A model for design and performance estimation of pick-and-sort order picking systems

Purpose - The purpose of this paper is to study the performances of "pick-and-sort" order-picking systems (OPSs) and investigate picking efficiency and design issues as a function of the number and length of the picking waves.Design methodology approach - An analytical model is proposed to...

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Bibliographic Details
Published in:Journal of manufacturing technology management 2011-01, Vol.22 (2), p.261-282
Main Authors: Marchet, Gino, Melacini, Marco, Perotti, Sara
Format: Article
Language:English
Subjects:
Algorithms
Automation
Computational efficiency
Computing time
Costs
Design engineering
Efficiency
Estimates
Literature reviews
Mathematical models
Order picking
Picking
Queuing theory
Sorting
Wavelengths
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Summary:Purpose - The purpose of this paper is to study the performances of "pick-and-sort" order-picking systems (OPSs) and investigate picking efficiency and design issues as a function of the number and length of the picking waves.Design methodology approach - An analytical model is proposed to estimate the picking efficiency as a function of wavelength. The model, which has been tested by simulations, includes an algorithm to estimate the expected overlapping of order lines. Finally, a case study illustrates the use of the model in the initial assessment phase of OPS design, and resolves the trade-off between picking efficiency and sorting cost.Findings - The effect of the wavelength on picking efficiency is calculated.Research limitations implications - The trade-off analysis between picking efficiency and sorting cost refers to a specific sorting system and picking area layout.Practical implications - The paper provides a tool to support the design of "pick-and-sort" OPS, where the importance of the length of the picking wave emerges.Originality value - This paper presents an innovative model that can be used in the initial phase of "pick-and-sort" OPS design.
ISSN:1741-038X
1758-7786
DOI:10.1108/17410381111102252