Abstract
In recent years the increase in time-based competition and the growth of e-commerce have put pressure on managers to reduce the costs of warehouse design and management activities. This paper presents a new integrated approach to support the decision making process in optimising a picker to part, forward-reserve, less than unit load order picking system. An analytical model and a multi-parametric dynamic model to quickly estimate the travelled distance during a picking cycle are introduced. The factorial analysis of several what-if scenarios reveals which factors and combinations of factors are the most critical in affecting the picking system’s response.
Similar content being viewed by others
References
Manzini R, Gamberi M, Regattieri A (2005) Design and control of an AS/RS. Int J Adv Manuf Technol DOI: 10.1007/s00170–004–2427–6
Van den Berg JP (1999) A literature survey on planning and control of warehousing systems. IIE Trans 31:751–762
Gray AE, Karmarkar US, Seidmann A (1992) Design and operation of an order-consolidation warehouse: models and application. Eur J Oper Res 58:14–36
Manzini R, Gamberi M, Regattieri A (2005) Design and control of a flexible order-picking system (FOPS). A new integrated approach to the implementation of an expert system. Int J Manuf Technol Manag 16(1):18–35
Manzini R, Gamberi M, Regattieri A, Persona A (2004) Framework for designing a flexible cellular assembly system. Int J Prod Res 42(17): 3505–3528
Manzini R, Ferrari E, Gamberi M, Persona A, Regattieri A (2005) Simulation performance in the optimisation of the supply chain. Int J Manuf Technol Manag 16(2):127–144
Manzini R, Pareschi A, Regattieri A, Basso A (2003) La progettazione e il controllo di sistemi Flessibili di Order Picking (OPS). Proceedings of the 30th national conference ANIMP, Rapallo, Italy
Jawahar N, Aravindan P, Ponnambalam SG (1998) Optimal random storage allocation for an AS/RS in an FMS. Int J Adv Manuf Technol 14(2):116–132
Chetty Krishnaiah OV, Reddy Sarveswar M (2003) Genetic algorithms for studies on AS/RS integrated with machines. Int J Adv Manuf Technol 22(11–12):932–940
Chincholkar AK, Krishnaiah Chetty OV (1996) Simultaneous optimisation of control factors in automated storage and retrieval systems and FMS using stochastic coloured Petri nets and the Taguchi method. Int J Adv Manuf Technol 12(2):137–144
Sankar SS, Ponnanbalam SG, Rajendran C (2003) A multiobjective genetic algorithm for scheduling a flexible manufacturing system. Int J Adv Manuf Technol 22(3–4):229–236
Malmborg CJ, Al-Tassan K (2000) An integrated performance model for orderpicking systems with randomize storage. Appl Math Model 24:95–111
Haskett JL (1963) Cube-per-order index—a key to warehouse stock location. Trans Distrib Manag 3:27–31
Kallina C, Lynn J (1976) Application of the cube-per-order index rule for stock location in distribution warehouse. Interfaces 7:37–46
Frazelle EH, Hackman ST, Platzman LK (1989) Improving order picking productivity through intelligent stock assignment planning. Proceedings of the council of logistics management annual conference, St. Louis, MO, pp 353–371
Van den Berg JP, Gademann AJRM (2000) Simulation study of an automated storage/retrieval system. Int J Prod Res 38:1339–1356
Caron F, Marchet G, Perego A (2000) Optimal layout in low-level picker-to-part systems. Int J Prod Res 38:101–117
Roodbergen KJ, de Koster R (2001) Routing order pickers in a warehouse with middle aisle. Eur J Oper Res 133:32–43
Ferrari E, Gamberi M, Manzini R, Pareschi A, Persona A, Regattieri A (2003) An integrated optimisation process for the production planning and control of a flexible manufacturing system. Proceedings of the business and industry symposium, advanced simulation technologies conference, Orlando, Florida, pp 79–84
Lawler EL, Lenstra JK, Rinnooy Kan AHG, Shmoys DB (1985) The traveling salesman problem. Wiley, New York
Lawler EL, Lenstra JK, Rinnooy Kan AHG, Shmoys DB (1993) Sequencing and scheduling: algorithms and complexity. In: Graves SC et al. (eds) Handbooks in OR & MS. Elsevier Science, St. Louis, MO, vol 4, ch 9, pp 445–522
Kosfeld M (1998) Warehouse design through dynamic simulation. Proceedings of the winter simulation conference, Medeiros, pp 1049–1053
Helo PT (2000) Dynamic modelling of surge effect and capacity limitation in supply chains. Int J Prod Res 38:4521–4533
Riddalls CE, Bennett S, Tipi NS (2000) Modelling the dynamics of supply chains. Int J Syst Sci 8:969–976
Ratliff HD, Rosenthall AS (1983) Order picking in a rectangular warehouse: a solvable case of the travelling salesman problem. Oper Res 31:507–521
Hall RW (1993) Distance approximations for routing manual pickers in a warehouse. IIE Trans 25:76–87
Yoon CS, Sharp GP (1995) Example application of the cognitive design procedure for an order pick system: case study. Eur J Oper Res 87:223–246
Yoon CS, Sharp GP (1996) A structured procedure for analysis and design of order pick systems. IIE Trans 28:379–389
Larson TN, March H, Kusiak A (1997) A heuristic approach to warehouse layout with class based storage. IIE Trans 29:337–348
Petersen CG (1997) An evaluation of order picking routing policies. Int J Oper Prod Manage 17:1098–1111
Caron F, Marchet G, Perego A (1998) Routing policies and COI-based storage policies in picker-to-part systems. Int J Prod Res 36:713–732
Chew EP, Tang LC (1999) Travel time analysis for general item location assignment in a rectangular warehouse. Eur J Oper Res 112:582–597
Van den Berg JP, Zijm WHM (1999) Models for warehouse management: classification and examples. Int J Prod Econ 59:519–528
Vaughan TS, Petersen CG (1999) The effect of warehouse cross aisles on order picking efficiency. Int J Prod Res 37:881–897
Rouwenhorst B, Reuter B, Stockrahm V, van Houtum GJ, Mantel RJ, Zijm WHM (2000) Warehouse design and control: framework and literature review. Eur J Oper Res 122:515–533
Zerangue NF, Bodner DA, Govindaraj T, Karathur KN, McGinnis LF, Goetschalckx M, Sharp GP (2001) A process model of expertise in the design of warehousing and distribution systems. Proceedings of the IEEE international conference on systems, man, and cybernetics 5:3403–3408
Hwang H, Oh YH, Cha CN (2003) A stock location rule for a low level picker-to-part system. Eng Optim 35:285–295
Brynzer H, Johansson MI (1996) Storage location assignment: using the product structure to reduce order picking times. Int J Prod Econ 46–47:595–603
Ferrari E, Gamberi M, Manzini R, Pareschi A, Persona A, Regattieri A (2002) Effectiveness of dynamic simulation supporting and optimizing design and management of warehouse facilities. Proceedings of the business and industry symposium, advanced simulation technologies conference, San Diego, California, vol 34, pp 76–81
Papadimitriou C, Steiglitz K (1982) Combinatorial optimisation. Prentice Hall, Englewood Cliffs, New Jersey
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Manzini, R., Gamberi, M., Persona, A. et al. Design of a class based storage picker to product order picking system. Int J Adv Manuf Technol 32, 811–821 (2007). https://doi.org/10.1007/s00170-005-0377-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-005-0377-2