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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 basic concepts in the application of computer simulation techniques to materials handling and distribution problems are introduced in the context of strategic planning and option evaluation. Case studies are used to illustrate those concepts and the various techniques involved. The interaction required between client, materials handling system designer, and systems analyst to maximise the benefits from the use of sophisticated modelling tools is discussed.

Vertical lift module (VLM) is a parts-to-picker system for order picking of small products, which are stored into two columns of trays served by a lifting crane. A dual-bay VLM order picking (dual-bay VLM-OP) system is a particular solution where the operator works in parallel with the crane, allowing higher throughput performance. The purpose of this paper is to define models for different operating configurations able to improve the total throughput of the dual-bay VLM-OP system.

Analytical models are developed to estimate the throughput of a dual-bay VLM-OP. A deep evaluation has been carried out, considering different storage assignment policies and the sequencing retrieval of trays.

A more accurate estimation of the throughput is demonstrated, compared to the application of previous models. Some use guidelines for practitioners and academics are derived from the analysis based on real data.

Differing from previous contributions, these models include the acceleration/deceleration of the crane and the probability of storage and retrieve of each single tray. This permits to apply these models to different storage assignment policies and to suggest when these policies can be profitably applied. They can also model the sequencing retrieval of trays.

Increasing personnel costs and labour shortages have pushed retailers to give increasing attention to their intralogistics operations. We study hybrid order picking systems, in which humans and robots share work time, workspace and objectives and are in permanent contact. This necessitates a collaboration of humans and their mechanical coworkers (cobots).

Through a longitudinal case study on individual-level technology adaption, we accompanied a pilot testing of an industrial truck that automatically follows order pickers in their travel direction. Grounded on empirical field research and a unique large-scale data set comprising N = 2,086,260 storage location visits, where N = 57,239 storage location visits were performed in a hybrid setting and N = 2,029,021 in a manual setting, we applied a multilevel model to estimate the impact of this cobot settings on task performance.

We show that cobot settings can reduce the time required for picking tasks by as much as 33.57%. Furthermore, practical factors such as product weight, pick density and travel distance mitigate this effect, suggesting that cobots are especially beneficial for short-distance orders.

Given that the literature on hybrid order picking systems has primarily applied simulation approaches, the study is among the first to provide empirical evidence from a real-world setting. The results are discussed from the perspective of Industry 5.0 and can prevent managers from making investment decisions into ineffective robotic technology.

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.

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.

The effect of the wavelength on picking efficiency is calculated.

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

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.

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

This article aims to investigate the most applied lean warehouse practices in Brazilian warehouses.

To perform this research, three phases were conducted: a literature review, a multiple case study, and an analysis of lean warehouses practices implementation by an engineering committee. Thus, both qualitative and quantitative approaches were used. Additionally, the study has an applied nature, with an exploratory and descriptive character.

Results showed that regardless of the type of criterion used, the most implanted practices are those that do not involve investments in technology. On the other hand, practices like RFID and Cross Docking systems were not found in any of the operations, which shows numerous possibilities for improvement.

The main contribution of this article is to initiate a debate about the management and productivity of Brazilian warehouses, a theme still little explored by the academic community despite the importance that the logistic scenario represents for Brazil as an emerging country and leader in Latin America, participating actively in several global supply chains.

This paper identifies, configures and analyses a solution aimed at increasing the efficiency of in-store picking for e-grocers and combining the traditional store-based option with a warehouse-based logic (creating a back area dedicated to the most required online items).

The adopted methodology is a multi-method approach combining analytical modelling and interviews with practitioners. Interviews were performed with managers, whose collaboration allowed the development and application of an empirically-grounded model, aimed to estimate the performances of the proposed picking solution in its different configurations. Various scenarios are modelled and different policies are evaluated.

The proposed solution entails time benefits compared to traditional store-based picking for three main reasons: lower travel time (due to the absence of offline customers), lower retrieval time (tied to the more efficient product allocation in the back) and lower time to manage stock-outs (since there are no missing items in the back). Considering the batching policies, order picking is always outperformed by batch and zone picking, as they allow for the reduction of the average travelled distance per order. Conversely, zone picking is more efficient than batch picking when demand volumes are high.

From an academic perspective, this work proposes a picking solution that combines the store-based and warehouse-based logics (traditionally seen as opposite/alternative choices). From a managerial perspective, it may support the definition of the picking process for traditional grocers that are offering – or aim to offer – e-commerce services to their customers.

This paper aims to examine the relationship between the main decisions for designing distribution centers (DCs) and the contextual characteristics of the distribution networks.

Experts were surveyed and responses analyzed quantitatively through multivariate data techniques. This study considered four contextual characteristics that were deemed as influential for DC design: types of routes in the distribution network, quantity of DCs, distribution network levels and company size.

This paper evidenced which decisions are affected by each contextual characteristic encompassed in this study. This paper identified that the characteristic types of route in the distribution network must be carefully considered, as it had the greatest amount of associations with the decisions for designing a DC.

Despite its importance, most studies on design of DCs disregard the effect of the context in which DCs are inserted. This research provides arguments to support decision-making process of DCs design, increasing assertiveness of their planning. This work fulfills a literature gap by empirically examining the effect of contextual variables on the decisions related to DC design. Regarding practice, this paper addressed a fundamental issue for managers looking to design a DC, as it evidenced how contextual characteristics impact the decision-making.

As organizations move toward organizational learning the responsibilities of members change. Organizational members, themselves, should be giving consideration to what these new responsibilities should be, rather than leaving this task to management. Six possible responsibilities are suggested here to begin such a discussion. These responsibilities call on organizational members to accept greater responsibility for the generation and sharing of knowledge, but equally important is determining the organization’s purpose and sharing in its governance.