Research Article
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The impact of collaborative robot speed on the throughput performance in an order-picking warehouse

Year 2023, Volume: 7 Issue: 2, 1672 - 1684, 29.12.2023

Mahmut Tutam

https://doi.org/10.56554/jtom.1258323

Abstract

Order-picking operations are one of the most costly and labor-intensive activities in warehouses. In recent years, collaborative order-picking systems have been used increasingly in warehouses to reduce order pickers’ workloads and increase their performances. In a collaborative order-picking system, the collaborative robot can be ridden by an order picker or move autonomously alongside the order picker walking between pick locations. This collaborative system raises research questions, such as how much the collaborative robot speed affects the throughput performance of order-picking operations and how this effect changes for different pick-list sizes. Therefore, this study aims to develop an integer programming model to investigate the impact of the robot speed on the throughput capacity in an order-picking warehouse using collaborative robots and to solve the model developed for various pick-list sizes. The objective of the optimization model is to minimize the total tour time covering all locations in a pick-list. Moreover, the optimal strategy to walk along or ride the cobot for the order-picker is determined, depending on the distance between the pick locations. Considering the speed increase leads to accidents, a time penalty for the speed increase is added to the optimization model. Eventually, Monte Carlo simulation is used to generate pick-lists randomly, and the optimization model is solved by using Dynamic Programming. As a result of the study, it is shown that the throughput performance can be increased up to %60 by optimizing the robot speed depending on the pick-list size.

Keywords

Pick-list size Collaborative robot Optimal routing Optimal collaboration strategy Optimal collaborative robot speed.

Project Number

1059B191900637

References

  • Al-Araidah, O., Okudan-Kremer, G., Gunay, E. E. ve Chu, C.-Y. (2021). A Monte Carlo simulation to estimate fatigue allowance for female order pickers in high traffic manual picking systems. International Journal of Production Research, 59(15), 4711–4722. https://doi.org/10.1080/00207543.2020.1770357
  • Bartholdi, J. J. ve Hackman, S. T. (2019). Warehouse & distribution science: release 0.98.1. Atlanta, GA: Supply Chain and Logistics Institute. Erişim adresi: http://warehouse-science.com
  • Boz, E. ve Aras, N. (2022). Order picker routing problem in a single block warehouse. Journal of Turkish Operations Management, 6(1), 1113–1120. Erişim adresi: https://dergipark.org.tr/tr/pub/jtom/issue/70951/1091208
  • Carolina Handling. (2023). Increase Picking Accuracy. Boost Productivity. Erişim adresi: https://www.carolinahandling.com/campaign/pick2pallet
  • Çelik, M. ve Süral, H. (2016). Order picking in a parallel-aisle warehouse with turn penalties. International Journal of Production Research, 54(14), 4340–4355. https://doi.org/10.1080/00207543.2016.1154624
  • Chen, W., Zhang, Y. ve Zhou, Y. (2022). Integrated scheduling of zone picking and vehicle routing problem with time windows in the front warehouse mode. Computers & Industrial Engineering, 163, 107823. https://doi.org/10.1016/j.cie.2021.107823
  • Crown Equipment Corporation. (2013). Crown QuickPickTM Remote: [Order Picking Technology]: Productivity. Motivation. Safety. Retrieved from Order Picking Technology | QuickPick Remote | Crown Lift Trucks UK Erişim adresi: https://www.crown.com/uk/forklifts/pdfs/brochures/order-picker-quickpick-remote-brochure-GB.pdf
  • De Koster, R., Le-Duc, T. ve Roodbergen, K. J. (2007). Design and control of warehouse order picking: A literature review. European Journal of Operational Research, 182(2), 481–501. https://doi.org/10.1016/j.ejor.2006.07.009 E-ticaret bilgi platformu. (2021). 2021 Yılı İlk Altı Ay E-Ticaret Verileri Açıklandı. Erişim adresi: https://www.eticaret.gov.tr/istatistikler
  • Eren Şenaras, A. ve İnanç, Ş. (2018). Vba implementation via dynamic programming for agv line. Journal of Life Economics, 5(4), 255–264. https://doi.org/10.15637/jlecon.273
  • Goeke, D. ve Schneider, M. (2021). Modeling Single-Picker Routing Problems in Classical and Modern Warehouses. INFORMS Journal on Computing, 33(2). https://doi.org/10.1287/ijoc.2020.1040
  • Hong, S. (2014). Two-worker blocking congestion model with walk speed m in a no-passing circular passage system. European Journal of Operational Research, 235(3), 687–696. https://doi.org/10.1016/j.ejor.2013.10.013
  • Hong, S. (2019). A performance evaluation of bucket brigade order picking systems: Analytical and simulation approaches. Computers & Industrial Engineering, 135, 120–131. https://doi.org/10.1016/j.cie.2019.05.037 Hong, S., Johnson, A. L. ve Peters, B. A. (2013). A note on picker blocking models in a parallel-aisle order picking system. IIE Transactions, 45(12), 1345–1355. https://doi.org/10.1080/0740817X.2012.745204
  • Hong, S., Johnson, A. L. ve Peters, B. A. (2015). Quantifying picker blocking in a bucket brigade order picking system. International Journal of Production Economics, 170, 862–873. https://doi.org/10.1016/j.ijpe.2015.04.012
  • Jaghbeer, Y., Hanson, R. ve Johansson, M. I. (2020). Automated order picking systems and the links between design and performance: a systematic literature review. International Journal of Production Research, 58(15), 4489–4505. https://doi.org/10.1080/00207543.2020.1788734
  • Macedo, R., Coelho, F., Relvas, S. ve Barbosa-Póvoa, A. P. (2021). In-House Logistics Operations Enhancement in the Automobile Industry Using Simulation. Springer Proceedings in Mathematics & Statistics, 374. Springer, Cham. https://doi.org/10.1007/978-3-030-85476-8_4
  • Masae, M., Glock, C. H. ve Grosse, E. H. (2020). Order picker routing in warehouses: A systematic literature review. International Journal of Production Economics, 224, 107564. https://doi.org/10.1016/j.ijpe.2019.107564
  • Miller, A. (2004). Order Picking for the 21st Century Voice vs. Scanning Technology. Erişim adresi: https://www.logisticsit.com/absolutenm/articlefiles/688-voice_vs_scanning.pdf
  • Miller, C. E., Zemlin, R. A., Tucker, A. W. ve Zemlin, R. A. (1960). Integer Programming Formulation of Traveling Salesman Problems. Journal of the ACM, 7(4), 326–329. https://doi.org/10.1145/321043.321046
  • Motmans, R. (2012). Reducing whole body vibration in forklift drivers. Work, 41(1), 2476–2481. https://doi.org/10.3233/WOR-2012-0484-2476
  • Nilsson, G. (2004). Traffic safety dimensions and the power model to describe the effect of speed on safety. Lund Institute of Technology, Department of Technology and society, traffic engineering, 221. Erişim adresi: https://lucris.lub.lu.se/ws/portalfiles/portal/4394446/1693353.pdf Petersen, C. G. (1999). The impact of routing and storage policies on warehouse efficiency. International of Operations & Production Management, 19(10), 1053–1064. https://doi.org/10.1108/01443579910287073
  • Ratliff, H. D. ve Rosenthal, A. S. (1983). Order-Picking in a Rectangular Warehouse: a Solvable Case of the Traveling Salesman Problem. Operations Research, 31(3), 507–521. https://doi.org/10.1287/opre.31.3.507
  • Rojanapitoon, T. ve Teeravaraprug, J. (2020). Economic Order Picker Routing Considering Travel Time and Vehicular Energy Consumption with Varying Aisle Traffic. International Journal of Intelligent Engineering and Systems, 13(3), 317–328. Erişim adresi: https://www.scopus.com/inward/record.uri?eid=2-s2.0- 85107081697&partnerID=40&md5=ee445a16a02624774dec9b92060d35c6
  • Tompkins, J. A., White, J. A., Bozer, Y. A. ve Tanchoco, J. M. A. (2010). Facilities planning (4th ed.). New York, NY: John Wiley & Sons. Erişim adresi: https://www.wiley.com/en-us/Facilities+Planning%2C+4th+Edition-p9781119016076
  • Tuna, G. ve Tunçel, G. (2012). Depo Yönetiminde Sipariş Toplama Sistemleri: Bir Literatür Araştırması. Dokuz Eylül Üniversitesi Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 14(3), 15–31. Erişim adresi: https://dergipark.org.tr/tr/pub/deumffmd/issue/40820/492511
  • Tutam, M. (2024). Kolaboratif robot kullanılan sipariş-toplama depo tasarımlarının en iyilenmesi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 39(1), 203–216. https://doi.org/10.17341/gazimmfd.974331
  • UNEX Manufacturing. (2023). What is Order Picking? Erişim adresi: https://www.unex.com/applications/picking/order-picking
  • Van Gils, T., Ramaekers, K., Caris, A. ve De Koster, R. B. M. (2018). Designing efficient order picking systems by combining planning problems: State-of-the-art classification and review. European Journal of Operational Research, 267(1), 1–15. https://doi.org/10.1016/j.ejor.2017.09.002
  • Yener, F. ve Yazgan, H. R. (2019). Optimal warehouse design: Literature review and case study application. Computers & Industrial Engineering, 129, 1–13. https://doi.org/10.1016/j.cie.2019.01.006
  • Zhang, X., Vries, J., Koster, R. ve Liu, C. (2021). Fast and Faultless? Quantity and Quality Feedback in Order Picking. Production and Operations Management, 31(4), 1536–1559. https://doi.org/10.1111/poms.13630

Bir sipariş toplama deposunda iş birlikçi robot hızının çıktı performansı üzerindeki etkisi

Year 2023, Volume: 7 Issue: 2, 1672 - 1684, 29.12.2023

Mahmut Tutam

https://doi.org/10.56554/jtom.1258323

Abstract

Sipariş toplama operasyonları depolarda en fazla maliyet ve iş yükü oluşturan aktivitelerden birisidir. Sipariş toplayıcıların iş yükünün azaltılması ve performanslarının yükseltilmesi için son yıllarda depolarda kolaboratif sipariş toplama sistemleri daha fazla kullanılmaktadır. Kolaboratif bir sipariş toplama sisteminde, kolaboratif robot bir sipariş toplayıcı tarafından sürülebilmekte veya sipariş toplama noktaları arasında yürüyen sipariş toplayıcının yanı sıra otonom olarak hareket edebilmektedir. Bu kolaboratif sistem, kolaboratif robot hızının sipariş toplama operasyonlarının çıktı performansına etkisi ne kadardır? ve bu etki farklı toplama liste büyüklükleri için nasıl değişmektedir? gibi sorular ortaya çıkarmaktadır. Dolayısıyla, bu çalışma kolaboratif robot kullanılan bir sipariş toplama deposunda robot hızının çıktı performansına etkisini araştırmak amacıyla bir tamsayılı programlama modeli oluşturmaktayı ve çeşitli sipariş listesi büyüklükleri için geliştirilen modeli çözmeyi hedeflemektedir. Optimizasyon modelinin amacı bir toplama listesindeki tüm lokasyonları kapsayan tur süresini minimize etmektir. Ayrıca, sipariş lokasyonları arasındaki mesafeye bağlı olarak sipariş toplayıcının kolaboratif robotun yanında yürümesi veya kolaboratif robotu sürmesi için optimal strateji belirlenmiştir. Dahası, hız artışının kazalara yol açtığı dikkate alınarak optimizasyon modeline hız artışı için bir zaman cezası eklenmiştir. Son olarak, rastgele toplama listeleri oluşturmak için Monte Carlo simülasyonu kullanılmış ve Dinamik Programlama kullanılarak optimizasyon modeli çözülmüştür. Çalışmanın sonucunda, toplama listesi büyüklüğüne bağlı olarak robot hızın optimize edilmesiyle çıktı performansının %60'a kadar artırılabileceği gösterilmiştir.

Keywords

Toplama listesi büyüklüğü Kolaboratif robot Optimal rotalama Optimal iş birliği stratejisi Optimal kolaboratif robot hızı

Supporting Institution

TÜBİTAK

Project Number

1059B191900637

Thanks

Bu makalede bulunan çalışmalar TÜBİTAK (Türkiye Bilimsel Teknolojik ve Araştırma Kurumu) 1059B191900637 numaralı proje kapsamında yer almaktadır. Sağlanan destekten dolayı TÜBİTAK’a teşekkür ederiz.

References

  • Al-Araidah, O., Okudan-Kremer, G., Gunay, E. E. ve Chu, C.-Y. (2021). A Monte Carlo simulation to estimate fatigue allowance for female order pickers in high traffic manual picking systems. International Journal of Production Research, 59(15), 4711–4722. https://doi.org/10.1080/00207543.2020.1770357
  • Bartholdi, J. J. ve Hackman, S. T. (2019). Warehouse & distribution science: release 0.98.1. Atlanta, GA: Supply Chain and Logistics Institute. Erişim adresi: http://warehouse-science.com
  • Boz, E. ve Aras, N. (2022). Order picker routing problem in a single block warehouse. Journal of Turkish Operations Management, 6(1), 1113–1120. Erişim adresi: https://dergipark.org.tr/tr/pub/jtom/issue/70951/1091208
  • Carolina Handling. (2023). Increase Picking Accuracy. Boost Productivity. Erişim adresi: https://www.carolinahandling.com/campaign/pick2pallet
  • Çelik, M. ve Süral, H. (2016). Order picking in a parallel-aisle warehouse with turn penalties. International Journal of Production Research, 54(14), 4340–4355. https://doi.org/10.1080/00207543.2016.1154624
  • Chen, W., Zhang, Y. ve Zhou, Y. (2022). Integrated scheduling of zone picking and vehicle routing problem with time windows in the front warehouse mode. Computers & Industrial Engineering, 163, 107823. https://doi.org/10.1016/j.cie.2021.107823
  • Crown Equipment Corporation. (2013). Crown QuickPickTM Remote: [Order Picking Technology]: Productivity. Motivation. Safety. Retrieved from Order Picking Technology | QuickPick Remote | Crown Lift Trucks UK Erişim adresi: https://www.crown.com/uk/forklifts/pdfs/brochures/order-picker-quickpick-remote-brochure-GB.pdf
  • De Koster, R., Le-Duc, T. ve Roodbergen, K. J. (2007). Design and control of warehouse order picking: A literature review. European Journal of Operational Research, 182(2), 481–501. https://doi.org/10.1016/j.ejor.2006.07.009 E-ticaret bilgi platformu. (2021). 2021 Yılı İlk Altı Ay E-Ticaret Verileri Açıklandı. Erişim adresi: https://www.eticaret.gov.tr/istatistikler
  • Eren Şenaras, A. ve İnanç, Ş. (2018). Vba implementation via dynamic programming for agv line. Journal of Life Economics, 5(4), 255–264. https://doi.org/10.15637/jlecon.273
  • Goeke, D. ve Schneider, M. (2021). Modeling Single-Picker Routing Problems in Classical and Modern Warehouses. INFORMS Journal on Computing, 33(2). https://doi.org/10.1287/ijoc.2020.1040
  • Hong, S. (2014). Two-worker blocking congestion model with walk speed m in a no-passing circular passage system. European Journal of Operational Research, 235(3), 687–696. https://doi.org/10.1016/j.ejor.2013.10.013
  • Hong, S. (2019). A performance evaluation of bucket brigade order picking systems: Analytical and simulation approaches. Computers & Industrial Engineering, 135, 120–131. https://doi.org/10.1016/j.cie.2019.05.037 Hong, S., Johnson, A. L. ve Peters, B. A. (2013). A note on picker blocking models in a parallel-aisle order picking system. IIE Transactions, 45(12), 1345–1355. https://doi.org/10.1080/0740817X.2012.745204
  • Hong, S., Johnson, A. L. ve Peters, B. A. (2015). Quantifying picker blocking in a bucket brigade order picking system. International Journal of Production Economics, 170, 862–873. https://doi.org/10.1016/j.ijpe.2015.04.012
  • Jaghbeer, Y., Hanson, R. ve Johansson, M. I. (2020). Automated order picking systems and the links between design and performance: a systematic literature review. International Journal of Production Research, 58(15), 4489–4505. https://doi.org/10.1080/00207543.2020.1788734
  • Macedo, R., Coelho, F., Relvas, S. ve Barbosa-Póvoa, A. P. (2021). In-House Logistics Operations Enhancement in the Automobile Industry Using Simulation. Springer Proceedings in Mathematics & Statistics, 374. Springer, Cham. https://doi.org/10.1007/978-3-030-85476-8_4
  • Masae, M., Glock, C. H. ve Grosse, E. H. (2020). Order picker routing in warehouses: A systematic literature review. International Journal of Production Economics, 224, 107564. https://doi.org/10.1016/j.ijpe.2019.107564
  • Miller, A. (2004). Order Picking for the 21st Century Voice vs. Scanning Technology. Erişim adresi: https://www.logisticsit.com/absolutenm/articlefiles/688-voice_vs_scanning.pdf
  • Miller, C. E., Zemlin, R. A., Tucker, A. W. ve Zemlin, R. A. (1960). Integer Programming Formulation of Traveling Salesman Problems. Journal of the ACM, 7(4), 326–329. https://doi.org/10.1145/321043.321046
  • Motmans, R. (2012). Reducing whole body vibration in forklift drivers. Work, 41(1), 2476–2481. https://doi.org/10.3233/WOR-2012-0484-2476
  • Nilsson, G. (2004). Traffic safety dimensions and the power model to describe the effect of speed on safety. Lund Institute of Technology, Department of Technology and society, traffic engineering, 221. Erişim adresi: https://lucris.lub.lu.se/ws/portalfiles/portal/4394446/1693353.pdf Petersen, C. G. (1999). The impact of routing and storage policies on warehouse efficiency. International of Operations & Production Management, 19(10), 1053–1064. https://doi.org/10.1108/01443579910287073
  • Ratliff, H. D. ve Rosenthal, A. S. (1983). Order-Picking in a Rectangular Warehouse: a Solvable Case of the Traveling Salesman Problem. Operations Research, 31(3), 507–521. https://doi.org/10.1287/opre.31.3.507
  • Rojanapitoon, T. ve Teeravaraprug, J. (2020). Economic Order Picker Routing Considering Travel Time and Vehicular Energy Consumption with Varying Aisle Traffic. International Journal of Intelligent Engineering and Systems, 13(3), 317–328. Erişim adresi: https://www.scopus.com/inward/record.uri?eid=2-s2.0- 85107081697&partnerID=40&md5=ee445a16a02624774dec9b92060d35c6
  • Tompkins, J. A., White, J. A., Bozer, Y. A. ve Tanchoco, J. M. A. (2010). Facilities planning (4th ed.). New York, NY: John Wiley & Sons. Erişim adresi: https://www.wiley.com/en-us/Facilities+Planning%2C+4th+Edition-p9781119016076
  • Tuna, G. ve Tunçel, G. (2012). Depo Yönetiminde Sipariş Toplama Sistemleri: Bir Literatür Araştırması. Dokuz Eylül Üniversitesi Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 14(3), 15–31. Erişim adresi: https://dergipark.org.tr/tr/pub/deumffmd/issue/40820/492511
  • Tutam, M. (2024). Kolaboratif robot kullanılan sipariş-toplama depo tasarımlarının en iyilenmesi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 39(1), 203–216. https://doi.org/10.17341/gazimmfd.974331
  • UNEX Manufacturing. (2023). What is Order Picking? Erişim adresi: https://www.unex.com/applications/picking/order-picking
  • Van Gils, T., Ramaekers, K., Caris, A. ve De Koster, R. B. M. (2018). Designing efficient order picking systems by combining planning problems: State-of-the-art classification and review. European Journal of Operational Research, 267(1), 1–15. https://doi.org/10.1016/j.ejor.2017.09.002
  • Yener, F. ve Yazgan, H. R. (2019). Optimal warehouse design: Literature review and case study application. Computers & Industrial Engineering, 129, 1–13. https://doi.org/10.1016/j.cie.2019.01.006
  • Zhang, X., Vries, J., Koster, R. ve Liu, C. (2021). Fast and Faultless? Quantity and Quality Feedback in Order Picking. Production and Operations Management, 31(4), 1536–1559. https://doi.org/10.1111/poms.13630
There are 29 citations in total.

Details

Primary Language Turkish
Subjects Industrial Engineering
Journal Section Research Article
Authors

Mahmut Tutam 0000-0002-2018-5458

Project Number 1059B191900637
Publication Date December 29, 2023
Submission Date March 1, 2023
Acceptance Date August 9, 2023
Published in Issue Year 2023 Volume: 7 Issue: 2

Cite

APA Tutam, M. (2023). Bir sipariş toplama deposunda iş birlikçi robot hızının çıktı performansı üzerindeki etkisi. Journal of Turkish Operations Management, 7(2), 1672-1684. https://doi.org/10.56554/jtom.1258323
AMA Tutam M. Bir sipariş toplama deposunda iş birlikçi robot hızının çıktı performansı üzerindeki etkisi. JTOM. December 2023;7(2):1672-1684. doi:10.56554/jtom.1258323
Chicago Tutam, Mahmut. “Bir Sipariş Toplama Deposunda Iş birlikçi Robot hızının çıktı Performansı üzerindeki Etkisi”. Journal of Turkish Operations Management 7, no. 2 (December 2023): 1672-84. https://doi.org/10.56554/jtom.1258323.
EndNote Tutam M (December 1, 2023) Bir sipariş toplama deposunda iş birlikçi robot hızının çıktı performansı üzerindeki etkisi. Journal of Turkish Operations Management 7 2 1672–1684.
IEEE M. Tutam, “Bir sipariş toplama deposunda iş birlikçi robot hızının çıktı performansı üzerindeki etkisi”, JTOM, vol. 7, no. 2, pp. 1672–1684, 2023, doi: 10.56554/jtom.1258323.
ISNAD Tutam, Mahmut. “Bir Sipariş Toplama Deposunda Iş birlikçi Robot hızının çıktı Performansı üzerindeki Etkisi”. Journal of Turkish Operations Management 7/2 (December 2023), 1672-1684. https://doi.org/10.56554/jtom.1258323.
JAMA Tutam M. Bir sipariş toplama deposunda iş birlikçi robot hızının çıktı performansı üzerindeki etkisi. JTOM. 2023;7:1672–1684.
MLA Tutam, Mahmut. “Bir Sipariş Toplama Deposunda Iş birlikçi Robot hızının çıktı Performansı üzerindeki Etkisi”. Journal of Turkish Operations Management, vol. 7, no. 2, 2023, pp. 1672-84, doi:10.56554/jtom.1258323.
Vancouver Tutam M. Bir sipariş toplama deposunda iş birlikçi robot hızının çıktı performansı üzerindeki etkisi. JTOM. 2023;7(2):1672-84.

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