Order Batch Formations for Less Picker Blocking in a Narrow Aisle Picking System
This paper analyses the best batch formations for order picking throughput in narrow aisle order picking systems. Our analytical comparison finds that a high pick density variation leads to a heavy picker blocking. Simulation experiments show that a distance based batching algorithm reduces picker blocking by decreasing the number of aisles visited and stabilizing the variation in number of picks per aisle by packing orders tightly, and that the solution quality and mechanism for determining the batch size dictated by the sorting strategy causes varying amounts of blocking. We conclude that combining a distance based batching method with an appropriate batch sizing strategy will reduce picker blocking and shorten travel in narrow aisle picking systems.