Kit preparation for mixed-model assembly: efficiency impact of confirmation methods

Abstract

Purpose Confirmations are applied in kit preparation for mixed-model assembly to promote quality, but research that explains the impact on time efficiency has been lacking. The purpose of this paper is to determine the extent to which the type of confirmation method relates to time-efficient kit preparation when order batching is applied. Design/methodology/approach An industrially relevant laboratory experiment is applied, simulating kit preparation with order batching for mixed-model assembly. The time efficiency is studied as associated with four confirmation methods – barcode ring scanner, button presses, voice commands and RFID-reading wristbands – when applied as pick-from and place-to confirmation. Furthermore, the paper also considers the quality outcome. Findings Efficiency is promoted by methods that minimise interrupting the picker’s motions when performing pick-from confirmations and with methods that allow each hand to place components and perform place-to confirmations simultaneously – here represented by button presses and RFID-reading wristbands. Moreover, combining various methods for the tasks of pick-from or place-to confirmation can benefit efficiency. Research limitations/implications Pickers at an early stage of the learning curve (one shift of training) were considered. Practical implications The findings promote the customised applications of picking information systems in industry. Social implications Combining various methods for the tasks of pick-from and place-to confirmation can provide more fitting applications that better align with the picker’s preferences. Originality/value Combinations of various methods when applied as either pick-from or place-to confirmation, or both, are studied.

Testing vision picking technology in warehouse operations: Evidence from laboratory experiments

“…The last parameter is the existence of pick confirmation during the order picking process. According to [36], during the order picking process there are two different types of confirmation. The first is the pick-from confirmation which is used to ensure that picking is performed from the right locations, while the second type focuses on the place-to confirmation which is used to ensure that the components are placed in the right tote (for the cases of multiple order picking -pick to cart).…”

“…The first is the pick-from confirmation which is used to ensure that picking is performed from the right locations, while the second type focuses on the place-to confirmation which is used to ensure that the components are placed in the right tote (for the cases of multiple order picking -pick to cart). Based on the results of literature review, most studies use a confirmation system, in order to increase the accuracy as well as the quality of the process [36]. The confirmation of picks can be done with different ways.…”

“…Also, [8,17,22] mention that a voice confirmation is a reliable solution, while other studies assess the use of a confirmation button for the picks confirmation [26,27]. On the other hand, according to [36], button presses are commonly used in association with light indicators in pick-by-lightsystems, while voice commands are typically used in pick-by-voice systems. To this end, in our laboratory tests, RFID technology (via RFID bracelet) was used for the picking confirmation, based on [17] and [35] recommendations.…”

“…To this end, in our laboratory tests, RFID technology (via RFID bracelet) was used for the picking confirmation, based on [17] and [35] recommendations. RFID scans, based on a technology that recently has emerged in applications that support picking activities, have shown promising potential in order picking process [36].…”

Modelling time efficiency of cobot-supported kit preparation

“…4), are shown in Table 1 and Table 2. The example values are based on experiments data reported in Fager et al [22] and Fager [23] for manual kit preparation, and the cobots example values are based on values reported in literature [e.g. 7] and observations in a laboratory.…”