Research Article
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Year 2023, Issue: 055, 132 - 145, 31.12.2023

Mahmut Tutam

https://doi.org/10.59313/jsr-a.1354278

Abstract

Project Number

1059B191900637

References

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Minimization of metabolic energy expenditure in collaborative order picking

Year 2023, Issue: 055, 132 - 145, 31.12.2023

Mahmut Tutam

https://doi.org/10.59313/jsr-a.1354278

Abstract

Order picking is one of the most repetitive, labor-intensive, and physically demanding operations in warehouses. Picking hundreds of orders daily requires high metabolic energy expenditure and is characterized by poor ergonomics posing high risks for musculoskeletal disorders. In traditional order picking, the order picker walks around racks in a warehouse throughout the day. Alternatively, it is aimed at minimizing inefficient time and musculoskeletal strains with ride-on order picking by allowing the order picker to stand on an operator’s platform of an order-picking truck and ride the truck between stop locations. However, the order picker has to step down from the platform at each stop location and step up onto the platform before riding the truck to the next stop location. Therefore, riding the truck with frequent stops leads to more metabolic energy expenditure and musculoskeletal disorders than walking, although it is faster. Benefiting advantages of both traditional and ride-on order picking, a relatively new order picking truck (collaborative order picking truck) is deployed in warehouses to reduce inefficient walking time and ergonomic riding disorders. In collaborative order picking, the order picker can walk from a stop location directly to the next pick location while the truck moves to the next stop location autonomously or ride the truck to the next stop location in case of having a large distance between stop locations. This paper develops an optimization model to minimize total metabolic energy expenditure in collaborative order picking by finding the shortest route and the best collaboration decision (walk or ride). Based on the Monte Carlo simulation, the metabolic energy expenditure with collaborative order picking is analyzed. Our results indicate metabolic energy savings with collaborative order picking up to 200% and 83% compared to traditional and ride-on order picking, respectively.

Keywords

Order picking Collaborative Robot Optimal Routing Ergonomics Metabolic Energy Expenditure

Supporting Institution

The Scientific and Technological Research Council of Türkiye

Project Number

1059B191900637

References

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  • Y. Jaghbeer, R. Hanson, and M. I. Johansson, “Automated order picking systems and the links between design and performance: a systematic literature review,” Int. J. Prod. Res., vol. 58, no. 15, pp. 4489–4505, Aug. 2020, doi: 10.1080/00207543.2020.1788734.
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  • B. Gajšek, G. Đukić, T. Opetuk, and H. Cajner, “Human in Manual Order Picking Systems,” in Ćosić P. (ed.) Management of Technology – Step to Sustainable Production (MOTSP) conference proceedings, 2017, pp. 5–17.
  • A. Otto, N. Boysen, A. Scholl, and R. Walter, “Ergonomic workplace design in the fast pick area,” OR Spectr., vol. 39, no. 4, pp. 945–975, Oct. 2017, doi: 10.1007/s00291-017-0479-x.
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  • T. De Lombaert, K. Braekers, R. De Koster, and K. Ramaekers, “In pursuit of humanised order picking planning: methodological review, literature classification and input from practice,” Int. J. Prod. Res., pp. 1–31, Jun. 2022, doi: 10.1080/00207543.2022.2079437.
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  • E. H. Grosse, C. H. Glock, and W. P. Neumann, “Human factors in order picking system design: A content analysis,” IFAC-PapersOnLine, vol. 28, no. 3, pp. 320–325, 2015, doi: 10.1016/j.ifacol.2015.06.101.
  • A. J. Chambers, J. M. Haney, T. Huppert, and M. S. Redfern, “The Effect of Prolonged Walking With Intermittent Standing on Erector Spinae and Soleus Muscle Oxygenation and Discomfort.,” J. Sports Sci. Med., vol. 18, no. 2, pp. 337–343, Jun. 2019.
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  • Still, “Order Picker OPX 20-25 Thrillingly dynamic,” 2022. https://www.still-forklift.is/trucks/new-trucks/order-pickers/opx-20-25.html.
  • H. D. Ratliff and A. S. Rosenthal, “Order-Picking in a Rectangular Warehouse: a Solvable Case of the Traveling Salesman Problem.,” Oper. Res., vol. 31, no. 3, pp. 507–521, 1983, doi: 10.1287/opre.31.3.507.
  • E. H. Grosse, C. H. Glock, and W. P. Neumann, “Human factors in order picking: a content analysis of the literature,” Int. J. Prod. Res., vol. 55, no. 5, pp. 1260–1276, Mar. 2017, doi: 10.1080/00207543.2016.1186296.
  • M. Abdoli-Eramaki, J. M. Stevenson, M. J. Agnew, and A. Kamalzadeh, “Comparison of 3D dynamic virtual model to link segment model for estimation of net L4/L5 reaction moments during lifting,” Comput. Methods Biomech. Biomed. Engin., vol. 12, no. 2, pp. 227–237, Apr. 2009, doi: 10.1080/10255840802434233.
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  • R. R. Bishu, B. Donohue, and P. Murphy, “Cognitive ergonomics of a mail order filling company: Part 2 — influence of shelf coding and address information on acquisition time,” Appl. Ergon., vol. 23, no. 2, pp. 115–120, Apr. 1992, doi: 10.1016/0003-6870(92)90083-8.
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  • J. Marvel, R. Shell, and G. Weckman, “An application of heuristic algorithms for determining inventory location in a distribution warehouse,” Int. J. Ind. Eng. Theory, Appl. Pract., vol. 8, pp. 5–15, 2001.
  • M. Christmansson et al., “A case study of a principally new way of materials kitting—an evaluation of time consumption and physical workload,” Int. J. Ind. Ergon., vol. 30, no. 1, pp. 49–65, Jul. 2002, doi: 10.1016/S0169-8141(02)00077-X.
  • J. J. Saleem, B. M. Kleiner, and M. A. Nussbaum, “Empirical evaluation of training and a work analysis tool for participatory ergonomics,” Int. J. Ind. Ergon., vol. 31, no. 6, pp. 387–396, Jun. 2003, doi: 10.1016/S0169-8141(03)00024-6.
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There are 63 citations in total.

Details

Primary Language English
Subjects Industrial Engineering, Ergonomi and Human Factors Management, Packaging, Storage and Transportation (Excl. Food and Agricultural Products)
Journal Section Research Articles
Authors

Mahmut Tutam 0000-0002-2018-5458

Project Number 1059B191900637
Publication Date December 31, 2023
Submission Date September 2, 2023
Published in Issue Year 2023 Issue: 055

Cite

IEEE M. Tutam, “Minimization of metabolic energy expenditure in collaborative order picking”, JSR-A, no. 055, pp. 132–145, December 2023, doi: 10.59313/jsr-a.1354278.
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