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Order batching in a bucket brigade order picking system considering picker blocking

Author

Listed:
  • Soondo Hong

    (Pusan National University)

  • Andrew L. Johnson

    (Texas A&M University)

  • Brett A. Peters

    (University of Wisconsin - Milwaukee)

Abstract

Bucket brigade order picking improves operational productivity by balancing workloads among pickers with a minimal level of managerial planning and oversight. However, due to variability and uncertainty of the pick locations within a particular order or batch, pickers can encounter blocking delays and thus lose productivity. This study formulates a model to quantify blocking delays and develops a control model to reduce blocking in bucket brigade order picking systems. The Indexed Batching Model for Bucket brigades (IBMB) has indexed batching constraints for generating batch alternatives, bucket brigade picker blocking constraints for quantifying blocking delay, and release-time updating constraints for progressively connecting the batching results with blocking quantification. The IBMB minimizes total retrieval time and improves picker utilization from 2 to 9 % across diverse and practical order picking situations while maintaining the static Work-In-Process. We note that modeling the separation of retrieved batches into orders still remains a challenge.

Suggested Citation

  • Soondo Hong & Andrew L. Johnson & Brett A. Peters, 2016. "Order batching in a bucket brigade order picking system considering picker blocking," Flexible Services and Manufacturing Journal, Springer, vol. 28(3), pages 425-441, September.
    • Handle: RePEc:spr:flsman:v:28:y:2016:i:3:d:10.1007_s10696-015-9223-5
    DOI: 10.1007/s10696-015-9223-5
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    References listed on IDEAS

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    1. Hong, Soondo, 2014. "Two-worker blocking congestion model with walk speed m in a no-passing circular passage system," European Journal of Operational Research, Elsevier, vol. 235(3), pages 687-696.
    2. de Koster, Rene & Le-Duc, Tho & Roodbergen, Kees Jan, 2007. "Design and control of warehouse order picking: A literature review," European Journal of Operational Research, Elsevier, vol. 182(2), pages 481-501, October.
    3. John J. Bartholdi, III & Donald D. Eisenstein, 2005. "Using Bucket Brigades to Migrate from Craft Manufacturing to Assembly Lines," Manufacturing & Service Operations Management, INFORMS, vol. 7(2), pages 121-129, August.
    4. Yu, Mengfei & de Koster, René B.M., 2009. "The impact of order batching and picking area zoning on order picking system performance," European Journal of Operational Research, Elsevier, vol. 198(2), pages 480-490, October.
    5. John J. Bartholdi & Donald D. Eisenstein, 1996. "A Production Line that Balances Itself," Operations Research, INFORMS, vol. 44(1), pages 21-34, February.
    Full references (including those not matched with items on IDEAS)

    Citations

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    Cited by:

    1. Valle, Cristiano Arbex & Beasley, John E. & da Cunha, Alexandre Salles, 2017. "Optimally solving the joint order batching and picker routing problem," European Journal of Operational Research, Elsevier, vol. 262(3), pages 817-834.
    2. Giannikas, Vaggelis & Lu, Wenrong & Robertson, Brian & McFarlane, Duncan, 2017. "An interventionist strategy for warehouse order picking: Evidence from two case studies," International Journal of Production Economics, Elsevier, vol. 189(C), pages 63-76.
    3. Fangyu Chen & Yongchang Wei & Hongwei Wang, 2018. "A heuristic based batching and assigning method for online customer orders," Flexible Services and Manufacturing Journal, Springer, vol. 30(4), pages 640-685, December.
    4. van Gils, Teun & Ramaekers, Katrien & Caris, An & de Koster, René B.M., 2018. "Designing efficient order picking systems by combining planning problems: State-of-the-art classification and review," European Journal of Operational Research, Elsevier, vol. 267(1), pages 1-15.
    5. Li, Dongni & Lyu, Yao & Zhang, Jinhui & Cui, Zihua & Yin, Yong, 2024. "Order sequencing for a bucket brigade seru in a mass customization environment," International Journal of Production Economics, Elsevier, vol. 270(C).
    6. Soondo Hong, 2018. "The effects of picker-oriented operational factors on hand-off delay in a bucket brigade order picking system," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 40(3), pages 781-808, July.

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