Order picking is the process of retrieving products from storage in response to a specific customer order. Although this process’ design has significant impact on warehouse global performance, a practical-oriented design procedure is still lacking in literature. This paper presents a novel order picking system design methodology based on Design for Six Sigma approach, that aims to assist designers making decisions by suggesting the most effective operational and organizational policies and the equipment needed in order to fulfill customer’s orders. A case research in a home appliances manufacturer is presented in order to demonstrate the effectiveness of this approach.


order picking process design methodology design for six sigma case research 


  1. 1.
    Baker, P., Canessa, M.: Warehouse design: A structured approach. European Journal of Operational Research 193, 425–436 (2009)CrossRefGoogle Scholar
  2. 2.
    Banks, J., Carson, J.S., Nelson, B.L.: Discrete-Event System Simulation. Prentice Hall, United States (2010)Google Scholar
  3. 3.
    Box, G.E.P., Hunter, J.S., Hunter, W.G.: Statistics for experimenters - Design, Innovation and Discover. John Wiley & Sons (2005)Google Scholar
  4. 4.
    Brue, G., Lausny, R.G.: Design for Six Sigma. McGraw Hill (2003)Google Scholar
  5. 5.
    Chackelson, C., Errasti, A., Cipres, D., Lahoz, F.: Design of a part to picker system. Design of experiments application aided by discrete event simulation. Dyna. 86, 515–522 (2011)CrossRefGoogle Scholar
  6. 6.
    De Koster, R., Le-Duc, T., Roodbergen, J.: Design and control of warehouse order picking: A literature review. European Journal of Operational Research 102, 481–501 (2007)CrossRefGoogle Scholar
  7. 7.
    Dallari, F., Marchet, G., Melacini, M.: Design of order picking system. International Journal of Advanced Manufacturing Technologies 42, 1–12 (2009)CrossRefGoogle Scholar
  8. 8.
    Ekren, B., Heragu, S., Krishnamurthy, A., Malmborg, C.: Simulation based experimental design to identify factors affecting performance of AVS/RS. Computer and Industrial Engineering (2009) (article in press)Google Scholar
  9. 9.
    Errasti, A.: Logística de almacenaje. Diseño y gestión de almacenes y plataformas logísticas. World Class Warehousing. Ediciones Pirámide, España (2011)Google Scholar
  10. 10.
    Errasti, A., Chackelson, C., Arcelus, M.: Estado del arte y retos para la mejora de sistemas de preparación de pedidos en almacenes: Estudio Delphi. Dirección y Organización 40, 78–85 (2010)Google Scholar
  11. 11.
    Frazelle, E.: World-Class Warehousing and Material Handling. McGraw-Hill, New York (2002)Google Scholar
  12. 12.
    Goetschalckx, M., Ashayeri, J.: Classification and design of order picking systems. Logistics World, 99–106 (June 1989)Google Scholar
  13. 13.
    Gu, J., Goetschalckx, M., McGinnis, L.: Research on warehouse design and performance evaluation: A comprehensive review. European Journal of Operational Research 203, 539–549 (2010)zbMATHCrossRefGoogle Scholar
  14. 14.
    Hahn, G.J.: Six Sigma: 20 key lessons learned. Quality and Reliability Engineering International 21, 225–233 (2005)CrossRefGoogle Scholar
  15. 15.
    Kleijnen, J.P.C.: Verification and validation of simulation models. European Journal of Operational Research 82, 145–162 (1995)zbMATHCrossRefGoogle Scholar
  16. 16.
    Law, A.M., Kelton, W.D.: Simulation Modeling and Analysis. McGraw-Hill, New York (1991)Google Scholar
  17. 17.
    Linderman, K., Schroeder, R., Zaheer, S., Choo, A.: Six Sigma: A goal-theoretic perspective. Journal of Operations Management 21, 193–203 (2003)CrossRefGoogle Scholar
  18. 18.
    Manzini, R., Gamberi, M., Persona, A., et al.: Design of a class based storage picker to product order picking system. International Journal of Advanced Manufacturing Technologies 32, 811–821 (2007)CrossRefGoogle Scholar
  19. 19.
    Montgomery, D.C.: Generation III Six Sigma. Quality and Reliability Engineering International 21, 3–4 (2005)Google Scholar
  20. 20.
    Montgomery, D.C.: Designed Experiments in Process improvement. Quality and Reliability Engineering International 22, 863–864 (2006)CrossRefGoogle Scholar
  21. 21.
    Montgomery, D.C.: Design and Analysis of Experiments. John Wiley & Sons (2008)Google Scholar
  22. 22.
    Rushton, A., Croucher, P., Baker, P.: The handbook of logistics and distribution management. Kogan Page Publishers (2006)Google Scholar
  23. 23.
    Sargent, R.G.: Verifying and validating simulation model. In: Proc. of 1996. Winter Simulation Conf., pp. 55–64 (1996)Google Scholar
  24. 24.
    Yang, K., El-Haik, B.: Design for Six Sigma: A roadmap for product development. McGraw-Hill (2003)Google Scholar
  25. 25.
    Yoon, C.S., Sharp, G.P.: A structured procedure for analysis and design of order pick systems. IIE Transactions 28, 379–389 (1996)CrossRefGoogle Scholar

Copyright information

© IFIP International Federation for Information Processing 2012

Authors and Affiliations

  • Claudia Chackelson
    • 1
  • Ander Errasti
    • 1
  • Martín Tanco
    • 2
  1. 1.TecnunUniversity of NavarraSan SebastianSpain
  2. 2.University of MontevideoMontevideoUruguay

Personalised recommendations