IDEAS home Printed from https://ideas.repec.org/a/spr/opsear/v60y2023i4d10.1007_s12597-023-00672-x.html
   My bibliography  Save this article

Energy-based storage assignment in a multi-aisle warehouse

Author

Listed:
  • Danish Nasir

    (Indian Institute of Management Lucknow)

  • Rakesh Venkitasubramony

    (Indian Institute of Management Lucknow)

  • Suresh Kumar Jakhar

    (Indian Institute of Management Lucknow)

Abstract

An order picker performs repetitive tasks, which may result in fatigue, body pain, and injuries. Therefore, it is essential to approach the storage location assignment from an ergonomic standpoint as well. This study presents an energy consumption based optimization model for storage location assignment in an industrial warehouse that stores metal bars. Through a full factorial experiment, we study how product-location parameters like diameter, weight and location height influence time elements like pull and lift/lower time. Using this information, we predict the energy expenditure of pickers for each product-location combination. Then, we formulate an optimization model to decide the storage location assignment that effectively minimizes the total energy expenditure of pickers. The full factorial experiment shows that all the primary factors are significant. Moreover, computational experiments show that storage assignment based on energy optimization is significantly beneficial as compared to distance-based optimization. The energy expenditure decreases with increase in number of vertical levels. The model can predict the energy expenditure of order picker for different warehouse layout designs and help warehouse manager to decide slot height, number of storage locations, blocks and vertical levels. Finally, we derive insights for future research and practical applications based on our findings.

Suggested Citation

  • Danish Nasir & Rakesh Venkitasubramony & Suresh Kumar Jakhar, 2023. "Energy-based storage assignment in a multi-aisle warehouse," OPSEARCH, Springer;Operational Research Society of India, vol. 60(4), pages 1951-1975, December.
  • Handle: RePEc:spr:opsear:v:60:y:2023:i:4:d:10.1007_s12597-023-00672-x
    DOI: 10.1007/s12597-023-00672-x
    as

    Download full text from publisher

    File URL: http://link.springer.com/10.1007/s12597-023-00672-x
    File Function: Abstract
    Download Restriction: Access to the full text of the articles in this series is restricted.

    File URL: https://libkey.io/10.1007/s12597-023-00672-x?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. Alena Otto & Nils Boysen & Armin Scholl & Rico Walter, 2017. "Ergonomic workplace design in the fast pick area," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 39(4), pages 945-975, October.
    2. Omar Al-Araidah & Doraid Dalalah & Ma'en Al-Abdel Azeez & Mohammad T. Khasawneh, 2017. "A heuristic for clustering and picking small items considering safe reach of the order picker," European Journal of Industrial Engineering, Inderscience Enterprises Ltd, vol. 11(2), pages 256-269.
    3. Calzavara, M. & Glock, C. H. & Grosse, E. H. & Persona, A. & Sgarbossa, F., 2017. "Analysis of economic and ergonomic performance measures of different rack layouts in an order picking warehouse," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 82127, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    4. Battini, D. & Glock, C. H. & Grosse, E. H. & Persona, A. & Sgarbossa, F., 2016. "Human energy expenditure in order picking storage assignment: a bi-objective method," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 77307, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    5. Glock, C. H. & Grosse, E. H. & Abedinnia, Hamid & Emde, Simon, 2019. "An integrated model to improve ergonomic and economic performance in order picking by rotating pallets," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 106923, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    6. Glock, Christoph H. & Grosse, Eric H. & Abedinnia, Hamid & Emde, Simon, 2019. "An integrated model to improve ergonomic and economic performance in order picking by rotating pallets," European Journal of Operational Research, Elsevier, vol. 273(2), pages 516-534.
    7. Yong Sze Zhao & Mohd Hafiidz Jaafar & Ahmad Sufril Azlan Mohamed & Nur Zaidi Azraai & Norhaniza Amil, 2022. "Ergonomics Risk Assessment for Manual Material Handling of Warehouse Activities Involving High Shelf and Low Shelf Binning Processes: Application of Marker-Based Motion Capture," Sustainability, MDPI, vol. 14(10), pages 1-15, May.
    8. I. Kudelska & G. Pawłowski, 2020. "Influence of assortment allocation management in the warehouse on the human workload," Central European Journal of Operations Research, Springer;Slovak Society for Operations Research;Hungarian Operational Research Society;Czech Society for Operations Research;Österr. Gesellschaft für Operations Research (ÖGOR);Slovenian Society Informatika - Section for Operational Research;Croatian Operational Research Society, vol. 28(2), pages 779-795, June.
    9. José Antonio Larco & René de Koster & Kees Jan Roodbergen & Jan Dul, 2017. "Managing warehouse efficiency and worker discomfort through enhanced storage assignment decisions," International Journal of Production Research, Taylor & Francis Journals, vol. 55(21), pages 6407-6422, November.
    10. Martina Calzavara & Christoph H. Glock & Eric H. Grosse & Fabio Sgarbossa, 2019. "An integrated storage assignment method for manual order picking warehouses considering cost, workload and posture," International Journal of Production Research, Taylor & Francis Journals, vol. 57(8), pages 2392-2408, April.
    11. Calzavara, M. & Glock, C. H. & Grosse, E. H. & Sgarbossa, F., 2019. "An integrated storage assignment method for manual order picking warehouses considering cost, workload and posture," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 107009, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    12. 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.
    13. Zheng Wang & Jiuh‐Biing Sheu & Chung‐Piaw Teo & Guiqin Xue, 2022. "Robot Scheduling for Mobile‐Rack Warehouses: Human–Robot Coordinated Order Picking Systems," Production and Operations Management, Production and Operations Management Society, vol. 31(1), pages 98-116, January.
    Full references (including those not matched with items on IDEAS)

    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. Diefenbach, Heiko & Grosse, Eric H. & Glock, Christoph H., 2024. "Human-and-cost-centric storage assignment optimization in picker-to-parts warehouses," European Journal of Operational Research, Elsevier, vol. 315(3), pages 1049-1068.
    2. Kumar, Suryakant & Sheu, Jiuh-Biing & Kundu, Tanmoy, 2023. "Planning a parts-to-picker order picking system with consideration of the impact of perceived workload," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 173(C).
    3. 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.
    4. Danish Nasir & Rakesh Venkitasubramony & Suresh Kumar Jakhar, 2025. "Ergonomics in warehouse design and operations: a systematic literature review," Operational Research, Springer, vol. 25(1), pages 1-28, March.
    5. Loske, Dominic & Klumpp, Matthias & Grosse, Eric H. & Modica, Tiziana & Glock, Christoph H., 2023. "Storage systems’ impact on order picking time: An empirical economic analysis of flow-rack storage systems," International Journal of Production Economics, Elsevier, vol. 261(C).
    6. Diefenbach, Heiko & Emde, Simon & Glock, Christoph H., 2020. "Loading tow trains ergonomically for just-in-time part supply," European Journal of Operational Research, Elsevier, vol. 284(1), pages 325-344.
    7. Jiuh‐Biing Sheu & Tsan‐Ming Choi, 2023. "Can we work more safely and healthily with robot partners? A human‐friendly robot–human‐coordinated order fulfillment scheme," Production and Operations Management, Production and Operations Management Society, vol. 32(3), pages 794-812, March.
    8. Stefan Fedtke & Nils Boysen & Patrick Schumacher, 2023. "In-line kitting for part feeding of assembly lines: workload balancing and storage assignment to reduce the workers’ walking effort," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 45(3), pages 717-758, September.
    9. Dominic Loske & Matthias Klumpp & Maria Keil & Thomas Neukirchen, 2021. "Logistics Work, Ergonomics and Social Sustainability: Empirical Musculoskeletal System Strain Assessment in Retail Intralogistics," Logistics, MDPI, vol. 5(4), pages 1-25, December.
    10. Al Theeb Nader A. & Al-Araidah Omar & Al-Ali Malik M. & Khudair Adnan I., 2023. "Impact of Human Energy Expenditure on Order Picking Productivity: A Monte Carlo Simulation Study in a Zone Picking System," Engineering Management in Production and Services, Sciendo, vol. 15(4), pages 12-24, December.
    11. Maria A. M. Trindade & Paulo S. A. Sousa & Maria R. A. Moreira, 2022. "Ramping up a heuristic procedure for storage location assignment problem with precedence constraints," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 646-669, September.
    12. 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).
    13. 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).
    14. Glock, Christoph H. & Grosse, Eric H. & Abedinnia, Hamid & Emde, Simon, 2019. "An integrated model to improve ergonomic and economic performance in order picking by rotating pallets," European Journal of Operational Research, Elsevier, vol. 273(2), pages 516-534.
    15. Anastasios Gialos & Vasileios Zeimpekis, 2024. "A state-of-the-art classification and review of parameters that affect the design, control, and operating strategies of order-picking systems," Operational Research, Springer, vol. 24(1), pages 1-52, March.
    16. Çelik, Melih & Archetti, Claudia & Süral, Haldun, 2022. "Inventory routing in a warehouse: The storage replenishment routing problem," European Journal of Operational Research, Elsevier, vol. 301(3), pages 1117-1132.
    17. 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.
    18. Vasiliki Kapou & Stavros T. Ponis & George Plakas & Eleni Aretoulaki, 2022. "An Innovative Layout Design and Storage Assignment Method for Manual Order Picking with Respect to Ergonomic Criteria," Logistics, MDPI, vol. 6(4), pages 1-21, December.
    19. 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.
    20. Lanza, Giacomo & Passacantando, Mauro & Scutellà, Maria Grazia, 2022. "Assigning and sequencing storage locations under a two level storage policy: Optimization model and matheuristic approaches," Omega, Elsevier, vol. 108(C).

    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:spr:opsear:v:60:y:2023:i:4:d:10.1007_s12597-023-00672-x. 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: Sonal Shukla or Springer Nature Abstracting and Indexing (email available below). General contact details of provider: http://www.springer.com .

    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.