Optimization of a multi-period order picking and multi-trip order-picker routing to minimize total tardiness

Order picking operation is one of the most well-known labor and cost intensive internal logistics processes. Withdrawal of the order in response to customer need is defined in order to collect a set of orders from storage zone in the shortest possible time. The purpose of this research is to provide a scientific and practical basis considering the constraints that enforce to achieve an acceptable level of performance in order picking systems. This is done by building a Mixed Integer Linear Programming (MILP) formulation and developing an adapted solution method suited to the structure of the problem

First, by reviewing the literature in the field of order picking systems, sufficient knowledge has been obtained at the operational level, and with emphasis on warehouse management constraints, a MILP formulation is proposed by integrating order batching and picker routing. After validating the model and solving it through GAMS software, due to the nature of the problem, which is an NP-hard type, the problem is solved with an efficient algorithm, which is a grouping version of the league championship algorithm, and the results are compared. To develop the algorithm, operators are fit to the specific structure of the problem, i.e., the assignment of orders (items) to order pickers (groups)

Developing a multi-period MILP formulation for multi-trip picker routing, assuming for the first time the possibility of product replenishment and limited access to pickers. For large-scale problem instances, the league championship algorithm is used. The results indicate the effective capability and efficiency of this algorithm for solving large test problem instances.

The issue of multi-period order picking and multi-trip routing of pickers is considered for the first time ‎in this paper. Because of the limited number of pickers, this must be taken into account in modeling. ‎The assumption of product replenishment is also considered for the first time in this article and its ‎modeling has been done. In this way, orders enter the warehouse over time, during different periods, ‎and are placed in a predetermined positions. The limited access to pickers in each period is also ‎discussed for the first time in this paper. Finally, the objective function of minimizing the total ‎tardiness, which is in line with the needs of the industry, is also introduced in this paper. Regarding the ‎solution method, a league championship metaheuristic algorithm is presented which takes into ‎account the problem structure (which corresponds to the structure of grouping problems) and ‎solution generation operators have been developed to maintain the new solution.‎