Effective Designing of Order Picking Systems Using Dynamic Simulation

Abstract

In this article, we describe the use of dynamic simulation when designing an effective system for order picking within a distribution warehouse. The simulation model was created in the Witness software environment for discrete dynamic simulation and is a modification of a general simulation model of material flows in supplier systems. Using the example of a batch system for picking orders in a drugstore goods warehouse, we discuss the possibilities of using a general simulation model of material flows as an effective framework for the development of system support for warehouse processes using WMS. The simulation model is based on the possibility of dividing any material flow in the supply system into a finite number of movements with the possibility of using one of the sources and fulfilment of certain conditions. In order to achieve the required optimisation of the order picking system, which depends, in particular, on the unknown duration of goods collection at the picking location, and on the duration of goods sorting in consolidation, the "what-if" analysis has been used as a tool to measure the impact of uncertainty of one or more variables entering the model on the uncertainty of output variables. The study showed that minimisation of the number of physical elements in the model leads to a significantly higher speed of its operation. By means of dynamic simulation, it is possible to test a large number of variants of the picking system layout in a relatively short time and minimise the risk of erroneous decisions associated with the implementation of a suitable WMS.

Efficient Order Picking in a Warehouse with Double Demand Seasonality

“…Due to its simplicity, model can be easily transferred to a different type of warehouse and it can be modified to fit new set of considered conditions. The outputs further confirm that model proposed by Kašparová and Dyntar (2021) is suitable for applications in the design and optimization of order picking systems.…”

“…We import demand data together with parameters of items coming from both categorization procedures into extended simulation model which is proposed in Witness Horizon disrete-event simulation software environment. This simulation model consists of modified basic modelling structures representing pickers (Kašparová and Dyntar, 2021). Number of pickers in the simulation is set in Initialization Actions using pre-defined Witness function SET QUANTITY OF for each simulated day separately to achieve the maximal utilization of workers.…”

“…These technologies involve traditional shelves for picking out of plastic crates and carton boxes, mobile racks with watering tubs for young plants picking and also ground palette positions for picking high volume items coming from the harvest Double seasonality distinctively affects storage assignment and routing in a considered individual order picking strategy (Van Gils et al, 2018) and makes warehouse management to be a very challenging task. To optimize the performance of such order picking system while maximizing the utilization of space in the picking area we employ the modification of the general simulation model of material flows in supplier systems (Dyntar, 2018) proposed by Kašparová and Dyntar (2021). This modification is proven to be suaitable for applications in the design and optimization of order picking systems (Dyntar and Kašparová, 2021).…”

Three Simulation Cases of Automated Warehouse Picking Systems: A Comparative Analysis

“…The WMS or Warehouse Management System, according to Kašparová and Dyntar (2021), is a system that provides information and allows to maintain control of the flow of merchandise within a warehouse from the moment of its reception until its dispatch; Likewise, this system serves as support for the operation of other business departments that use it, such as purchases and/or sales, which is why the integration of a WMS allows companies to increase efficiency, in response capacity, the various changes that may occur as a result of the warehouse or clients. Similarly, Caridade et al 100(2017) mention that the implementation of this system always constitutes a challenge both for the company that develops it and for the company that benefits from the software; since, for the design to be tailor-made, it must take into consideration all the company's warehouse processes such as storage, stock management, picking, production, packaging, etc.…”