The benefits of a dual-lane zone picking system with buffer-free conveyor lanes: An analytical approach
Journal : Computers & Industrial Engineering
Title : The benefits of a dual-lane zone picking system with buffer-free conveyor lanes: An analytical approach
Authors : Thao Huong Tran-Vo, Young Myoung Ko, Soondo Hong
Abstract : The increasing prevalence of small-footprint warehouses in urban areas necessitates a system that accommodates both fast order processing and space-saving requirements. This study introduces a Dual-lane Zone Picking system (DZP) featuring dual buffer-free conveyor lanes to improve picking performance in such warehouses. We develop an analytical model for a two-zone DZP, incorporating zone passing, a notable feature in sequential zone picking systems. We fit phase-type distributions for tote interarrival times and tote picking times, model the system as a Continuous-Time Markov Chain with a block-form transition generator, and apply the matrix geometric method to obtain the system’s stationary distribution and performance metrics. Numerical experiments demonstrate that DZP considerably reduces mean flow time and yields higher maximum throughput compared to traditional single-lane zone picking systems, especially in two-zone systems with high zone-passing probabilities. The results highlight the potential of the DZP to improve order picking efficiency and provide valuable insights into operational control.
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