Two-stage storage assignment to minimize travel time and congestion for warehouse order picking operations

• Published in: Computers & industrial engineering Vol. 139; p. 106129
• Main Authors: Lee, In Gyu, Chung, Sung Hoon, Yoon, Sang Won
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.01.2020
• Subjects: Correlated and traffic balanced storage assignment; Multi-objective evolutionary algorithms; Order picking operation; Supply chain management; Warehouse operations; Supply chain management; Order picking operation; Correlated and traffic balanced storage assignment; Multi-objective evolutionary algorithms; Warehouse operations
• ISSN: 0360-8352; 1879-0550
• DOI: 10.1016/j.cie.2019.106129

•We consider both travel time and traffic congestion in a storage assignment problem.•To do so, the C&TBSA method is proposed.•Several MOEAs are compared and evaluated.•A case study based on actual data is presented.•Managerial insights are derived. This research presents a systematic and integrated approach that extends the correlated storage assignment strategy to improve the efficiency of warehouse order picking operations. The correlated storage assignment can reduce a significant amount of travel costs, but could lead to traffic congestion due to the imbalanced traffic flow. Hence, this research proposes the correlated and traffic balanced storage assignment (C&TBSA) to minimize the travel time and picking delays, which is modeled in two stages: clustering and assignment. In the clustering stage, a bi-objective optimization model is formulated to group items with the consideration of both travel efficiency and traffic flow balance, which is solved using multi-objective evolutionary algorithms (MOEAs). In the assignment stage, items in each cluster are distributed to the available storage locations. C&TBSA is evaluated with an actual warehouse case study and the results show that C&TBSA outperforms random, class-based, and correlated storage assignment methods by 48.74%, 23.82%, and 7.58% respectively, regarding the total time consisting of travel time and picking delays.