Politecnico di Milano – School of Industrial and Information Engineering
Logistics Management Prof. Alessandro Perego
PRACTICAL LESSON #5 PICKING SYSTEMS – ASSESSMENT OF THE PICKING TIME – SOLUTION The Expected Picking Time (EPT) is the sum of Setup Time (SUT = 40s), Expected Travel Time (ETT) and Retrieval Time (RT). The configuration of the picking tour might affect the last two components. EPT = SUT + RT + ETT
CASE a) Order picking, traversal policy, random storage
Before starting with the calculation, it is necessary to check that the volume of a single container (0.8 m3) can include all the pieces to be retrieved in a picking tour: 1.2 𝐴𝑉 = 𝑁 ∙ 𝑁𝑃𝐿 ∙ 𝑃𝑖𝑒𝑐𝑒 𝑣𝑜𝑙𝑢𝑚𝑒 = 14 ∙ 4.5 ∙ = 0.0756 𝑚9 < 0.8 𝑚9 → 𝑂𝐾 1000 Retrieval time in CASE 1 assumes the value: 𝑅𝑇 = 𝑁 ∙ (𝑅𝑇𝐿 + 𝑁𝑃𝐿 ∙ 𝑅𝑇𝑃) = 14 ∙ (6 + 4.5 ∙ 2) = 210 𝑠 The Expected Travel Time is a function of the Expected travel distance within (𝐿E ) and across (𝐿F ) aisles for N picks. In turn, 𝐿E is a function of 𝑣. Given that, in case a), each aisle has the same access probability 𝑝E = 1/36: O 1 QU 𝑣 = J[1 − (1 − 𝑝E )M ] = 36 ∙ R1 − S1 − T V = 11.73 𝑎𝑖𝑠𝑙𝑒𝑠 36 EPQ 𝐿E = (𝑙E + 𝑤Y ) ∙ 𝑣 = (49 + 3.75) ∙ 11.73 = 618.8 𝑚 As regards 𝐿F , it depends on f: 𝐿F = 2 ∙ (𝑓 − 1) ∙ 𝑤\ + 2 ∙ 𝐷\⁄^ = 2 ∙ (17.24 − 1) ∙ 4.4 + 2 ∙ 6 = 154.91 𝑚 In conclusion: 𝐿\ + 𝐿Y 154.91 + 618.8 𝐸𝑇𝑇 = = = 773.71 𝑠 𝑆bc 1 𝐸𝑃𝑇 = 𝑆𝑈𝑇 + 𝑅𝑇 + 𝐸𝑇𝑇 = 40 + 210 + 773.71 = 1023.71 𝑠 The Expected Working Time per day is: 𝐸𝑃𝑇 220 ∙ 1023.71 𝐸𝑊𝑇fOg = #𝐷𝑎𝑖𝑙𝑦 𝑂𝑟𝑑𝑒𝑟𝑠 ∙ = = 62.56 ℎ/𝑑𝑎𝑦 3600 3600 Which, assuming an 8 hours shift with 7 hours of effective work, implies: 62.56 m n = 9 𝑤𝑜𝑟𝑘𝑒𝑟𝑠 7
CASE b) Order picking, return policy, random storage
CASE c) batch picking with sorting concurrent to the picking, traversal paths, random storage Expected Travel Time and Retrieval Time change. However, before computing the times it is necessary to repeat the volume check, given that the average number of pieces retrieved per picking tour has changed (𝑁 = 14 ∙ 4): 𝐴𝑉 = 𝑁 ∙ 𝑁𝑃𝐿 ∙ 𝑃𝑖𝑒𝑐𝑒 𝑣𝑜𝑙𝑢𝑚𝑒 = 4 ∙ 0.0756 = 0.3 𝑚9 < 0.8 𝑚9 → 𝑂𝐾 It is possible compute RT and EPT: 𝑅𝑇 = 𝑁 ∙ [𝑅𝑇𝐿 + 𝑁𝑃𝐿 ∙ (𝑅𝑇𝑃 + 𝑆𝑇𝑃)] = 14 ∙ 4 ∙ [6 + 4.5 ∙ (2 + 2)] = 1344 𝑠 O 1 QU∙U 𝑣 = J[1 − (1 − 𝑝E )M ] = 36 ∙ R1 − S1 − T V = 28.57 𝑎𝑖𝑠𝑙𝑒𝑠 36 EPQ 𝐿\ = (𝑤Y + 𝑙\ ) ∙ 𝑣 = (3.75 + 4.9) ∙ 28.57 = 1506.9 𝑚 Although 𝐿\ seems to increase considerably, the average 𝐿\ for 4 order in case a) is 618.8 ∙ 4 = 2475.2 𝑚: a 40% reduction. As regards 𝐿Y , the f parameters changes. A precise computation of f is not always strictly necessary. Like in this specific case, if with 14 line per picking tour we obtain an f factor of 17.24 (out of 18), with N = 56 we can safely assume that f = 18. Therefore: 𝐿Y = 2 ∙ (𝑓 − 1) ∙ 𝑤\ + 2 ∙ 𝐷\⁄^ = 2 ∙ 17 ∙ 4.4 + 2 ∙ 6 = 161.6 𝑚 161.6 + 1506.9 𝐸𝑃𝑇 = 40 + 1344 + = 3052.5 𝑠 1 𝐸𝑃𝑇 220 3052.5 𝐸𝑊𝑇 = #𝐷𝑎𝑖𝑙𝑦 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 ∙ = ∙ = 46.63 ℎ⁄𝑑 → 7 𝑤𝑜𝑟𝑘𝑒𝑟𝑠 3600 4 3600
CASE d) order picking, traversal path, item allocation based on access index ETT changes in both its two main components. To compute the new v and f parameters it is first necessary to define the probability to access each aisle, as reported in Table 1. Parameters for the first row (A+) are: #𝑎𝑖𝑠𝑙𝑒𝑠uv = % 𝑠𝑝𝑎𝑐𝑒 ∙ 𝑡𝑜𝑡 𝑎𝑖𝑠𝑙𝑒𝑠 = 5.6% ∙ 36 = 2 𝑃𝑖𝑐𝑘𝑖𝑛𝑔 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 35.3% 𝐴𝐼uv = = = 6.3 𝐷𝑒𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑠𝑝𝑎𝑐𝑒 5.6% %𝑟𝑒𝑡𝑟𝑖𝑒𝑣𝑎𝑙 35.3% 𝑝E,u∗ = = = 17.65% #𝑎𝑖𝑠𝑙𝑒𝑠 2
% space % retrievals #aisles AI pi (per aisle)
A+ 5.6 35.3 2 6.3 17.65% A 16.7 37.3 6 2.2 6.22% B 30.7 16.4 11 0.53 1.49% C 47 11 17 0.23 0.64% Table a: probability of access an aisle From which it derives: 9}
