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Order Pick

In: Business and Management

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DESIGN AND MANAGEMENT OF A LEAN ORDER PICKING SYSTEM

A thesis presented to the faculty of the Russ College of Engineering and Technology of Ohio University

In partial fulfillment of the requirements for the degree Master of Science

Chenying Kong November 2007

2 This thesis titled Design and Management of a Lean Order Picking System

by CHENYING KONG

has been approved for the Department of Industrial and Systems Engineering and the Russ College of Engineering and Technology by

Dale T. Masel Associate Professor of Industrial and Systems Engineering

Dennis Irwin Dean, Russ College of Engineering and Technology

3 ABSTRACT KONG, CHENYING, M.S., November 2007, Industrial and Systems Engineering Design And Management Of A Lean Order Picking System (107 pp.) Director of Thesis: Dale T. Masel

Order picking is the process of retrieving items from storage according to customer orders. It is significant to warehouse management because it typically accounts for over half of the operation costs. In this research, an order picking system that is designed by applying lean principles is discussed. The discussion is focused on three important decisions: layout design, storage location assignment, and workload scheduling. Combination of existing strategies has been applied to layout design in order to achieve the goal of lean. Buffer trays are applied in the fast pick area to reduce the impact of imbalance between zones. Heuristics are developed to assign storage locations and schedule workload, to optimize the performance of the system. The testing results show that the proposed warehouse with assignment and scheduling results obtained from the heuristics is more efficient than a traditional warehouse in terms of requested labor time of completing orders in one wave.

Approved: _____________________________________________________________ Dale T. Masel...

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