Additional effort estimation due to ergonomic conditions in order picking systems

Within a warehouse, the picking activity often relies on human operators. Therefore, when designing and evaluating a manual picking system, it is important to consider that, besides the high flexibility the pickers are able to warrant, they inevitably require an additional effort due to their ergonomic working conditions. In this paper, the authors propose a new model to consider such additional effort, starting from the concepts of human availability and rest allowance. The new method allows the evaluation of the current configuration of a certain warehouse, considering two different operative situations (directly employed operators and indirectly employed ones). Moreover, it makes it possible to estimate and to understand the benefits that can be achieved by introducing some ergonomic improvements. The proposed procedure has also been applied to a real industrial case study.