A model for design and performance estimation of pick‐and‐sort order picking systems

Abstract

Purpose

The purpose of this paper is to study the performances of “pick‐and‐sort” order‐picking systems (OPSs) and investigate picking efficiency and design issues as a function of the number and length of the picking waves.

Design/methodology/approach

An analytical model is proposed to estimate the picking efficiency as a function of wavelength. The model, which has been tested by simulations, includes an algorithm to estimate the expected overlapping of order lines. Finally, a case study illustrates the use of the model in the initial assessment phase of OPS design, and resolves the trade‐off between picking efficiency and sorting cost.

Findings

The effect of the wavelength on picking efficiency is calculated.

Research limitations/implications

The trade‐off analysis between picking efficiency and sorting cost refers to a specific sorting system and picking area layout.

Practical implications

The paper provides a tool to support the design of “pick‐and‐sort” OPS, where the importance of the length of the picking wave emerges.

Originality/value

This paper presents an innovative model that can be used in the initial phase of “pick‐and‐sort” OPS design.

Citation

Marchet, G., Melacini, M. and Perotti, S. (2011), "A model for design and performance estimation of pick‐and‐sort order picking systems", Journal of Manufacturing Technology Management, Vol. 22 No. 2, pp. 261-282. https://doi.org/10.1108/17410381111102252