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Optimising picking operations in distribution centres: a simulation and algorithm-based approach for travel distance reduction

Author

Listed:
  • Gamarra Caio Jorge

    (Centro Universitário FEI, Av. Humberto de Alencar Castelo Branco, 3972-B São Bernardo do Campo - SP, 09850-901, Brazil)

  • Sampaio Mauro

    (Instituto Mauá de Tecnologia, Sao Caetano do Sul, Praça Mauá 1 São Caetano do Sul - SP, Brazil)

  • Lima Fábio

    (Centro Universitário FEI, Av. Humberto de Alencar Castelo Branco, 3972-B São Bernardo do Campo - SP, 09850-901, Brazil)

Abstract

This study examines the pivotal role of the logistics sector in corporations, particularly those with diverse product portfolios. It focuses on the time-intensive “picking” process, driven by various products and material handling requirements for order fulfilment. The research presents a methodology that combines distribution centre modelling for simulation with an optimisation algorithm to enhance operational efficiency. The goal is to determine an optimal route for product retrieval, minimising employee travel distances, using the simulated annealing algorithm. The results showcase a significant 7 % reduction in employee travel distance during collection. This research is relevant to academia and practical applications as it presents an opportunity to reduce operational costs in distribution centres, enhance the efficiency of picking operations, and improve the competitiveness of companies. Furthermore, it contributes to operations research by addressing a complex problem with significant practical implications using a rather unused method to solve this problem of picking operations. The approach is empirically applied in a prominent Brazilian beverage company. This methodology proves valuable for optimising logistics operations in various industrial contexts, highlighting its practical applicability.

Suggested Citation

  • Gamarra Caio Jorge & Sampaio Mauro & Lima Fábio, 2024. "Optimising picking operations in distribution centres: a simulation and algorithm-based approach for travel distance reduction," Engineering Management in Production and Services, Sciendo, vol. 16(3), pages 98-114.
    • Handle: RePEc:vrs:ecoman:v:16:y:2024:i:3:p:98-114:n:1007
    DOI: 10.2478/emj-2024-0026
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    References listed on IDEAS

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    1. Eric H. Grosse & Christoph H. Glock & W. Patrick Neumann, 2017. "Human factors in order picking: a content analysis of the literature," International Journal of Production Research, Taylor & Francis Journals, vol. 55(5), pages 1260-1276, March.
    2. Diefenbach, Heiko & Glock, C. H., 2019. "Ergonomic and economic optimization of layout and item assignment of a U-shaped order picking zone," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 117196, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    3. Masae, Makusee, 2020. "Developing efficient order picker routing policies in manual picker-to-parts order picking systems," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 119000, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    4. Jianbin Li & Rihuan Huang & James B. Dai, 2017. "Joint optimisation of order batching and picker routing in the online retailer’s warehouse in China," International Journal of Production Research, Taylor & Francis Journals, vol. 55(2), pages 447-461, January.
    5. Dijkstra, Arjan S. & Roodbergen, Kees Jan, 2017. "Exact route-length formulas and a storage location assignment heuristic for picker-to-parts warehouses," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 102(C), pages 38-59.
    6. 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.
    7. Grosse, E. H. & Glock, C. H. & Neumann, W. P., 2017. "Human factors in order picking: a content analysis of the literature," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 80630, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    8. 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.
    9. Masae, M. & Glock, C. H. & Grosse, E. H., 2019. "Order picker routing in warehouses: A systematic literature review," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 118016, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    10. Diefenbach, Heiko & Glock, C. H., 2019. "Ergonomic and economic optimization of layout and item assignment of a U-shaped order picking zone," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 116991, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
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