Impact of Integrating Zone Bypass Conveyor on the Performance of a Pick-To-Light Order Picking System

Abstract

This thesis investigates the impact of integrating Zone Bypass (ZBP) conveyor to a Pick-To-Light (PTL) order picking system. This integration results in a new system (PTL+Z), which could be helpful to achieve higher levels of productivity in warehousing operations. Two options have been proposed to improve the current PTL system productivity. One is to adapt the ZBP conveyor, which will help each order to bypass unnecessary zones with nothing to pick. Another one is to better plan stock keeping units (SKU) assignment by applying level loading assignment. Mathematical models are developed to evaluate system throughput of PTL system with random assignment (PTL/R), PTL system with level loading assignment (PTL/L), PTL+Z system with random assignment (PTL+Z/R), and PTL+Z system with level loading assignment (PTL+Z/L). Simulation models are validated to test the reliability of mathematical models. Also, economic analysis is developed in term of payback period for decision purpose.