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Order picking is one of the most costly logistics processes in warehouses. As a result, the optimization of order picking processes has received an increased attention in recent years. One potential source for improving order picking is the reduction of picker blocking. The purpose of this paper is to investigate picker blocking under different storage assignment and order picker-route combinations and evaluate its effects on the performance of manual order picking processes.

This study develops an agent-based simulation model (ABS) for order picking in a rectangular warehouse. By employing an ABS, we are able to study the behaviour of individual order pickers and their interactions with the environment.

The simulation model determines shortest mean throughput times when the same routing policy is assigned to all order pickers. In addition, it evaluates the efficiency of alternative routing policies–storage assignment combinations.

The paper implies that ABS is well-suited for further investigations in the field of picker blocking, for example, with respect to the individual behaviour of agents.

Based on the results of this paper, warehouse managers can choose an appropriate routing policy that best matches their storage assignment policy and the number of order pickers employed.

This paper is the first to comprehensively study the effects of different combinations of order picker routing and storage assignment policies on the occurrence of picker blocking.

The Industry 4.0 initiative – with its ultimate objective of revolutionizing the supply-chain – putted more emphasis on smart and autonomous systems, creating new opportunities to add flexibility and agility to automatic manufacturing systems. These systems are designed to free people from monotonous and repetitive tasks, enabling them to concentrate in knowledge-based jobs. One of these repetitive functions is the order-picking task which consists of collecting parts from storage (warehouse) and distributing them among the ordering stations. An order-picking system can also pick finished parts from working stations to take them to the warehouse. The purpose of this paper is to present a simplified model of a robotic order-picking system, i.e. a mobile manipulator composed by an automated guided vehicle (AGV), a collaborative robot (cobot) and a robotic hand.

Details about its implementation are also presented. The AGV is needed to safely navigate inside the factory infrastructure, namely, between the warehouse and the working stations located in the shop-floor or elsewhere. For that purpose, an ActiveONE AGV, from Active Space Automation, was selected. The collaborative robot manipulator is used to move parts from/into the mobile platform (feeding the working stations and removing parts for the warehouse). A cobot from Kassow Robots was selected (model KR 810), kindly supplied by partner companies Roboplan (Portugal) and Kassow Robotics (Denmark). An Arduino MKR1000 board was also used to interconnect the user interface, the AGV and the collaborative robot. The graphical user interface was developed in C# using the Microsoft Visual Studio 2019 IDE, taking advantage of this experience in this type of language and programming environment.

The resulting prototype was fully demonstrated in the partner company warehouse (Active Space Automation) and constitutes a possible order-picking solution, which is ready to be integrated into advanced solutions for the factories of the future.

A solution to fully automate the order-picking task at an industrial shop-floor was presented and fully demonstrated. The objective was to design a system that could be easy to use, to adapt to different applications and that could be a basic infrastructure for advanced order-picking systems. The system proved to work very well, executing all the features required for an order-picking system working in an Industry 4.0 scenario where humans and machines must act as co-workers. Although all the system design objectives were accomplished, there are still opportunities to improve and add features to the presented solution. In terms of improvements, a different robotic hand will be used in the final setup, depending on the type of objects that are being required to move. The amount of equipment that is located on-board of the AGV can be significantly reduced, freeing space and lowering the weight that the AGV carries. For example, the controlling computer can be substituted by a single-board-computer without any advantage. Also, the cobot should be equipped with a wrist camera to identify objects and landmark. This would allow the cobot to fully identify the position and orientation of the objects to pick and drop. The wrist camera should also use bin-picking software to fully identify the shape of the objects to pick and also their relative position (if they are randomly located in a box, for example). These features are easy to add to the developed mobile manipulator, as there are a few vision systems in the market (some that integrate with the selected cobot) that can be easily integrated in the solution. Finally, this paper reports a development effort that neglected, for practical reasons, all issues related with certification, safety, training, etc. A future follow-up paper, reporting a practical use-case implementation, will properly address those practical and operational issues.

In the grocery business online start‐ups, e‐grocers, have in the last few years developed new business models to challenge the traditional bricks‐and‐mortar supermarkets. However, many of the big players in the e‐grocery business, such as Peapod and Webvan in the USA, still operate in the red. They have financed rapid growth by collecting hundreds of millions of dollars from investors. These huge investments have enabled the e‐grocers to enter the grocery market but, on the other hand, ineffective operations have used up capital on operating expenses. If the e‐grocers want to become serious challengers to the traditional bricks‐and‐mortar business, they need to cut operational costs dramatically and fast. This paper illustrates some basic principles for cutting operational costs in the e‐grocery business. The focus is on picking efficiency and order assembly costs. Solutions for achieving better picking efficiency are discussed. In addition, one detailed example of how a grocery distribution centre for efficient picking could be designed is presented.

A hybrid storage assignment (combination class-volume-based) framework considering quality proximity, customer and material categorization are key distinguished contents of this paper. In spite of using individual storage allocation approach, the hybrid allocation policy performs better under certain environment. The paper aims to discuss these issues.

Although it has been proved that every storage assignment policy has their advantages and limitations, one or more storage assignment policies with combination of zoning and layout design can be used together for further improvement. The authors have conducted this study at warehouse of a manufacturing firm that produce only single product with varieties of material and quality criteria. Picking optimization includes elimination of non-value-added activities like unwanted forklift and package movements, time and distance traveled for retrieval as well as storage. Other allied operations with respect to customer acceptance level and resource utilization are also considered.

The time and distance from manufacturing point to storage location are accountable as it also contributes to picking performance.

Quality-based cluster analysis is carried out to find out closeness among customers, which is used to propose algorithm with new layout design, zoning and storage allocation policy.

Order picking, the activity by which a number of goods are retrieved from a warehousing system to satisfy a number of customer orders, is an essential link in the supply chain and is the major cost component of warehousing. The critical issue is to simultaneously reduce the cost and increase the speed of the order picking activity. The main objectives of this paper are: evaluate various routing heuristics and an optimal routine in a volume‐based and random storage environment; compare the performance of volume‐based storage to random storage; and examine the impact of travel speed and picking rates on routing and storage policy performance. The experimental results show the solution gap between routing heuristics and optimal routing is highly dependent on the travel speed and picking rate, the storage policy, and the size of the pick list. In addition, volume‐based storage produced significant savings over random storage, but again these savings are dependent on the travel speed and picking rate.

Confirmations are applied in kit preparation for mixed-model assembly to promote quality, but research that explains the impact on time efficiency has been lacking. The purpose of this paper is to determine the extent to which the type of confirmation method relates to time-efficient kit preparation when order batching is applied.

An industrially relevant laboratory experiment is applied, simulating kit preparation with order batching for mixed-model assembly. The time efficiency is studied as associated with four confirmation methods – barcode ring scanner, button presses, voice commands and RFID-reading wristbands – when applied as pick-from and place-to confirmation. Furthermore, the paper also considers the quality outcome.

Efficiency is promoted by methods that minimise interrupting the picker’s motions when performing pick-from confirmations and with methods that allow each hand to place components and perform place-to confirmations simultaneously – here represented by button presses and RFID-reading wristbands. Moreover, combining various methods for the tasks of pick-from or place-to confirmation can benefit efficiency.

Pickers at an early stage of the learning curve (one shift of training) were considered.

The findings promote the customised applications of picking information systems in industry.

Combining various methods for the tasks of pick-from and place-to confirmation can provide more fitting applications that better align with the picker’s preferences.

Combinations of various methods when applied as either pick-from or place-to confirmation, or both, are studied.

The purpose of this paper is to determine whether man-hour efficiency of picking is affected by the use of batch preparation, compared to preparation of one kit at a time. This paper focuses on small kit preparation areas.

This paper is based on two experiments that were performed at a vehicle assembly plant and then analysed quantitatively.

The results provide a strong indication of the advantages associated with batch preparation, in terms of man-hour efficiency.

The fact that the effects identified during the experiments are substantial, over 20 per cent reduction of average time per picked component in Experiment 1 and 7 per cent in Experiment 2, indicates that the option of batch picking holds potentials for large cost reduction and should be considered when kit preparation systems are designed.

Limited research has dealt with the design of kit preparation systems, thus leaving considerable knowledge gaps. Previous research dealing with batch picking focuses on other environments than kitting and on large picking areas where batching can reduce walking distances. In contrast, the current paper focuses on small picking areas, which are common in industrial kitting applications. This paper provides a considerable contribution by demonstrating improvements in time efficiency that batch preparation can offer to small picking areas in addition to larger areas. The discussion also provides a basis for future research, which could focus on aspects other than time efficiency, such as the quality of kit preparation, and variables that might moderate the effect of batching.

Warehouse picking is often referred to as the most labour-intensive, expensive and time consuming operation in manual warehouses. These factors are becoming even more crucial due to recent trends in manufacturing and warehousing requiring the processing of orders that are always smaller and needed in a shorter time. For this reason, in recent years more efficient and better performing systems have been developed, employing various technological solutions that can support pickers during their work. The purpose of this paper is to introduce a comparison of five paperless picking systems (i.e. barcodes handheld, RFID tags handheld, voice picking, traditional pick-to-light, RFID pick-to-light).

Warehouse picking is often referred to as the most labour-intensive, expensive and time consuming operation in manual warehouses. These factors are becoming even more crucial due to recent trends in manufacturing and warehousing requiring the processing of orders that are always smaller and needed in a shorter time. For this reason, in recent years more efficient and better performing systems have been developed, employing various technological solutions that can support pickers during their work. The present paper introduces a comparison of five paperless picking systems (i.e. barcodes handheld, RFID tags handheld, voice picking, traditional pick-to-light, RFID pick-to-light.

The proposed approach contributes to the understanding of the performance of different technologies in different application fields; some solutions are more suitable for a low-level warehouse, others bring greater benefits in the case of picking from multilevel shelving.

The study concerns an issue that until now has received very little attention in the literature. It compares some traditional solutions with some innovative ones by an economic evaluation. The presented hourly cost function also takes into account the different errors arising and their probability of occurrence.

Recent studies have highlighted the importance of adopting a contingency approach to configuring omnichannel warehouses. Nonetheless, research on how various contextual factors influence the selection of warehouse configuration is scarce. This study fills this knowledge gap by exploring how and why certain configurations fit in different omnichannel contexts.

A case study is conducted with six leading Swedish omnichannel retailers. Focusing on outbound warehouse configurations, data are collected through interviews, on-site observations, and secondary sources. A multistep analysis is made, including both pattern matching and explanation building.

The qualitative analysis reveals 16 contextual factors, of which assortment range, requested online order fulfillment times, goods size and total transactions are the most influential. The study shows how contextual factors create different challenges, thereby influencing the choice of the configurations. In addition to market dynamics and task complexity, the study describes four categories of the factors and related challenges that are particularly important in omnichannels: speed, space, economies of scale and tied-up capital.

The findings highlight the importance of understanding context and imply that multiple challenges may require trade-offs when selecting configurations, for example, regarding what storage, processes and resources to integrate or separate. To confirm, extend, challenge and further operationalize the ideas and observations put forward in this paper, an agenda with future research issues is given for this accelerating, contemporary phenomenon.

Managers could leverage the frameworks proposed for the contextual profiling of their current and future positions. The frameworks provide support for understanding the important challenges and potential trade-offs and developing aligned configurations.

This study is original in the way it provides in-depth, case study findings about contextual factors and their influence on omnichannel warehouse configuration.

The purpose of this paper is to identify and analyse the difficulties encountered in the implementation of a voice picking system at a large multinational company of the tractor industrial segment, outlining a comparison related to the main critical factors concerning the system implementation at a Brazilian and a USA plant.

The methodology utilised was qualitative and exploratory conducted through case studies in the two plants of the multinational company. The main data were collected through interviews with key managers directly involved in the project of voice picking system implementation.

The results indicate that the picking processes in the two plants were similar, since both were designed for the production line and conducted using bar-code readers and paper lists. Nevertheless, the internal warehousing process in the USA was more mature and computerised, whereas the Brazilian process still had opportunity for improvement, such as, the visual storage process, where the operator was responsible for locating an empty position.

Since this research is an exploratory case study, its results cannot be generalised.

The paper provides relevant practical information and experiences to managers interested in implementing voice picking systems, as well as interested in improving the accuracy and productivity of logistics processes within warehouses.

The voice picking systems are more widespread in the USA than in Brazil, and therefore, companies around the world can use this studied case to better understand about the voice picking systems implementation process in both emerging and mature marketplaces.