A puzzle-based material handling system for order picking

We propose a new type of automated goods-to-person system based on a grid of unit-sized conveyors. The system uses a negotiation-based decentralized control algorithm to route required totes or cartons to one or more picking positions on the perimeter of the grid. We describe the algorithms to accomplish a puzzle-like movement of totes on the grid and explore several design parameters and their effects on system throughput. One interesting result is that a 77% increase in throughput is possible if the orders processed by different workstations have no SKU commonality. The degree of stock keeping unit (SKU) commonality also affects the choice of layout.

Automated summary

This study introduces a new automated goods-to-person system based on a grid of unit-sized conveyors, utilizing a negotiation-based decentralized control algorithm for routing. It explores the effects of design parameters on system throughput and finds that throughput can increase by 77% when orders processed by different workstations have no SKU commonality. The level of SKU commonality also plays a role in layout choice.