IDEAS home Printed from https://ideas.repec.org/a/eee/proeco/v206y2018icp169-183.html
   My bibliography  Save this article

Minimizing order picking makespan with multiple pickers in a wave picking warehouse

Author

Listed:
  • Ardjmand, Ehsan
  • Shakeri, Heman
  • Singh, Manjeet
  • Sanei Bajgiran, Omid

Abstract

In this paper, order assignment, order batching and picker routing problems with multiple pickers in a wave picking warehouse of a major US third party logistics company is studied and modeled mathematically. The proposed mathematical model is solved using an exact algorithm. Since the exact algorithm suffers from long CPU time, a Lagrangian decomposition heuristic combined with particle swarm optimization (LD-PSO) algorithm is proposed, which performs well for small size waves. To solve large-scale problems, a hybrid parallel simulated annealing and ant colony optimization (PSA-ACO) is presented. The proposed methods are tested using the warehouse data. The results are compared against the minimum makespan impact (MMI) heuristic that is currently being used in the warehouse and a state-of-the-art variable neighborhood descent (VND). While PSA-ACO slightly outperforms VND, for picking large waves, PSA-ACO and VND can improve the makespan by approximately 7.8% and 6.9% over MMI respectively. Numerical experiments show that increasing number of pickers and picking capacity has a greater impact on reducing makespan when the ratio of orders to number of pickers or picking capacity is high.

Suggested Citation

  • Ardjmand, Ehsan & Shakeri, Heman & Singh, Manjeet & Sanei Bajgiran, Omid, 2018. "Minimizing order picking makespan with multiple pickers in a wave picking warehouse," International Journal of Production Economics, Elsevier, vol. 206(C), pages 169-183.
    • Handle: RePEc:eee:proeco:v:206:y:2018:i:c:p:169-183
    DOI: 10.1016/j.ijpe.2018.10.001
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0925527318304146
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ijpe.2018.10.001?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
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Žulj, Ivan & Kramer, Sergej & Schneider, Michael, 2018. "A hybrid of adaptive large neighborhood search and tabu search for the order-batching problem," European Journal of Operational Research, Elsevier, vol. 264(2), pages 653-664.
    2. Scholz, André & Schubert, Daniel & Wäscher, Gerhard, 2017. "Order picking with multiple pickers and due dates – Simultaneous solution of Order Batching, Batch Assignment and Sequencing, and Picker Routing Problems," European Journal of Operational Research, Elsevier, vol. 263(2), pages 461-478.
    3. Chen, Tzu-Li & Cheng, Chen-Yang & Chen, Yin-Yann & Chan, Li-Kai, 2015. "An efficient hybrid algorithm for integrated order batching, sequencing and routing problem," International Journal of Production Economics, Elsevier, vol. 159(C), pages 158-167.
    4. Albert H. Schrotenboer & Susanne Wruck & Kees Jan Roodbergen & Marjolein Veenstra & Arjan S. Dijkstra, 2017. "Order picker routing with product returns and interaction delays," International Journal of Production Research, Taylor & Francis Journals, vol. 55(21), pages 6394-6406, November.
    5. Melh Çelk & Haldun Süral, 2014. "Order picking under random and turnover-based storage policies in fishbone aisle warehouses," IISE Transactions, Taylor & Francis Journals, vol. 46(3), pages 283-300.
    6. Matusiak, Marek & de Koster, René & Kroon, Leo & Saarinen, Jari, 2014. "A fast simulated annealing method for batching precedence-constrained customer orders in a warehouse," European Journal of Operational Research, Elsevier, vol. 236(3), pages 968-977.
    7. Pan, Jason Chao-Hsien & Shih, Po-Hsun & Wu, Ming-Hung, 2015. "Order batching in a pick-and-pass warehousing system with group genetic algorithm," Omega, Elsevier, vol. 57(PB), pages 238-248.
    8. 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.
    9. Cheng, Chen-Yang & Chen, Yin-Yann & Chen, Tzu-Li & Jung-Woon Yoo, John, 2015. "Using a hybrid approach based on the particle swarm optimization and ant colony optimization to solve a joint order batching and picker routing problem," International Journal of Production Economics, Elsevier, vol. 170(PC), pages 805-814.
    10. Helsgaun, Keld, 2000. "An effective implementation of the Lin-Kernighan traveling salesman heuristic," European Journal of Operational Research, Elsevier, vol. 126(1), pages 106-130, October.
    11. Hugh Everett, 1963. "Generalized Lagrange Multiplier Method for Solving Problems of Optimum Allocation of Resources," Operations Research, INFORMS, vol. 11(3), pages 399-417, June.
    12. Soondo Hong & Andrew Johnson & Brett Peters, 2012. "Large-scale order batching in parallel-aisle picking systems," IISE Transactions, Taylor & Francis Journals, vol. 44(2), pages 88-106.
    13. H. Donald Ratliff & Arnon S. Rosenthal, 1983. "Order-Picking in a Rectangular Warehouse: A Solvable Case of the Traveling Salesman Problem," Operations Research, INFORMS, vol. 31(3), pages 507-521, June.
    14. Maria Albareda-Sambola & Antonio Alonso-Ayuso & Elisenda Molina & Clara Simón De Blas, 2009. "Variable Neighborhood Search For Order Batching In A Warehouse," Asia-Pacific Journal of Operational Research (APJOR), World Scientific Publishing Co. Pte. Ltd., vol. 26(05), pages 655-683.
    15. Roodbergen, Kees Jan & de Koster, Rene, 2001. "Routing order pickers in a warehouse with a middle aisle," European Journal of Operational Research, Elsevier, vol. 133(1), pages 32-43, August.
    16. Ardjmand, Ehsan & Sanei Bajgiran, Omid & Rahman, Shakil & Weckman, Gary R. & Young, William A., 2018. "A multi-objective model for order cartonization and fulfillment center assignment in the e-tail/retail industry," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 115(C), pages 16-34.
    17. Hsieh, Ling-Feng & Huang, Yi-Chen, 2011. "New batch construction heuristics to optimise the performance of order picking systems," International Journal of Production Economics, Elsevier, vol. 131(2), pages 618-630, June.
    18. Henn, Sebastian & Wäscher, Gerhard, 2012. "Tabu search heuristics for the order batching problem in manual order picking systems," European Journal of Operational Research, Elsevier, vol. 222(3), pages 484-494.
    19. Valle, Cristiano Arbex & Beasley, John E. & da Cunha, Alexandre Salles, 2017. "Optimally solving the joint order batching and picker routing problem," European Journal of Operational Research, Elsevier, vol. 262(3), pages 817-834.
    20. Fangyu Chen & Hongwei Wang & Yong Xie & Chao Qi, 2016. "An ACO-based online routing method for multiple order pickers with congestion consideration in warehouse," Journal of Intelligent Manufacturing, Springer, vol. 27(2), pages 389-408, April.
    21. 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.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Zhuang, Yanling & Zhou, Yun & Yuan, Yufei & Hu, Xiangpei & Hassini, Elkafi, 2022. "Order picking optimization with rack-moving mobile robots and multiple workstations," European Journal of Operational Research, Elsevier, vol. 300(2), pages 527-544.
    2. Jiang, Min & Huang, George Q., 2022. "Intralogistics synchronization in robotic forward-reserve warehouses for e-commerce last-mile delivery," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 158(C).
    3. Lam, H.Y. & Ho, G.T.S. & Mo, Daniel Y. & Tang, Valerie, 2023. "Responsive pick face replenishment strategy for stock allocation to fulfil e-commerce order," International Journal of Production Economics, Elsevier, vol. 264(C).
    4. 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.
    5. Grzegorz Tarczyński, 2023. "Linear programming models for optimal workload and batching in pick-and-pass warehousing systems," Operations Research and Decisions, Wroclaw University of Science and Technology, Faculty of Management, vol. 33(3), pages 141-158.
    6. Jingran Liang & Zhengning Wu & Chenye Zhu & Zhi-Hai Zhang, 2022. "An estimation distribution algorithm for wave-picking warehouse management," Journal of Intelligent Manufacturing, Springer, vol. 33(4), pages 929-942, April.
    7. Shandong Mou, 2022. "Integrated Order Picking and Multi-Skilled Picker Scheduling in Omni-Channel Retail Stores," Mathematics, MDPI, vol. 10(9), pages 1-19, April.
    8. AERTS, Babiche & CORNELISSENS, Trijntje & SÖRENSEN, Kenneth, 2022. "The internal warehouse replenishment problem: the importance of storage and replenishment policies," Working Papers 2022007, University of Antwerp, Faculty of Business and Economics.
    9. Rajabighamchi, Farzaneh & van Hoesel, Stan & Defryn, Christof, 2023. "The order picking problem under a scattered storage policy," Research Memorandum 006, Maastricht University, Graduate School of Business and Economics (GSBE).
    10. 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.
    11. Derhami, Shahab & Smith, Jeffrey S. & Gue, Kevin R., 2020. "A simulation-based optimization approach to design optimal layouts for block stacking warehouses," International Journal of Production Economics, Elsevier, vol. 223(C).
    12. Srinivas, Sharan & Yu, Shitao, 2022. "Collaborative order picking with multiple pickers and robots: Integrated approach for order batching, sequencing and picker-robot routing," International Journal of Production Economics, Elsevier, vol. 254(C).
    13. Ahmad Ebrahimi & Hyun-woo Jeon & Sang-yeop Jung, 2023. "Improving Energy Consumption and Order Tardiness in Picker-to-Part Warehouses with Electric Forklifts: A Comparison of Four Evolutionary Algorithms," Sustainability, MDPI, vol. 15(13), pages 1-28, July.
    14. 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.

    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. 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.
    2. 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.
    3. Çağla Cergibozan & A. Serdar Tasan, 2019. "Order batching operations: an overview of classification, solution techniques, and future research," Journal of Intelligent Manufacturing, Springer, vol. 30(1), pages 335-349, January.
    4. van Gils, Teun & Caris, An & Ramaekers, Katrien & Braekers, Kris, 2019. "Formulating and solving the integrated batching, routing, and picker scheduling problem in a real-life spare parts warehouse," European Journal of Operational Research, Elsevier, vol. 277(3), pages 814-830.
    5. Masae, Makusee & Glock, Christoph H. & Vichitkunakorn, Panupong, 2021. "A method for efficiently routing order pickers in the leaf warehouse," International Journal of Production Economics, Elsevier, vol. 234(C).
    6. Arbex Valle, Cristiano & Beasley, John E, 2020. "Order batching using an approximation for the distance travelled by pickers," European Journal of Operational Research, Elsevier, vol. 284(2), pages 460-484.
    7. Fangyu Chen & Yongchang Wei & Hongwei Wang, 2018. "A heuristic based batching and assigning method for online customer orders," Flexible Services and Manufacturing Journal, Springer, vol. 30(4), pages 640-685, December.
    8. 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.
    9. Fangyu Chen & Gangyan Xu & Yongchang Wei, 2019. "An Integrated Metaheuristic Routing Method for Multiple-Block Warehouses with Ultranarrow Aisles and Access Restriction," Complexity, Hindawi, vol. 2019, pages 1-14, June.
    10. 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.
    11. Xie, Lin & Li, Hanyi & Luttmann, Laurin, 2023. "Formulating and solving integrated order batching and routing in multi-depot AGV-assisted mixed-shelves warehouses," European Journal of Operational Research, Elsevier, vol. 307(2), pages 713-730.
    12. Yang, Peng & Zhao, Zhijie & Guo, Huijie, 2020. "Order batch picking optimization under different storage scenarios for e-commerce warehouses," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 136(C).
    13. Matusiak, Marek & de Koster, René & Kroon, Leo & Saarinen, Jari, 2014. "A fast simulated annealing method for batching precedence-constrained customer orders in a warehouse," European Journal of Operational Research, Elsevier, vol. 236(3), pages 968-977.
    14. Wagner, Stefan & Mönch, Lars, 2023. "A variable neighborhood search approach to solve the order batching problem with heterogeneous pick devices," European Journal of Operational Research, Elsevier, vol. 304(2), pages 461-475.
    15. Sandra Hahn & André Scholz, 2017. "Order Picking in Narrow-Aisle Warehouses: A Fast Approach to Minimize Waiting Times," FEMM Working Papers 170006, Otto-von-Guericke University Magdeburg, Faculty of Economics and Management.
    16. Valle, Cristiano Arbex & Beasley, John E. & da Cunha, Alexandre Salles, 2017. "Optimally solving the joint order batching and picker routing problem," European Journal of Operational Research, Elsevier, vol. 262(3), pages 817-834.
    17. Giannikas, Vaggelis & Lu, Wenrong & Robertson, Brian & McFarlane, Duncan, 2017. "An interventionist strategy for warehouse order picking: Evidence from two case studies," International Journal of Production Economics, Elsevier, vol. 189(C), pages 63-76.
    18. Matusiak, Marek & de Koster, René & Saarinen, Jari, 2017. "Utilizing individual picker skills to improve order batching in a warehouse," European Journal of Operational Research, Elsevier, vol. 263(3), pages 888-899.
    19. Žulj, Ivan & Salewski, Hagen & Goeke, Dominik & Schneider, Michael, 2022. "Order batching and batch sequencing in an AMR-assisted picker-to-parts system," European Journal of Operational Research, Elsevier, vol. 298(1), pages 182-201.
    20. Briant, Olivier & Cambazard, Hadrien & Cattaruzza, Diego & Catusse, Nicolas & Ladier, Anne-Laure & Ogier, Maxime, 2020. "An efficient and general approach for the joint order batching and picker routing problem," European Journal of Operational Research, Elsevier, vol. 285(2), pages 497-512.

    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:eee:proeco:v:206:y:2018:i:c:p:169-183. 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: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/locate/ijpe .

    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.