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Put‐to‐light order picking systems invert the basic logic of conventional picker‐to‐parts systems. Instead of successively visiting the storage positions of the stock keeping units (SKUs) when collecting picking orders, an order picker accompanies successive bins each containing multiple items of a specific SKU along a lane of subsequent orders. Whenever the picker passes an order requiring the current SKU, which is indicated by a light signal, she puts the requested number of items into the bin associated with the order. Such an order picking system is well‐suited if the assortment is not overly large and all orders demand similar SKUs, so that it is mainly applied in distribution centers of brick‐and‐mortar retail chains. This paper evaluates four different setups of put‐to‐light systems, which, during operations, require the solution of different storage assignment and SKU sequencing problems. We formulate these problems, prove computational complexity, and suggest suited solution algorithms. By applying these algorithms in a comprehensive computational study, we benchmark the impact of the four different setups on picking performance. In this way, warehouse managers receive decision support on how to set up their put‐to‐light systems.

This paper is dedicated to the cafeteria problem: given a single waiter operating multiple counters for different dishes arranged along a line and a set of customers with given subsets of dishes they desire, find a sequence of customers, which may not overtake each other, and a service schedule for the waiter, such that the makespan is minimized. This generic problem is shown to have different real-world applications in order picking with blocking restrictions. We present different heuristic and exact solution procedures for both problem parts, i.e., customer sequencing and waiter scheduling, and systematically compare these approaches. Our computational results reveal that the largest performance gains are enabled by not strictly processing order after order. Instead, the waiter should be allowed to flexibly swap between customers waiting along the line. Such a flexible service policy considerably reduces the makespan and the total walking distance of the waiter.