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An integrated storage assignment method for manual order picking warehouses considering cost, workload and posture

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  • Martina Calzavara
  • Christoph H. Glock
  • Eric H. Grosse
  • Fabio Sgarbossa

Abstract

This paper presents an integrated storage assignment method for low-level picker-to-parts order picking warehouses taking into account economic and ergonomic objectives. Three different pallet rack layouts are studied in this paper, namely (a) picking from full pallets on the floor, (b) picking from half-pallets on the floor, and (c) picking from half-pallets on the upper rank of the shelf. First, cost functions are developed to assess the total order picking performance impact of these different pallet rack layouts. Second, with regard to workload, the metabolic cost and energy expenditure rates for picking from the different rack layouts under study are derived. Third, for assessing the working posture during order picking, the Ovako Working Posture Analysing System index is used where the required data is collected using a motion capturing system. The developed models are combined to propose a heuristic storage assignment procedure that supports the decision of which item to store on which pallet. The developed storage assignment method is then applied to an industrial case study. The results of the paper support warehouse managers in assessing the order picking storage assignment from an ergonomics viewpoint and in estimating its impact on financial order picking performance.

Suggested Citation

  • Martina Calzavara & Christoph H. Glock & Eric H. Grosse & Fabio Sgarbossa, 2019. "An integrated storage assignment method for manual order picking warehouses considering cost, workload and posture," International Journal of Production Research, Taylor & Francis Journals, vol. 57(8), pages 2392-2408, April.
    • Handle: RePEc:taf:tprsxx:v:57:y:2019:i:8:p:2392-2408
    DOI: 10.1080/00207543.2018.1518609
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    Citations

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    Cited by:

    1. Lam, H.Y. & Ho, G.T.S. & Mo, Daniel Y. & Tang, Valerie, 2023. "Responsive pick face replenishment strategy for stock allocation to fulfil e-commerce order," International Journal of Production Economics, Elsevier, vol. 264(C).
    2. Briant, Olivier & Cambazard, Hadrien & Cattaruzza, Diego & Catusse, Nicolas & Ladier, Anne-Laure & Ogier, Maxime, 2020. "An efficient and general approach for the joint order batching and picker routing problem," European Journal of Operational Research, Elsevier, vol. 285(2), pages 497-512.
    3. Loske, Dominic & Klumpp, Matthias & Grosse, Eric H. & Modica, Tiziana & Glock, Christoph H., 2023. "Storage systems’ impact on order picking time: An empirical economic analysis of flow-rack storage systems," International Journal of Production Economics, Elsevier, vol. 261(C).
    4. 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.
    5. Diefenbach, Heiko & Grosse, Eric H. & Glock, Christoph H., 2024. "Human-and-cost-centric storage assignment optimization in picker-to-parts warehouses," European Journal of Operational Research, Elsevier, vol. 315(3), pages 1049-1068.
    6. Heiko Diefenbach & Simon Emde & Christoph H. Glock & Eric H. Grosse, 2022. "New solution procedures for the order picker routing problem in U-shaped pick areas with a movable depot," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 44(2), pages 535-573, June.
    7. 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).
    8. Al Theeb Nader A. & Al-Araidah Omar & Al-Ali Malik M. & Khudair Adnan I., 2023. "Impact of Human Energy Expenditure on Order Picking Productivity: A Monte Carlo Simulation Study in a Zone Picking System," Engineering Management in Production and Services, Sciendo, vol. 15(4), pages 12-24, December.

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