This paper develops a capacity model for sequential zone picking systems. These systems are popular internal transport and order-picking systems because of their scalability, flexibility, high-throughput ability, and fit for use for a wide range of products and order profiles. The major disadvantage of such systems is congestion and blocking under heavy use, leading to long order throughput times. To reduce blocking and congestion, most systems use the block-and-recirculate protocol to dynamically manage workload. In this paper, the various elements of the system, such as conveyor lanes and pick zones, are modeled as a multiclass block-and-recirculate queueing network with capacity constraints on subnetworks. Because of this blocking protocol, the stationary distribution of the queueing network is highly intractable. We propose an approximation method based on jumpover blocking. Multiclass jump-over queueing networks admit a product-form stationary distribution and can be efficiently evaluated by mean value analysis and Norton's theorem. This method can be applied during the design phase of sequential zone picking systems to determine the number of segments, number and length of zones, buffer capacities, and storage allocation of products to zones to meet performance targets. For a wide range of parameters, the results show that the relative error in the system throughput is typically less than 1% compared with simulation.

E-commerce fulfillment competition evolves around cheap, speedy, and time-definite delivery. Milkrun order picking systems have proven to be very successful in providing handling speed for a large, but highly variable, number of orders. In this system, an order picker picks orders that arrive in real-time during the picking process; by dynamically changing the stops on the picker's current picking route. The advantage of milkrun picking is that it reduces order picking setup time and worker travel time compared with conventional batch picking systems. This article is the first to study order throughput times of multi-line orders in a milkrun picking system. We model this system as a cyclic polling system with simultaneous batch arrivals, and determine the mean order throughput time for three picking strategies: exhaustive, locally-gated, and globally-gated. These results allow us to study the effect of different product allocations in an optimization framework. We show that the picking strategy that achieves the shortest order throughput times depends on the ratio between pick times and travel times. In addition, for a real-world application, we show that milkrun order picking significantly reduces the order throughput time compared with conventional batch picking.

Sequential zone picking systems are popular conveyor-based picker-to-parts order picking systems that divide the order picking area in work zones. When designing a zone picking system, it is important to know whether the throughput capability of the system can meet customer demand. However, the performance and maximum throughput capability of a zone picking system is largely determined by congestion and blocking that occur at the various conveyor merges in the system. In this paper we develop an analytical model to study the impact of conveyor merges in sequential zone picking systems. Because of finite buffers, blocking, recirculation, and merging, the resulting queueing model does not have a product-form stationary queue-length distribution which makes exact analysis practically infeasible. Therefore, we develop an approximate solution by using an aggregation technique and matrix-geometric methods to study the throughput capability of the system. The model is suitable to support rapid design of complex zone picking systems, in terms of number and length of zones, input and output buffer capacities, and storage allocation of products to zones to meet prespecified performance targets. Comparison of the approximation results to simulation show that for a wide range of parameters the mean relative error in the system throughput is typically less than 5%. The model accurately predicts the loss in throughput due to congestion and blocking at the merges, and can be used to allocate input and output buffer spaces to maximize the throughput capability of the system.

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We consider a cyclic polling system with general service times, general switch-over times, and simultaneous batch arrivals. This means that at an arrival epoch, a batch of customers may arrive simultaneously at the different queues of the system. For the locally-gated, globally-gated, and exhaustive service disciplines, we study the batch sojourn-time, which is defined as the time from an arrival epoch until service completion of the last customer in the batch. We obtain for the different service disciplines exact expressions for the Laplace-Stieltjes transform of the steady-state batch sojourn-time distribution, which can be used to determine the moments of the batch sojourn-time, and in particular, its mean. However, we also provide an alternative, more efficient way to determine the mean batch sojourntime, using Mean Value Analysis. Finally, we compare the batch sojourn-times for the different service disciplines in several numerical examples. Our results show that the best performing service discipline, in terms of minimizing the batch sojourn-time, depends on system characteristics. arXiv:1607.03345v1 [math.PR]