An integrated storage assignment method for manual order picking warehouses considering cost, workload and posture. Issue 8 (18th April 2019)

• Record Type: Journal Article
• Authors: Calzavara, Martina; Glock, Christoph H.; Grosse, Eric H.; Sgarbossa, Fabio
• Is Part Of: International journal of production research. Volume 57:Issue 8(2019)
• Page Start: 2392
• Page End: 2408
• Publication Date: 2019-04-18
• Subjects: order picking -- ergonomics -- cost -- warehouse -- human factors -- pallet storage -- storage assignment; Factory management -- Periodicals; 658.57
• DOI: 10.1080/00207543.2018.1518609
• Languages: English
• ISSNs: 0020-7543

Abstract

Abstract : This paper presents an integrated storage assignment method for low-level picker-to-parts order picking warehouses taking into account economic and ergonomic objectives. Three different pallet rack layouts are studied in this paper, namely (a) picking from full pallets on the floor, (b) picking from half-pallets on the floor, and (c) picking from half-pallets on the upper rank of the shelf. First, cost functions are developed to assess the total order picking performance impact of these different pallet rack layouts. Second, with regard to workload, the metabolic cost and energy expenditure rates for picking from the different rack layouts under study are derived. Third, for assessing the working posture during order picking, the Ovako Working Posture Analysing System index is used where the required data is collected using a motion capturing system. The developed models are combined to propose a heuristic storage assignment procedure that supports the decision of which item to store on which pallet. The developed storage assignment method is then applied to an industrial case study. The results of the paper support warehouse managers in assessing the order picking storage assignment from an ergonomics viewpoint and in estimating its impact on financial order picking performance.