Abstract
Under a bucket brigade order picking protocol, pickers collaborate to fulfill orders by continuously picking and traveling across pick faces in forward and backward directions. Picker blocking and hand-off delays, however, can significantly affect operational performance. This study investigates flow time (FT), work-in-process (WIP), and throughput (TH) in a two-picker bucket brigade order picking system (OPS) and analyzes the limiting properties of these three performance measures in terms of pick probability, forward walk time, backward walk time, and OPS size, considering both picker and hand-off delays. Numerical analyses and extended simulations confirm that a decrease in the work-in-process level resulting from pickers’ backward walk speeds and hand-offs reduces operational performance.
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