See the light: Optimization of put‐to‐light order picking systems

Abstract

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.

The forgotten sons: Warehousing systems for brick-and-mortar retail chains

“…Layout design: when setting up a put system two main decisions need to be taken: sizing the system holding capacity for order bins and dividing labor among multiple pickers. The former aspect is treated in Boysen, Stephan, and Füßler (2020) ; Boysen (2017, 2019) . The basic trade-off is to either enlarge the system holding capacity, so that more order bins can retrieve the current SKU, which, however, increases the walking distance of the picker along the lane.…”

“…These results are confirmed by a subsequent study for a related warehousing system based on picking workstations, see Füßler and Boysen (2019) . Boysen et al (2020) , instead, investigate put systems having enough capacity to store all order bins of all stores simultaneously. They benchmark different layout options (e.g., widely visible put-to-light displays, such that a picker can prematurely return whenever reaching the last order bin requiring the current SKU) and investigate their impact on picking performance.…”

“…Moreover, if a picker has to pass the complete lane anyway, then the storage assignment has no impact on picking performance. Boysen et al (2020) , however, consider the case where a picker only has to walk up to the last order bin requiring the respective SKU and can prematurely return. In this case, the storage assignment of order bins reduces the total waling distance of the picker and thus impacts picking performance.…”

Dispositivos tecnológicos na coleta e separação de pedidos: Revisão bibliográfica

“…O picker escolhe os itens com as luzes indicadas e depois coloca os itens em um transporte ou algum mecanismo de AS/RS. Nos 6 artigos que trataram do assunto, foram identificadas diversas metodologias diferentes (DE Vries et al 2016;Guo et al 2015, Battini et al 2015, Kim & Hong 2020, Boysen et al 2020, Gajsek et al 2020, Füchtenhans, Grosse & Glock, 2021). De Vries et al (2016 realizaram um experimento para analisar três tecnologias de coleta de pedido e qual influência a personalidade do picker tem nas atividades usando tais tecnologias.…”

Order Picking and E-Commerce: Introducing Non-Parametric Efficiency Measurement for Sustainable Retail Logistics

“…Electronic commerce and retail logistics are facing a multitude of technology-driven changes in current times [1][2][3][4][5][6][7]: order picking has been identified as one of the most labor-intensive as well as costly activities within warehouse logistics and is experiencing changes due to new technologies in the form of artificial intelligence and automation. As human worker's activities will be required for a long time to come, investigating the efficiency of the human workforce and warehouse processes is of central importance for e-commerce businesses.…”