05.023 CrossRefGoogle Scholar
  44. 44.
    Pan JCH, Shih PH, Wu MH, Lin JH (2015) A storage assignment heuristic method based on genetic algorithm for a pick-and-pass warehousing system. Comput Ind Eng 81:1–13.  https://doi.org/10.1016/j.cie.2014.12.010 CrossRefGoogle Scholar
  45. 45.
    Moshref-Javadi M, Lehto MR (2016) Material handling improvement in warehouses by parts clustering. Int J Prod Res 54:4256–4271.  https://doi.org/10.1080/00207543.2016.1140916 CrossRefGoogle Scholar
  46. 46.
    Pang KW, Chan HL (2017) Data mining-based algorithm for storage location assignment in a randomised warehouse. Int J Prod Res 55:4035–4052.  https://doi.org/10.1080/00207543.2016.1244615 CrossRefGoogle Scholar
  47. 47.
    Accorsi R, Baruffaldi G, Manzini R (2018) Picking efficiency and stock safety: a bi-objective storage assignment policy for temperature-sensitive products. Comput Ind Eng 115:240–252.  https://doi.org/10.1016/j.cie.2017.11.009 CrossRefGoogle Scholar
  48. 48.
    Bindi F, Manzini R, Pareschi A, Regattieri A (2009) Similarity-based storage allocation rules in an order picking system: an application to the food service industry. Int J Logist Res Appl 12:233–247.  https://doi.org/10.1080/13675560903075943 CrossRefGoogle Scholar
  49. 49.
    Bottani E, Cecconi M, Vignali G, Montanari R (2012) Optimisation of storage allocation in order picking operations through a genetic algorithm. Int J Log Res Appl 15(2):127–146.  https://doi.org/10.1080/13675567.2012.694860 CrossRefGoogle Scholar
  50. 50.
    Lim JSH, Foo DCY, Ng DKS, Aziz R, Tan RR (2014) Graphical tools for production planning in small medium industries (SMIs) based on pinch analysis. J Manuf Syst 33(4). The Society of Manufacturing Engineers):639–646.  https://doi.org/10.1016/j.jmsy.2014.06.001 CrossRefGoogle Scholar
  51. 51.
    Malmborg CJ, Bhaskaran K (1990) A revised proof of optimality for the cube-per-order index rule for stored item location. Appl Math Model 14(2):87–95.  https://doi.org/10.1016/0307-904X(90)90076-H MathSciNetCrossRefzbMATHGoogle Scholar
  52. 52.
    Kallina C, Lynn J (1976) Application of the cube-per-order index rule for stock location in a distribution warehouse. Interfaces 7(1):37–46.  https://doi.org/10.1287/inte.7.1.37 CrossRefGoogle Scholar
  53. 53.
    Sagan H, Bishir JW (1991) Optimal allocation of storage space. Eur J Oper Res 55(1):82–90.  https://doi.org/10.1016/0377-2217(91)90193-Y CrossRefzbMATHGoogle Scholar
  54. 54.
    Li Z, Low MYH, Lim RYG (2009) Optimal decision-making on product allocation for crossdocking and warehousing operations. Int J Serv Oper Informatics 4(4):352.  https://doi.org/10.1504/IJSOI.2009.029184 Google Scholar
  55. 55.
    Xie J, Yi M, Ernst AT, Li X, Song A (2014) Scaling up solutions to storage location assignment problems by genetic programming. In Simulated Evolution and Learning, pp 691–702Google Scholar
  56. 56.
    Malmborg CJ, Altassan KM (1998) Analysis of storage assignment policies in less than unit load warehousing systems. Int J Prod Res 36(12):3459–3475.  https://doi.org/10.1080/002075498192157 CrossRefzbMATHGoogle Scholar
  57. 57.
    Roodbergen KJ, Vis IFA, Don Taylor G Jr (2015) Simultaneous determination of warehouse layout and control policies. Int J Prod Res 53(11). Taylor & Francis):3306–3326.  https://doi.org/10.1080/00207543.2014.978029 CrossRefGoogle Scholar
  58. 58.
    Marchet G, Melacini M, Perotti S (2015) Investigating order picking system adoption: a case-study-based approach. Int J Log Res Appl 18(1):82–98.  https://doi.org/10.1080/13675567.2014.945400 CrossRefGoogle Scholar
  59. 59.
    Selviaridis K, Spring M (2007) Third party logistics: a literature review and research agenda. Int J Logist Manag 18(1):125–150.  https://doi.org/10.1108/09574090710748207 CrossRefGoogle Scholar
  60. 60.
    Davarzani H, Norrman A (2015) Toward a relevant agenda for warehousing research: literature review and practitioners’ input. Logist Res 8.  https://doi.org/10.1007/s12159-014-0120-1
  61. 61.
    Werneck Barbosa M, de la Calle Vicente A, Ladeira MB, de Oliveira MPV (2017) Managing supply chain resources with big data analytics: a systematic review. Int J Log Res Appl Taylor & Francis 21:1–24.  https://doi.org/10.1080/13675567.2017.1369501 CrossRefGoogle Scholar
  62. 62.
    Baruffaldi G, Accorsi R, Manzini R (2018) Warehouse management system customization and information availability in 3pl companies: a decision-support tool. Ind Manag Data Syst.  https://doi.org/10.1108/IMDS-01-2018-0033

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Riccardo Manzini
    • 1
    Email author
  • Riccardo Accorsi
    • 1
  • Giulia Baruffaldi
    • 1
  • Daniele Santi
    • 1
  • Alessandro Tufano
    • 1
  1. 1.Department of Industrial Engineering, Warehousing CenterAlma Mater Studiorum – Bologna UniversityBolognaItaly

Personalised recommendations