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Large-scale order batching in parallel-aisle picking systems

Author

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  • Soondo Hong
  • Andrew Johnson
  • Brett Peters

Abstract

This article discusses an order batching formulation and heuristic solution procedure suitable for a large-scale order picking situation in parallel-aisle picking systems. Order batching can decrease the total travel distance of pickers not only through reducing the number of trips but also by shortening the length of each trip. In practice, some order picking systems retrieve 500–2000 orders per hour and include ten or more aisles. The proposed heuristic produces near-optimal solutions with run times of roughly 70 s in a ten-aisle system. The quality of the solutions is demonstrated by comparing with a lower bound developed as a linear programming relaxation of the batching formulation developed in this article. A simulation study indicates that the proposed heuristic outperforms existing methods described in the literature or used in practice. In addition, the resulting order picking operations are relatively robust to picker blocking.

Suggested Citation

  • Soondo Hong & Andrew Johnson & Brett Peters, 2012. "Large-scale order batching in parallel-aisle picking systems," IISE Transactions, Taylor & Francis Journals, vol. 44(2), pages 88-106.
    • Handle: RePEc:taf:uiiexx:v:44:y:2012:i:2:p:88-106
    DOI: 10.1080/0740817X.2011.588994
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    Citations

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    Cited by:

    1. Pan, Jason Chao-Hsien & Shih, Po-Hsun & Wu, Ming-Hung, 2015. "Order batching in a pick-and-pass warehousing system with group genetic algorithm," Omega, Elsevier, vol. 57(PB), pages 238-248.
    2. Minfang Huang & Qiong Guo & Jing Liu & Xiaoxu Huang, 2018. "Mixed Model Assembly Line Scheduling Approach to Order Picking Problem in Online Supermarkets," Sustainability, MDPI, vol. 10(11), pages 1-16, October.
    3. Çağla Cergibozan & A. Serdar Tasan, 2019. "Order batching operations: an overview of classification, solution techniques, and future research," Journal of Intelligent Manufacturing, Springer, vol. 30(1), pages 335-349, January.
    4. Matusiak, Marek & de Koster, René & Kroon, Leo & Saarinen, Jari, 2014. "A fast simulated annealing method for batching precedence-constrained customer orders in a warehouse," European Journal of Operational Research, Elsevier, vol. 236(3), pages 968-977.
    5. Arbex Valle, Cristiano & Beasley, John E, 2020. "Order batching using an approximation for the distance travelled by pickers," European Journal of Operational Research, Elsevier, vol. 284(2), pages 460-484.
    6. Boysen, Nils & de Koster, René & Weidinger, Felix, 2019. "Warehousing in the e-commerce era: A survey," European Journal of Operational Research, Elsevier, vol. 277(2), pages 396-411.
    7. Hong, Soondo & Johnson, Andrew L. & Peters, Brett A., 2012. "Batch picking in narrow-aisle order picking systems with consideration for picker blocking," European Journal of Operational Research, Elsevier, vol. 221(3), pages 557-570.
    8. Mowrey, Corinne H. & Parikh, Pratik J., 2014. "Mixed-width aisle configurations for order picking in distribution centers," European Journal of Operational Research, Elsevier, vol. 232(1), pages 87-97.
    9. Pardo, Eduardo G. & Gil-Borrás, Sergio & Alonso-Ayuso, Antonio & Duarte, Abraham, 2024. "Order batching problems: Taxonomy and literature review," European Journal of Operational Research, Elsevier, vol. 313(1), pages 1-24.
    10. 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.
    11. Hong, Soondo & Johnson, Andrew L. & Peters, Brett A., 2015. "Quantifying picker blocking in a bucket brigade order picking system," International Journal of Production Economics, Elsevier, vol. 170(PC), pages 862-873.
    12. 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.
    13. Ardjmand, Ehsan & Shakeri, Heman & Singh, Manjeet & Sanei Bajgiran, Omid, 2018. "Minimizing order picking makespan with multiple pickers in a wave picking warehouse," International Journal of Production Economics, Elsevier, vol. 206(C), pages 169-183.
    14. 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.
    15. 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.
    16. Hong, Soondo & Kim, Youngjoo, 2017. "A route-selecting order batching model with the S-shape routes in a parallel-aisle order picking system," European Journal of Operational Research, Elsevier, vol. 257(1), pages 185-196.

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