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Manual order consolidation with put walls: the batched order bin sequencing problem

Author

Listed:
  • Nils Boysen

    (Friedrich-Schiller-Universität Jena, Lehrstuhl für Operations Management)

  • Konrad Stephan

    (Friedrich-Schiller-Universität Jena, Lehrstuhl für Operations Management)

  • Felix Weidinger

    (Friedrich-Schiller-Universität Jena, Lehrstuhl für Operations Management)

Abstract

Batching and zoning are popular picking strategies to speed up picker-to-parts order fulfillment systems. On the negative side, these strategies require a subsequent order consolidation to separate the customer orders. In a widespread setup implemented by many online retailers put walls are applied to consolidate orders manually. A batch of orders picked under a batching and/or zoning strategy and, thus, distributed over multiple bins arrives via a conveyor system in the consolidation area. Here, a logistics worker retrieves the items from the successively arriving bins and—guided by a put-to-light mechanism—places them into the put wall. The wall is a simple reach-through rack separated into multiple shelves each temporarily dedicated to a specific customer order. On the other side of the wall reside packing workers, who empty shelves and pack completed orders into cardboard boxes. We aim to optimize the bin sequence in which a batch arrives at the consolidation area, such that the probability of starving packers waiting idle for completed orders is reduced. For this purpose, we formulate the batched order bin sequencing problem and derive suited optimization procedures. In our computational study, we investigate under which circumstances optimized bin sequences are especially valuable to reduce the packers’ idle times.

Suggested Citation

  • Nils Boysen & Konrad Stephan & Felix Weidinger, 2019. "Manual order consolidation with put walls: the batched order bin sequencing problem," EURO Journal on Transportation and Logistics, Springer;EURO - The Association of European Operational Research Societies, vol. 8(2), pages 169-193, June.
  • Handle: RePEc:spr:eurjtl:v:8:y:2019:i:2:d:10.1007_s13676-018-0116-0
    DOI: 10.1007/s13676-018-0116-0
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    References listed on IDEAS

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    Cited by:

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    2. Raji Alahmad & Kazuo Ishii, 2021. "A Puzzle-Based Sequencing System for Logistics Items," Logistics, MDPI, vol. 5(4), pages 1-18, October.
    3. Xiulian Hu & Yi-Fei Chuang, 2023. "E-commerce warehouse layout optimization: systematic layout planning using a genetic algorithm," Electronic Commerce Research, Springer, vol. 23(1), pages 97-114, March.
    4. Žulj, Ivan & Salewski, Hagen & Goeke, Dominik & Schneider, Michael, 2022. "Order batching and batch sequencing in an AMR-assisted picker-to-parts system," European Journal of Operational Research, Elsevier, vol. 298(1), pages 182-201.
    5. Mustapha Haouassi & Yannick Kergosien & Jorge E. Mendoza & Louis-Martin Rousseau, 2022. "The integrated orderline batching, batch scheduling, and picker routing problem with multiple pickers: the benefits of splitting customer orders," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 614-645, September.
    6. Zhong, Shuya & Giannikas, Vaggelis & Merino, Jorge & McFarlane, Duncan & Cheng, Jun & Shao, Wei, 2022. "Evaluating the benefits of picking and packing planning integration in e-commerce warehouses," European Journal of Operational Research, Elsevier, vol. 301(1), pages 67-81.
    7. Boysen, Nils & Stephan, Konrad & Schwerdfeger, Stefan, 2024. "Order consolidation in warehouses: The loop sorter scheduling problem," European Journal of Operational Research, Elsevier, vol. 316(2), pages 459-472.
    8. Boysen, Nils & de Koster, René & Füßler, David, 2021. "The forgotten sons: Warehousing systems for brick-and-mortar retail chains," European Journal of Operational Research, Elsevier, vol. 288(2), pages 361-381.
    9. Khir, Reem & Erera, Alan & Toriello, Alejandro, 2023. "Robust planning of sorting operations in express delivery systems," European Journal of Operational Research, Elsevier, vol. 306(2), pages 615-631.
    10. Kumar, Suryakant & Sheu, Jiuh-Biing & Kundu, Tanmoy, 2023. "Planning a parts-to-picker order picking system with consideration of the impact of perceived workload," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 173(C).

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