Integrating storage allocation with manual order picking and replenishment operations in a distribution centre

Jean-François Cordeau, Pasquale Legato and Rina Mary Mazza

International Journal of Production Research, 2025, vol. 63, issue 7, 2694-2710

Abstract: This paper introduces a mathematical programming formulation and a simulation-based heuristic for the allocation of storage positions to products picked by human operators on man-aboard vehicles traveling through the warehouse of a wholesale company. In this problem, the tactical level of the assignment decisions affects the operational level of the picking process. We propose a simulation-optimisation framework that integrates the two. Our formulation of the storage location assignment problem also handles the constraint according to which a picking position should be paired with a (vertical) replenishment position for a given item. To solve realistic instances, we design an iterated local search (ILS) metaheuristic with an embedded discrete-event simulator (DES) that evaluates the most promising moves at each iteration. The DES allows reproducing the handling operations performed by multiple order pickers under uncertainty, mutual interferences and congestion-related phenomena. Overall, the flexible simulation-optimisation (SO) framework evaluates the operational times and daily productivity of the order picking organisation. Numerical results are presented for real data, under an S-shape picking policy with a skip-and-go rule to deal with lacking items. Under a proper tuning of the ILS parameters, the SO framework allows to achieve a nearly 17% improvement in warehouse productivity.

Date: 2025
References: Add references at CitEc
Citations:

Downloads: (external link)
http://hdl.handle.net/10.1080/00207543.2024.2401901 (text/html)
Access to full text is restricted to subscribers.

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:taf:tprsxx:v:63:y:2025:i:7:p:2694-2710

Ordering information: This journal article can be ordered from
http://www.tandfonline.com/pricing/journal/TPRS20

DOI: 10.1080/00207543.2024.2401901

Access Statistics for this article

International Journal of Production Research is currently edited by Professor A. Dolgui

More articles in International Journal of Production Research from Taylor & Francis Journals
Bibliographic data for series maintained by Chris Longhurst ().