Human Energy Expenditure in High-Level Order Picking

Yıl 2023, Cilt: 12 Sayı: 3, 911 - 924, 28.09.2023

Murat Binici , Mehmet Mutlu Yenisey

https://doi.org/10.17798/bitlisfen.1336357

Öz

Order picking is one of the most significant components of the warehouse management. More than 50% of the cost incurred in warehouses is due to the order picking process. Although this process has mostly been considered within the framework of economic objectives, in recent years the ergonomic perspective has become increasingly visible. Order picking studies regarding ergonomic objectives have mostly focused on low-level order picking systems, but the human factor has been ignored in high-level order picking. In order to fill this gap, this study focuses on the order picking process of a single block high-level warehouse with a special focus on human factor. For this purpose, a capacity-constrained mathematical model based on order batching and routing for the minimization of human energy expenditure is proposed. In this three-dimensional (3D) warehouse system, the distances and travel times between locations were first determined using Tchebychev formulas in order to calculate the human energy expenditure between order locations. Then, human energy matrices between order locations were created using human energy calculation formulas based on time and item weight. These matrices, which were created for three different randomly generated sample data sets, were used in the mathematical model solution and the optimum batches and routes were determined. In order to compare the results, First-come First-serve (FCFS) batching and S-shaped routing, which are simple and common batching and routing methods used in practice, were applied for the sample problem data sets and it was observed that the mathematical model gave better results.

Anahtar Kelimeler

Order picking, High-level warehouse, Human energy expenditure, Order batching and routing, Tchebychev distance

Kaynakça

• [1] S. Ene and N. Öztürk, “Storage location assignment and order picking optimization in the automotive industry,” The International Journal of Advanced Manufacturing Technology, vol. 60, no. 5–8, pp. 787–797, Aug. 2011. doi: https://doi.org/10.1007/s00170-011-3593-y.
• [2] C. G. Petersen and G. Aase, “A comparison of picking, storage, and routing policies in manual order picking,” International Journal of Production Economics, vol. 92, no. 1, pp. 11–19, Nov. 2004. doi: https://doi.org/10.1016/j.ijpe.2003.09.006.
• [3] M. B. M. De Koster, E. S. Van der Poort, and M. Wolters, “Efficient order batching methods in warehouses,” International Journal of Production Research, vol. 37, no. 7, pp. 1479–1504, May 1999. doi: https://doi.org/10.1080/002075499191094.
• [4] J. A. Cano, P. Cortés, J. Muñuzuri, and A. Correa-Espinal, “Solving the picker routing problem in multi-block high-level storage systems using metaheuristics,” Flexible Services and Manufacturing Journal, Feb. 2022. doi: https://doi.org/10.1007/s10696-022-09445-y.
• [5] J. C.-H. Pan, M.-H. Wu, and W.-L. Chang, “A travel time estimation model for a high-level picker-to-part system with class-based storage policies,” European Journal of Operational Research, vol. 237, no. 3, pp. 1054–1066, Sep. 2014. doi: https://doi.org/10.1016/j.ejor.2014.02.037.
• [6] S. Vanheusden, T. van Gils, K. Ramaekers, T. Cornelissens, and A. Caris, “Practical factors in order picking planning: state-of-the-art classification and review,” International Journal of Production Research, pp. 1–25, Apr. 2022, doi: https://doi.org/10.1080/00207543.2022.2053223.
• [7] L. C. Tang and E.-P. Chew, “Order picking systems: Batching and storage assignment strategies,” Computers & Industrial Engineering, vol. 33, no. 3–4, pp. 817–820, Dec. 1997, doi: https://doi.org/10.1016/s0360-8352(97)00245-3.
• [8] F. Caron, G. Marchet, and A. Perego, “Routing policies and COI-based storage policies in picker-to-part systems,” International Journal of Production Research, vol. 36, no. 3, pp. 713–732, Mar. 1998, doi: https://doi.org/10.1080/002075498193651.
• [9] E. H. Grosse, C. H. Glock, M. Y. Jaber, and W. P. Neumann, “Incorporating human factors in order picking planning models: framework and research opportunities,” International Journal of Production Research, vol. 53, no. 3, pp. 695–717, Jun. 2014, doi: https://doi.org/10.1080/00207543.2014.919424.
• [10] G. Casella, A. Volpi, R. Montanari, L. Tebaldi, and E. Bottani, “Trends in order picking: a 2007–2022 review of the literature,” Production and Manufacturing Research: An Open Access Journal, vol. 11, no. 1, Mar. 2023, doi: https://doi.org/10.1080/21693277.2023.2191115.
• [11] T. De Lombaert, K. Braekers, R. De Koster, and K. Ramaekers, “In pursuit of humanised order picking planning: methodological review, literature classification and input from practice,” International Journal of Production Research, vol. 61, no. 10, pp. 3300–3330, Jun. 2022, doi: https://doi.org/10.1080/00207543.2022.2079437.
• [12] D. Battini, C. H. Glock, E. H. Grosse, A. Persona, and F. Sgarbossa, “Human energy expenditure in order picking storage assignment: A bi-objective method,” Computers & Industrial Engineering, vol. 94, pp. 147–157, Apr. 2016, doi: https://doi.org/10.1016/j.cie.2016.01.020.
• [13] M. Calzavara, C. H. Glock, E. H. Grosse, and F. Sgarbossa, “An integrated storage assignment method for manual order picking warehouses considering cost, workload and posture,” International Journal of Production Research, vol. 57, no. 8, pp. 2392–2408, Sep. 2018, doi: https://doi.org/10.1080/00207543.2018.1518609.
• [14] F. Zangaro, S. Finco, D. Battini, and I. Zennaro, “An optimization model for the storage assignment of the reference under ergonomics constraints,” Proceedings of the Summer School Francesco Turco, September 11–13, 2019. [Online]. Available: https://www.summerschool-aidi.it/edition-2019/cms/extra/papers/116.pdf. [Accessed: Sep. 12, 2023.]
• [15] M. Zhang, S. Winkelhaus, and E. H. Grosse, “Evaluation of human workload in a hybrid order picking system,” IFAC-PapersOnLine, vol. 54, no. 1, pp. 458–463, 2021, doi: https://doi.org/10.1016/j.ifacol.2021.08.053.
• [16] J. A. Larco, R. de Koster, K. J. Roodbergen, and J. Dul, “Managing warehouse efficiency and worker discomfort through enhanced storage assignment decisions,” International Journal of Production Research, vol. 55, no. 21, pp. 6407–6422, Apr. 2016, doi: https://doi.org/10.1080/00207543.2016.1165880.
• [17] B. Gajšek, S. Šinko, T. Kramberger, M. Butlewski, E. Özceylan, and G. Đukić, “Towards Productive and Ergonomic Order Picking: Multi-Objective Modeling Approach,” Applied Sciences, vol. 11, no. 9, p. 4179, May 2021, doi: https://doi.org/10.3390/app11094179.
• [18] D. Dukic, and D. Oluio, “Order-picking routing policies: Simple heuristics, advanced heuristics or optimal algorithm.” Strojniski Vestnik, vol. 50, no. 11, pp. 530-535, Jan. 2004. [Online]. Available: https://www.researchgate.net/publication/296803926_Order-picking_routing_policies_Simple_heuristics_advanced_heuristics_or_optimal_algorithm. [Accessed: Sep. 12, 2023.]
• [19] P. Parikh and R. D. Meller, “A travel-time model for a person-onboard order picking system,” European Journal of Operational Research, vol. 200, no. 2, pp. 385–394, Jan. 2010, doi: https://doi.org/10.1016/j.ejor.2008.12.031.
• [20] R. Wang, L. Zang, and X. Tan, “An Optimal Routing Model of High-level Picker-to-part System,” Lecture notes in electrical engineering, pp. 371–383, Sep. 2012, doi: https://doi.org/10.1007/978-1-4471-4600-1_32.
• [21] A. GARG, D. B. CHAFFIN, and G. D. HERRIN, “Prediction of metabolic rates for manual materials handling jobs,” American Industrial Hygiene Association Journal, vol. 39, no. 8, pp. 661–674, Aug. 1978, doi: https://doi.org/10.1080/0002889778507831.
• [22] “BT Optio 1t Yüksek Seviye,” Toyota. https://toyota-forklifts.com.tr/ueruenlerimiz/siparis-toplama-makineleri/yueksek-seviye-toplama/bt-optio-1t-yueksek-seviye/ (accessed Sep. 12, 2023).
• [23] S. Ene, İ. Küçükoğlu, A. Aksoy, and N. Öztürk, “A genetic algorithm for minimizing energy consumption in warehouses,” Energy, vol. 114, pp. 973–980, Nov. 2016, doi: https://doi.org/10.1016/j.energy.2016.08.045.
• [24] J. Won and S. Olafsson *, “Joint order batching and order picking in warehouse operations,” International Journal of Production Research, vol. 43, no. 7, pp. 1427–1442, Apr. 2005, doi: https://doi.org/10.1080/00207540410001733896.
• [25] C.-C. Lin, J.-R. Kang, C.-C. Hou, and C.-Y. Cheng, “Joint order batching and picker Manhattan routing problem,” Computers & Industrial Engineering, vol. 95, pp. 164–174, May 2016, doi: https://doi.org/10.1016/j.cie.2016.03.009