The effects of pick density on order picking areas with narrow aisles

The cost and service performance of an order fulfillment center are determined partly by how workers are organized into an order picking system. One common approach is batch picking, in which workers circumnavigate a picking area with other workers, gathering items on a pick list. In some systems with high space utilization, narrow aisles prohibit workers from passing one another when in the same aisle, and this leads to congestion. We build analytical and simulation models of these systems to investigate their behavior under different levels of activity. Among other things, our results suggest that when the system is busier and pick density is high (that is, when workers stop often to make picks) congestion is less of a problem and workers are more productive.