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Integrated storage-order picking systems: Technology, performance models, and design insights

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  • Tappia, Elena
  • Roy, Debjit
  • Melacini, Marco
  • De Koster, René

Abstract

In many warehouses shuttle-based technologies have replaced the traditional AS/R system based storage technologies. The impact these systems have on downstream order picking performance is largely unknown. To study the interactions between upstream storage and downstream picking systems, we develop a novel analytical model for integrated storage and order picking systems. The resulting semi-open queuing model is solved using the matrix-geometric method. Using the queuing network model, we are able to study the effect of storage system technology on order throughput times, and the effect of the picking station input buffer size on order picking performance. Further, we analyze the effect of a constant work-in-process (CONWIP) control for orders on system performance. Our results indicate that using SBS/R instead of AS/R-based storage systems yields investment cost savings (i.e., fewer aisles in the storage area and fewer picking stations), paired with a lower total throughput time at a given order arrival rate. Numerical studies show how the total throughput time, first, benefits and then becomes stable by increasing the input buffer size at the picking stations. Retrieving item tote at the storage system in advance with respect to the picker availability is also advantageous, especially in the SBS/R system.

Suggested Citation

  • Tappia, Elena & Roy, Debjit & Melacini, Marco & De Koster, René, 2019. "Integrated storage-order picking systems: Technology, performance models, and design insights," European Journal of Operational Research, Elsevier, vol. 274(3), pages 947-965.
    • Handle: RePEc:eee:ejores:v:274:y:2019:i:3:p:947-965
    DOI: 10.1016/j.ejor.2018.10.048
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    2. Gharehgozli, Amir & Xu, Chao & Zhang, Wenda, 2021. "High multiplicity asymmetric traveling salesman problem with feedback vertex set and its application to storage/retrieval system," European Journal of Operational Research, Elsevier, vol. 289(2), pages 495-507.
    3. 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.
    4. Yi Li & Zhiyang Li, 2022. "Shuttle-Based Storage and Retrieval System: A Literature Review," Sustainability, MDPI, vol. 14(21), pages 1-18, November.
    5. Jiang, Min & Leung, K.H. & Lyu, Zhongyuan & Huang, George Q., 2020. "Picking-replenishment synchronization for robotic forward-reserve warehouses," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 144(C).
    6. Manuel Ostermeier & Andreas Holzapfel & Heinrich Kuhn & Daniel Schubert, 2022. "Integrated zone picking and vehicle routing operations with restricted intermediate storage," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 44(3), pages 795-832, September.
    7. Mohamed Amjath & Laoucine Kerbache & James MacGregor Smith, 2024. "A Closed Queueing Networks Approach for an Optimal Heterogeneous Fleet Size of an Inter-Facility Bulk Material Transfer System," Logistics, MDPI, vol. 8(1), pages 1-38, March.
    8. Boysen, Nils & Schwerdfeger, Stefan & Stephan, Konrad, 2023. "A review of synchronization problems in parts-to-picker warehouses," European Journal of Operational Research, Elsevier, vol. 307(3), pages 1374-1390.
    9. Emilio Moretti & Elena Tappia & Martina Mauri & Marco Melacini, 2022. "A performance model for mobile robot-based part feeding systems to supermarkets," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 580-613, September.
    10. Janka Saderova & Andrea Rosova & Marian Sofranko & Peter Kacmary, 2021. "Example of Warehouse System Design Based on the Principle of Logistics," Sustainability, MDPI, vol. 13(8), pages 1-16, April.
    11. Amjath, Mohamed & Kerbache, Laoucine & Smith, James MacGregor & Elomri, Adel, 2022. "Fleet sizing of trucks for an inter-facility material handling system using closed queueing networks," Operations Research Perspectives, Elsevier, vol. 9(C).
    12. Nils Boysen & David Füßler & Konrad Stephan, 2020. "See the light: Optimization of put‐to‐light order picking systems," Naval Research Logistics (NRL), John Wiley & Sons, vol. 67(1), pages 3-20, February.
    13. 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).

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