Please use this identifier to cite or link to this item: https://hdl.handle.net/10419/310292 
Year of Publication: 
2022
Citation: 
[Journal:] Logistics [ISSN:] 2305-6290 [Volume:] 6 [Issue:] 4 [Article No.:] 83 [Year:] 2022 [Pages:] 1-21
Publisher: 
MDPI, Basel
Abstract: 
Background: This paper aims to improve the overall performance of manual warehouse Order Picking (OP) processes by proposing an innovative method for designing a picking area layout, and introducing a storage assignment strategy with respect to ergonomics and workers' physical fatigue. Methods: The proposed method categorizes the available picking slots based on size and ABC analysis. It takes into consideration a set of ergonomic constraints pertinent to the rack heights and travel distance restrictions for each slot type, leading to the assignment of a location to each slot type based on its individual characteristics. In doing so, the proposed method introduces an innovative 'flame-shape' aisle layout. Finally, the products are assigned to their optimal locations, targeting OP time minimization, balanced workload allocation, and ergonomics optimization through a ranking system measuring the 'difficulty' of retrieving the products based on their weight, popularity, and slot location. Results: The proposed method led to a productivity rise of 14.9% along with a significant decrease of the 'difficulty' index, by 31%. Conclusions: The results prove that a prominent performance improvement can be achieved when both travel distance and manual workload minimization are targeted for determining the picking area layout and storage design.
Subjects: 
ergonomics
intralogistics
order picking
process optimization
slotting
warehouse
Persistent Identifier of the first edition: 
Creative Commons License: 
cc-by Logo
Document Type: 
Article
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