An Evaluation of Order-picking Tour Efficiency in Two-block Warehouses

Abstract

This study investigates the effects of critical operational and strategical decisions in order-picking warehouses on order pickers' tour lengths. For this study one of the most-commonly applied layouts in practice called two-block layout with a central cross aisle was considered. A full factorial experimental design and multiple-comparisons (Bonferroni t-tests) were applied to statistically determine the significance of various levels of storage policies pick-list sizes warehouse shape ratios warehouse sizes and their all interactions on average tour length. The analysis showed that deeper storage areas were superior to wider areas in small- and medium-sized warehouses. Warehouse designs with a 1: 1 width-to-depth shape ratio offered the most robust layouts. Within-storage aisle policy significantly reduced order-picking tour length and generally outperformed other storage policies.