ERROR DETECTION IN MANUAL ORDER PICKING OPERATIONS: WEIGHT CHECK POINT

Yıl 2022, Cilt: 21 Sayı: 2, 751 - 767, 30.04.2022

Abdullah Oktay Dündar , Alper Mustafa Ölger

https://doi.org/10.21547/jss.934606

Cited By: 1

Öz

In this study, a weight control system is proposed to detect erroneous picks caused by pickers in manual order picking operations. With this system, erroneous picking will be detected in the warehouse and errors will be corrected before shipment. The study was carried out in a logistics warehouse with 30% of total shipments consisting of mixed pallets, and the effect of missing shipments for 1 year before and after the proposed weight checkpoint on customer complaints was examined. In the study, it was determined that 13,762 pallets were outside the specified tolerance range at the weight checkpoint. It was ensured that the errors in the pallets were eliminated by performing the necessary controls by the pickers. With the proposed system, 92.9% reduction in the number of parcels sent to the customer incorrectly and reduction of 82.4% in customer complaints was achieved. It has been observed that the weight checkpoint in manual order picking has made significant contributions to reducing error rates and customer complaints.

Anahtar Kelimeler

Warehouse Management, Manual Order Picking, Error Detection, Weight Checkpoint

MANUEL SİPARİŞ TOPLAMA OPERASYONLARINDA HATA TESPİT UYGULAMASI: AĞIRLIK KONTROL NOKTASI

Öz

Bu çalışmada, manuel sipariş toplama operasyonlarında toplayıcı personel kaynaklı hatalı toplamaların tespit edilmesi için bir ağırlık kontrol sistemi önerilmektedir. Bu sistem ile hatalı toplamalar depo içerisinde tespit edilecek ve sevkiyattan önce hataların düzeltilmesi sağlanacaktır. Çalışma, toplam sevkiyatların %30’u karma paletlerden oluşan bir lojistik depoda gerçekleştirilmiş olup, önerilen ağırlık kontrol noktasından önceki ve sonraki 1 yıllık eksik gönderimlerin müşteri şikâyetleri üzerine etkisi incelenmiştir. Çalışmada önerilen ağırlık kontrol noktasında 13.762 adet paletin belirlenen tolerans aralığının dışında olduğu tespit edilmiştir. Toplayıcılar tarafından gerekli kontroller yapılarak paletlerdeki hataların giderilmesi sağlanmıştır. Bu sistem ile müşteriye hatalı sevk edilen koli sayısında %92,9’luk, müşteri şikâyetlerinde ise %82,4’lük bir azalma sağlanmıştır. Gerçekleştirilen çalışma ile manuel sipariş toplamada ağırlık kontrol noktasının hata oranlarını ve müşteri şikâyetlerini azaltmada önemli katkılar sağladığı gözlenmiştir.

Anahtar Kelimeler

Depo Yönetimi, Manuel Sipariş Toplama, Hata Tespiti, Ağırlık Kontrol Noktası

Kaynakça

• Atmaca, E., & Öztürk, A. (2014). Literatür araştırması: sipariş toplama politikaları ve otomatik depolama ve boşaltma sistemleri (AS/RS). Nevşehir Bilim ve Teknoloji Dergisi, 2(2), 120-134.
• Baechler, A., Baechler, L., Autenrieth, S., Kurtz, P., Hoerz, T., Heidenreich, T., & Kruell, G. (2016, January). A comparative study of an assistance system for manual order picking--called pick-by-projection--with the guiding systems pick-by-paper, pick-by-light and pick-by-display. In 2016 49th Hawaii International Conference on System Sciences (HICSS) (pp. 523-531). IEEE.
• Dallari, F., Marchet, G., & Melacini, M. (2009). Design of order picking system. The international journal of advanced manufacturing technology, 42(1-2), 1-12.
• De Koster, R., Le-Duc, T., & Roodbergen, K. J. (2007). Design and control of warehouse order picking: A literature review. European journal of operational research, 182(2), 481-501.
• De Vries, J., De Koster, R., & Stam, D. (2016). Exploring the role of picker personality in predicting picking performance with pick by voice, pick to light and RF-terminal picking. International Journal of Production Research, 54(8), 2260-2274.
• Dujmešić, N., Bajor, I., & Rožić, T. (2018). Warehouse processes improvement by pick by voice technology. Tehnički vjesnik, 25(4), 1227-1233.
• Đukić, G., Česnik, V., & Opetuk, T. (2010). Order-picking methods and technologies for greener warehousing. Strojarstvo, 52(1), 23-31.
• Funk, M., Shirazi, A. S., Mayer, S., Lischke, L., & Schmidt, A. (2015, September). Pick from here! An interactive mobile cart using in-situ projection for order picking. In Proceedings of the 2015 ACM International Joint Conference on Pervasive and Ubiquitous Computing (pp. 601-609).
• Gajšek, B., Đukić, G., Opetuk, T., & Cajner, H. (2017). Human in manual order picking systems. In Conference Proceedings-Management of Technology–Step to Sustainable Production.
• Grosse, E. H., Glock, C. H., & Neumann, W. P. (2017). Human factors in order picking: a content analysis of the literature. International Journal of Production Research, 55(5), 1260-1276.
• Grosse, E. H., Glock, C. H., Jaber, M. Y., & Neumann, W. P. (2015). Incorporating human factors in order picking planning models: framework and research opportunities. International Journal of Production Research, 53(3), 695-717.
• Guo, A., Raghu, S., Xie, X., Ismail, S., Luo, X., Simoneau, J., ... & Starner, T. (2014, September). A comparison of order picking assisted by head-up display (HUD), cart-mounted display (CMD), light, and paper pick list. In Proceedings of the 2014 ACM International Symposium on Wearable Computers (pp. 71-78).
• Guo, A., Wu, X., Shen, Z., Starner, T., Baumann, H., & Gilliland, S. (2015). Order picking with head-up displays. Computer, 48(6), 16-24.
• Hompel, M., & Schmidt, T. (2006). Warehouse management: automation and organisation of warehouse and order picking systems. New York: Springer Science & Business Media.
• Hsu, C. M., Chen, K. Y., & Chen, M. C. (2005). Batching orders in warehouses by minimizing travel distance with genetic algorithms. Computers in industry, 56(2), 169-178.
• Hwang, H., Oh, Y. H., & Lee, Y. K. (2004). An evaluation of routing policies for order-picking operations in low-level picker-to-part system. International Journal of Production Research, 42(18), 3873-3889.
• Ito, Y., & Kato, S. (2016, September). An apriori-based approach to product placement in order picking. In 2016 IEEE International Conference on Agents (ICA) (pp. 114-115). IEEE.
• Jarvis, J. M., & McDowell, E. D. (1991). Optimal product layout in an order picking warehouse. IIE transactions, 23(1), 93-102.
• Kretschmer, V., Eichler, A., Spee, D., & Rinkenauer, G. (2017). Cognitive ergonomics in the intralogistics sector. In Interdisciplinary Conference on Production, Logistics and Traffic, Darmstadt.
• Leung, K. H., Lee, C. K., & Choy, K. L. (2020). An integrated online pick-to-sort order batching approach for managing frequent arrivals of B2B e-commerce orders under both fixed and variable time-window batching. Advanced Engineering Informatics, 45, 101125.
• Petersen, C. G., & Aase, G. (2004). A comparison of picking, storage, and routing policies in manual order picking. International Journal of Production Economics, 92(1), 11-19.
• Poon, T. C., Choy, K. L., Chan, F. T., Ho, G. T., Gunasekaran, A., Lau, H. C., & Chow, H. K. (2011). A real-time warehouse operations planning system for small batch replenishment problems in production environment. Expert Systems with Applications, 38(7), 8524-8537.
• Reif, R., & Günthner, W. A. (2009). Pick-by-vision: augmented reality supported order picking. The Visual Computer, 25(5-7), 461-467.
• Roodbergen, K. J., & Vis, I. F. (2006). A model for warehouse layout. IIE transactions, 38(10), 799-811.
• Schwerdtfeger, B. (2010). Pick-by-vision: Bringing hmd-based augmented reality into the warehouse. Unpublished Doctoral thesis. Technical University of Munich, Germany. Retrieved 5 August 2020 from: https://mediatum.ub.tum.de/doc/992985/file.pdf
• Schwerdtfeger, B., Reif, R., Gunthner, W. A., Klinker, G., Hamacher, D., Schega, L., ... & Tumler, J. (2009, October). Pick-by-Vision: A first stress test. In 2009 8th IEEE International Symposium on Mixed and Augmented Reality (pp. 115-124). IEEE.
• Tappia, E., Roy, D., Melacini, M., & De Koster, R. (2019). Integrated storage-order picking systems: Technology, performance models, and design insights. European Journal of Operational Research, 274(3), 947-965.
• Thomas, C., Panagiotopoulos, T., Kotipalli, P., Haynes, M., & Starner, T. (2018, October). RF-pick: comparing order picking using a HUD with wearable RFID verification to traditional pick methods. In Proceedings of the 2018 ACM International Symposium on Wearable Computers (pp. 168-175).
• Tompkins, J. A., White, J. A., Bozer, Y. A., & Tanchoco, J. M. A. (2010). Facilities planning. United States of America: John Wiley & Sons.
• Tsai, C. Y., Liou, J. J., & Huang, T. M. (2008). Using a multiple-GA method to solve the batch picking problem: considering travel distance and order due time. International Journal of Production Research, 46(22), 6533-6555.
• Tunç S., Kutlu, B., Zincidi, A., & Atmaca, E. (2008). Depo sisteminde sipariş toplama sürecinin iyileştirilmesi. Gazi Üniversitesi Mühendislik-Mimarlık Fakültesi Dergisi, 23(2).
• Wu, X., Haynes, M., Guo, A., & Starner, T. (2016, September). A comparison of order picking methods augmented with weight checking error detection. In Proceedings of the 2016 ACM International Symposium on Wearable Computers (pp. 144-147).
• Yu, M., & De Koster, R. B. (2009). The impact of order batching and picking area zoning on order picking system performance. European Journal of Operational Research, 198(2), 480-490.