Comparative Analysis of Manual and Technology-Assisted Systems of Warehouse Operations: A Human Factors Account

Abstract

Purpose - The purpose of the present study is to explore and compare manual and technology-assisted systems and related warehouse order-picking operations through the lens of human factors. Design/Methodology/Approach - Theoretical analyses and an empirical study were performed. First, we conducted a literature review on human factors in order-picking planning to identify common research themes. Then, we explored order-picker perspectives (n=113) via survey. Findings - Results highlighted the similarities between manual and technology-assisted warehouse orderpicking systems in terms of physical demand, work hours, and the incidence of errors. Physical demand was largely contributed to by traveling and lifting tasks, and was further intensified by extended work hours. Despite the use of technology, technology-assisted systems registered a higher percentage of errors attributed to individual factors (44% vs 31%), specifically related to boredom and loss of attention. Additional insights from pickers were in agreement with literature findings that technological and organizational factors significantly contribute to the attainment of worker productivity and well-being. Research Implications - This study contributes to the stream of order-picking and warehouse-operations literature by obtaining essential human-factors insights directly from the principal actors. The study gained worker perspectives that might provide practitioners with initiatives that could increase worker well-being and productivity. In addition, researchers could also tap research directions aligning academic study with practical relevance.