Cold Storage Order Picking Performance: Effects of Load Unit Utilization and Product Volume
Increasing labor costs in retail have intensified the focus on order-fulfillment performance, particularly in warehouse operations. In this context, manual picker-to-parts systems, especially in cold storage environments processing deep-frozen products below -20°C, are of significant interest. Our study explores order picking in such cold storage environments, where products are packed into insulated, roll containers serving as load units. While existing research has explored the effects of product characteristics such as weight, volume, and different load units like pallets from a theoretical perspective, the specific interplay between load unit utilization levels and product volume remains underexplored in practical settings. To address this gap, we conducted a field study focusing on a cold storage of a prominent German brick-and-mortar grocery retailer and analyzed a comprehensive longitudinal dataset comprising 227,274 storage location visits by 29 order pickers in January 2023. Employing a mixed-effects model, we examined the impact of these factors on order picking time (OPT). Our findings revealed a subtle relationship: a 1% increase in load unit utilization level correlates with a 1% increase in OPT, signifying that higher utilization levels negatively impact pickers’ performance. Notably, our analysis also indicated that product volume moderates this effect. Specifically, lower product volumes can mitigate the adverse effects of high load unit utilization, whereas higher product volumes amplify these effects. This research offers valuable insights for warehouse managers, particularly in cold storage settings on finding the balance between OPT and load unit utilization.
Read more