IDEAS home Printed from https://ideas.repec.org/a/vrs/ecoman/v16y2024i3p98-114n1007.html
   My bibliography  Save this article

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
    as

    Download full text from publisher

    File URL: https://doi.org/10.2478/emj-2024-0026
    Download Restriction: no
    File URL: https://libkey.io/10.2478/emj-2024-0026?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    References listed on IDEAS

    as
    1. 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.
    2. 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.
    3. 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.
    4. 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).
    5. 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).
    6. 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.
    7. 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).
    8. 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).
    9. 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.
    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).
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. 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.
    2. 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.
    3. Danish Nasir & Rakesh Venkitasubramony & Suresh Kumar Jakhar, 2025. "Ergonomics in warehouse design and operations: a systematic literature review," Operational Research, Springer, vol. 25(1), pages 1-28, March.
    4. 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.
    5. 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).
    6. Vasiliki Kapou & Stavros T. Ponis & George Plakas & Eleni Aretoulaki, 2022. "An Innovative Layout Design and Storage Assignment Method for Manual Order Picking with Respect to Ergonomic Criteria," Logistics, MDPI, vol. 6(4), pages 1-21, December.
    7. Onal, Sevilay & Zhu, Wen & Das, Sanchoy, 2023. "Order picking heuristics for online order fulfillment warehouses with explosive storage," International Journal of Production Economics, Elsevier, vol. 256(C).
    8. 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.
    9. Anderson Rogério Faia Pinto & Marcelo Seido Nagano, 2020. "Genetic algorithms applied to integration and optimization of billing and picking processes," Journal of Intelligent Manufacturing, Springer, vol. 31(3), pages 641-659, March.
    10. 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.
    11. Li Zhou & Huwei Liu & Junhui Zhao & Fan Wang & Jianglong Yang, 2022. "Performance Analysis of Picking Routing Strategies in the Leaf Layout Warehouse," Mathematics, MDPI, vol. 10(17), pages 1-28, September.
    12. XiaoLi Zhang & Jelle de Vries & René de Koster & ChenGuang Liu, 2022. "Fast and Faultless? Quantity and Quality Feedback in Order Picking," Production and Operations Management, Production and Operations Management Society, vol. 31(4), pages 1536-1559, April.
    13. Boysen, Nils & de Koster, René, 2025. "50 years of warehousing research—An operations research perspective," European Journal of Operational Research, Elsevier, vol. 320(3), pages 449-464.
    14. Zhang, Jun & Liu, Feng & Tang, Jiafu & Li, Yanhui, 2019. "The online integrated order picking and delivery considering Pickers’ learning effects for an O2O community supermarket," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 123(C), pages 180-199.
    15. Nikolaos Chondromatidis & Anastasios Gialos & Vasileios Zeimpekis, 2022. "Investigating the Performance of the Order-Picking Process by Using Smart Glasses: A Laboratory Experimental Approach," Logistics, MDPI, vol. 6(4), pages 1-26, December.
    16. Glock, Christoph H. & Grosse, Eric H. & Abedinnia, Hamid & Emde, Simon, 2019. "An integrated model to improve ergonomic and economic performance in order picking by rotating pallets," European Journal of Operational Research, Elsevier, vol. 273(2), pages 516-534.
    17. Jose Alejandro Cano & Pablo Cortés & Jesús Muñuzuri & Alexander Correa-Espinal, 2023. "Solving the picker routing problem in multi-block high-level storage systems using metaheuristics," Flexible Services and Manufacturing Journal, Springer, vol. 35(2), pages 376-415, June.
    18. Jiuh‐Biing Sheu & Tsan‐Ming Choi, 2023. "Can we work more safely and healthily with robot partners? A human‐friendly robot–human‐coordinated order fulfillment scheme," Production and Operations Management, Production and Operations Management Society, vol. 32(3), pages 794-812, March.
    19. Maria A. M. Trindade & Paulo S. A. Sousa & Maria R. A. Moreira, 2022. "Ramping up a heuristic procedure for storage location assignment problem with precedence constraints," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 646-669, September.
    20. Silva, Allyson & Coelho, Leandro C. & Darvish, Maryam & Renaud, Jacques, 2020. "Integrating storage location and order picking problems in warehouse planning," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 140(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:vrs:ecoman:v:16:y:2024:i:3:p:98-114:n:1007. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Peter Golla (email available below). General contact details of provider: https://www.sciendo.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.