A model for design and performance estimation of pick‐and‐sort order picking systems

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Abstract
Purpose: The purpose of this paper is to study the performances of “pick‐and‐sort” order‐picking systems (OPSs) and investigate picking efficiency and design issues as a function of the number and length of the picking waves.Design/methodology/approach: An analytical model is proposed to estimate the picking efficiency as a function of wavelength. The model, which has been tested by simulations, includes an algorithm to estimate the expected overlapping of order lines. Finally, a case study illustrates the use of the model in the initial assessment phase of OPS design, and resolves the trade‐off between picking efficiency and sorting cost.Findings: The effect of the wavelength on picking efficiency is calculated.Research limitations/implications: The trade‐off analysis between picking efficiency and sorting cost refers to a specific sorting system and picking area layout.Practical implications: The paper provides a tool to support the design of “pick‐and‐sort” OPS, where the importance of the length of the picking wave emerges.Originality/value: This paper presents an innovative model that can be used in the initial phase of “pick‐and‐sort” OPS design.

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