![]() Testing showed that the optimal cluster picking solution should focus on reducing picking cart travel distance. The cart then spends time picking until all lines are picked and returns home before being released, ready to go again (click to enlarge) Metric collection included aisle and cart congestion, cart journey completion time, and waiting times.Ĭart movement simulation: orders are grouped and assigned to a cart which is then seized. The model accounted for warehouse shifts, the number of pickers in each shift, and gave the possibility to compare alternative waving strategies against FCFS. ![]() In this way, the engineers could resolve congestion and other bottlenecks in the order picking processes. The model was used to replicate the cluster picking method and compare it against alternatives. SolutionĮngineers developed a simulation model of cluster picking in a warehouse. Their solution would be a software tool that could be deployed at medium size warehouses. The Operations Science Team at DHL Supply Chain wanted to improve on basic cluster picking by reducing congestion and improving efficiency. Read more about warehouse throughput in the DHL Supply Chain case study. At maximum capacity, congestion and inefficiency can become challenges. Cluster pick is an attempt at maintaining a good level of throughput while dealing with many orders. The cluster pick method is used in medium size warehouses instead of picking orders individually, as practiced in small warehouses, or batch picking, which is used in large warehouses. It is commonly implemented with a first come first served (FCFS) wave strategy. ProblemĬluster picking is a method for collecting stock keeping items (SKU) for multiple orders in a single assignment. Here, learn about their research, solution, and case study results.ĭHL Supply Chain is a division of Deutsche Post DHL Group with a global network and extensive logistics portfolio, including warehousing, transport, and value-added services. In these cases, what are the optimal order picking methods?ĭHL Supply Chain conducted research and developed an optimization tool for order picking in medium-size warehouses. In between, there is a gray area, where orders are complex and warehouses neither large nor small. Small storage facilities will often pick orders individually while large multi-zone facilities will gather orders in batches. ![]() The picking methods employed in warehouses vary depending on warehouse size.
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