An efficient algorithm to cluster order picking items in a wide aisle

Abstract

In many warehousing systems cases of items have to be retrieved manually from both sides of a wide aisle and deposited on a vehicle which travels on the center line of the aisle. The picker will stop the vehicle, pick and load cases of items onto the vehicle and then drive to the next stop. There is a tradeoff between the time to stop and start the vehicle and the increased walking distance if fewer vehicle stops are made. An algorithm is presented to determine the o optimal number and location of stops and to specify the items to be picked at each stop. Comparison with heuristic clustering methods indicates savings of 10% to 90%. The algorithm can be implemented in real time on a microcomputer.