Study and Analysis of Automated Order Picking Systems

Abstract

Order picking is an essential part of order processing in warehousing and distribution operations and can be performed using manual, automated, or semi-automated systems. This thesis analyzes two automated systems, which include carousel and AS/RS (automated storage and retrieval system). The main goal of this research is to develop mathematical models to compare the performance of both systems under random and class-based storage assignments. Simulation models are used to validate the reliability of mathematical models. The outputs of mathematical and simulation models are consistent indicating carousel system with class-based assignment has the highest throughput. Economic analysis is used to estimate the payback periods required to convert from manual to AS/RS and carousel systems. The economic analysis shows that converting from manual to AS/RS with class-based assignment has the shortest payback period.