Optimal order picking process in picker-to-part warehouses

Abstract

Over the past decade, consumer shopping habits have increasingly shifted towards online grocery purchases, creating a growing demand for efficient and scalable warehouse operations. As order volumes and complexity rise, the optimization of warehouse processes has become essential to meet requirements while controlling operational costs. This study addresses the Joint Order Batching Picker Routing Problem (JOBPRP) by developing an exact optimization approach and examining the interdependencies among key warehouse processes, such as batching, routing, and product allocation. Using a case study of Crisp B.V., an online grocery retailer, the proposed algorithm was implemented to optimize configurations across multiple temperature-controlled zones with varying operational characteristics, such as differing pick densities and operational constraints. The research shows that all warehouse processes are interconnected and the best performing configuration is depending on the operational characteristics of the warehouse. The optimization approach achieved a 39.14% reduction in weekly travel distance compared to Crisp’s current benchmark, highlighting its potential to significantly enhance travel distances. These findings highlight the significant impact of integrating order batching and picker routing on warehouse efficiency. The study not only demonstrates the critical correlation between warehouse processes but also provides actionable insights for optimizing order picking in high-density, large-scale warehouses