ORDER PICKING SYSTEMS IN WAREHOUSE MANAGEMENT: A LITERATURE REVIEW

Year 2012, Volume: 14 Issue: 3, 15 - 31, 01.09.2012

Gökçeçiçek Tuna Gonca Tunçel

Abstract

Order picking activities play a critical role in supply chain management in terms of both production systems (supplying
components to assembly operations) and distribution operations (meeting customer demands). Trends in customer orders
reveal that customer orders are transformed from few-and-large orders to many-and-small ones. On the other hand, lead
times of customer orders get consistently shorter. Because of these changes, companies need to adopt an effective and
flexible order picking system in order to remain competitive in the market. Order picking, as a labor intensive activity, deeply
affects both overall logistic operations and service level provided to customers. Additionally, order picking process
constitutes more than half of the total warehousing cost. For these reasons, it is crucial for companies to design and perform
an effective order picking process. In recent years, planning the order picking systems that minimize the travel time or the
travel distance, considering the specific constraints and parameters, has become the basis for many studies. In this study,
critical factors that play role in design and control of order picking process is reviewed comprehensively to aid decision
makers in constituting the optimal order picking system in warehouse management. In this context, product flow types in
warehouses, classification of order picking systems, storage assignments decisions, routing methods, order batching, and
zoning policies are investigated.

Keywords

Order picking, Warehouse management, Design of order picking system

DEPO YÖNETİMİNDE SİPARİŞ TOPLAMA SİSTEMLERİ: BİR LİTERATÜR ARAŞTIRMASI

Abstract

components to assembly operations) and distribution operations (meeting customer demands). Trends in customer orders reveal that customer orders are transformed from few-and-large orders to many-and-small ones. On the other hand, lead times of customer orders get consistently shorter. Because of these changes, companies need to adopt an effective and flexible order picking system in order to remain competitive in the market. Order picking, as a labor intensive activity, deeply affects both overall logistic operations and service level provided to customers. Additionally, order picking process constitutes more than half of the total warehousing cost. For these reasons, it is crucial for companies to design and perform an effective order picking process. In recent years, planning the order picking systems that minimize the travel time or the travel distance, considering the specific constraints and parameters, has become the basis for many studies. In this study, critical factors that play role in design and control of order picking process is reviewed comprehensively to aid decision makers in constituting the optimal order picking system in warehouse management. In this context, product flow types in warehouses, classification of order picking systems, storage assignments decisions, routing methods, order batching, and zoning policies are investigated

Keywords

Sipariş toplama, Depo yönetimi, Sipariş toplama sistemi tasarımı

References

• Armstrong R. D., Cook V. D., Saipe A. L. (1979): “Optimal Batching in a Semi-Automated Order Picking System”, The Journal of the Operational Research Society, Cilt 30, No. 8, s.711-720.
• Bartholdi J. J., Hackman S. T. (2005): “Warehouse & distribution science”, Available on line at: http://www.tli.gatech.edu/whscience/ book/wh-sci.pdf.
• Benders J. F. (1962): “Partitioning Procedures for Solving Mixed-Variable Programming Problems”, Numerische Mathematic, Cilt 4, s.238-252.
• 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”, International Journal of Logistics: Research and Applications, Cilt 12, No. 4, s.233-247.
• Caron F., Marchet G., Perego A. (1998): “Routing Policies and COI-Based Storage Policies in Picker-to-Part Systems”, International Journal of Production Research, Cilt 36, No. 3, s.713-732.
• Caron F., Marchet G., Perego A. (2000): “Optimal Layout in Low-Level Picker-to-Part Systems”, International Journal of Production Research, Cilt 38, No. 1, s.101-117.
• Chan F. T. S., Chan H. K. (2011): “Improving the Productivity of Order Picking of a Manual- Pick and Multi-Level Rack Distribution Warehouse Through the Implementation of Class- Based Storage”, Expert Systems with Applications, Cilt 38, s.2686-2700.
• Chang F. L., Liu Z. X., Xin Z., Liu D. D. (2007): “Research on Order Picking Optimization Problem of Automated Warehouse”, Systems Engineering-Theory and Practice, Cilt 27, No. 2, s.139–143.
• Choe K., Sharp G. (1991): “Small Parts Order Picking: Design and Operation”, Available at: http://www2.isye.gatech.edu/~mgoetsch/cali/Logistics%20Tutorial/order/article.htm, Georgia Tech Research Corporation, Atlanta, Erişim Tarihi: Mart 2012.
• Dallari F., Marchet G., Melacini M. (2009): “Design of Order Picking System”, International Journal of Advanced Manufacturing Technology, Cilt 42, No. 1-2, s.1-12.
• De Koster R., Neuteboom A. J. (Ed.) (2001): “The Logistics of Supermarket Chains: A Comparison of Seven Chains in the Netherlands”. Doetinchem: Elsevier Business Information.
• De Koster R., Le-Duc T., Roodbergen K. J. (2007): “Design and Control of Warehouse Order Picking: A Literature Review”, European Journal of Operational Research, Cilt 182, No. 2, s.481-501.
• Frazelle E. A., Sharp G. P. (1989): “Correlated Assignment Strategy Can Improve any Order Picking Operation”, Industrial Engineering, Cilt 21, No. 4, s.33-37.
• Gademann N., Van de Velde S. (2005): “Batching to Minimize Total Travel Time in a Parallel-Aisle Warehouse”, IIE Transactions, Cilt 37, No. 1, s.63-75.
• Goetschalckx M., Ratliff H. D. (1988): “Sequencing Picking Operations in a Man-Aboard Order Picking System”, Material Flow, Cilt 4, s.255-263.
• Gu J., Goetschalckx M., McGinnis L. F. (2007): “Research on Warehouse Operation: A Comprehensive Review”, European Journal of Operational Research, Cilt 177, s.1-21.
• Hall R. W. (1993): “Distance Approximate for Routing Manual Pickers in a Warehouse”, IIE Transactions, Cilt 25, No. 4, s.76-87.
• Hausman W.H., Schwarz L.B., Graves S.C. (1976): “Optimal storage assignment in automatic warehousing systems”, Management Science, 22(6), 629-638.
• Heragu S. S., Du L., Mantel R. J., Schuur P. B. (2005): “Mathematical Model for Warehouse Design and Product Allocation”, International Journal of Production Research, Cilt 43, No. 5, 327-338.
• Heskett J. L. (1964): “Putting the Cube-Per-Order Index to Work in Warehouse Layout”, Transport and Distribution Management, Cilt 4, s.23-30.
• Hsieh L. F., Huang Y. C. (2011): “New Batch Construction Heuristics to Optimise the Performance of Order Picking Systems”, International Journal of Production Economics, Cilt 131, s.618-630.
• Hwang H. S., Cho G. S. (2006): “A Performance Evaluation Model for Order Picking Warehouse Design”, Computers and Industrial Engineering, Cilt 51, No. 2, s.335-342.
• Le-Duc T., De Koster R. (2005): “Layout Optimization for Class Based Storage Strategy Warehouses”, (Ed.: R. de Koster, W.Delfmann), Supply Chain Management-European Perspectives. CBS Press, Kopenhag, s. 191-214.
• Lehrer T., Potrc I., Sraml M., Tollazi T. (2010): “Travel Time Models for Automated Warehouses with Aisle Transferring Storage and Retrieval Machine”, European Journal of Operational Research, Cilt 205, s.571-583.
• Lehrer T., Potrc I., Sraml M. (2011): “Simulation Analysis of Mini-Load Multi-Shuttle Automated Storage and Retrieval Systems”, International Journal of Advanced Manufacturing Technology, Cilt 54, s.337-348.
• 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”, Journal of Manufacturing Technology Management, Cilt 16, No. 1, s.18–35.
• Oudijk D., Roodbergen K. J., De Koster R., Mekern M. (1999), “The Interactive Erasmus Logistica Warehouse Website”, http://www.fbk.eur.nl/OZ/LOGISTICA.
• Pan J. C. H., Shih P. H. (2008): “Evaluation of the Throughput of a Multiple-Picker Order Picking System with Congestion Consideration”, Computers and Industrial Engineering, Cilt 55, No. 2, s.379-389.
• Pan J. C. H., Wu M. H. (2009): “A Study of Storage Assignment Problem for an Order Picking Line in a Pick-and-Pass Warehousing System”, Computers and Industrial Engineering, Cilt 57, s.261-268.
• Pan J. C. H., Shih P. H., Wu M. H. (2012): “Storage Assignment Problem with Travel Distance and Blocking Considerations for a Picker-to-Part Order Picking System”, Computers and Industrial Engineering, Cilt 62, s.527-535.
• Parikh P. J., Meller R. D. (2008): “Selecting between Batch and Zone Order Picking Strategies in a Distribution Center”, Transportation Research Part E, Cilt 44, No. 5, s.696-719.
• Petersen C. G. (1997): “An Evaluation of Order Picking Routing Policies”, International Journal of Operations and Production Management, Cilt 17, No. 11, s.1098-1111.
• Petersen C. G., Schmenner R. W. (1999): “An Evaluation of Routing and Volume-Based Storage Policies In An Order Picking Operation”, Decision Sciences, 30(2), 481-501.
• Petersen C.G., Aase G. (2004): “A Comparison Of Picking, Storage, And Routing Policies In Manual Order Picking”, International Journal of Production Economics, Cilt 92, s.11-19.
• Petersen C. G., Aase, G., Heiser D. R. (2004): “Improving Order-Picking Performance Through the Implementation of Class-Based Storage”, International Journal of Physical Distribution and Logistics Management, Cilt 34, No. 7, s.534-544.
• Ratliff H. D., Rosenthal A. S. (1983): “Order Picking in a Rectangular Warehouse: A Solvable Case of the Traveling Salesman Problem”, Operations Research, Cilt 31, No. 3, s.507- 521.
• Roodbergen K. J., De Koster R. (1998): “Routing Order Pickers in a Warehouse with Multiple Cross Aisles”, (Ed.: R. J. Graves, L. F. Mc Ginnis, D. J. Medeiros, R. E. Ward and M. R. Wilhelm), Progress in Material Handling Research: (Charlotte, NC: Material Handling Institute), s.451-467.
• Roodbergen K. J., De Koster R. (2001a): “Routing Methods for Warehouses with Multiple Cross Aisles”, International Journal of Production Research, Cilt 39, No. 9, s.1865-1883.
• Roodbergen K. J., De Koster R. (2001b): “Routing Order Pickers in a Warehouse with a Middle Aisle”,European Journal of Operational Research, Cilt 133, No. 1, s.32-43.
• Roodbergen K. J. (2005): “Storage Assignment Policies for Warehouses with Multiple Cross Aisles”, (Ed.: R. Meller, M. K. Ogle, B. A. Peters, G. D. Taylor, J. Usher), Progress in Material Handling Research, s.541–560.
• Roodbergen K. J., Vis I. F. A. (2006): “A Model for Warehouse Layout”, IIE Transactions Cilt 38, No. 10, s.799-811.
• Roodbergen K. J., Vis I. F .A. (2009): “A Survey of Literature on Automated Storage and Retrieval Systems”, European Journal of Operational Research, Cilt 194, s.343-362.
• Rouwenhorst B., Reuter B., Stockrahm V., Van Houtum G. J., Mantel R. J., Zijm W. H. M. (2000): “Warehouse Design and Control: Framework and Literature Review”, European Journal of Operational Research, Cilt 122, s.515-533.
• Tompkins J. A., White J. A., Bozer Y. A., Frazelle E. H., Tanchoco J. M. A. (2003): “Facilities Planning”, NJ: John Wiley and Sons.
• Vaughan T. S., Petersen C. G. (1999): “The Effect of Warehouse Cross Aisles on Order Picking Efficiency”, International Journal of Production Research, Cilt 37, s.881-897.
• Yu, M., De Koster, R. (2009): “The Impact of Order Batching and Picking Area Zoning on Order Picking System Performance”, European Journal of Operational Research, Cilt 198, No. 2, s.480-490.