Cost-neutral reduction of infection risk in picker-to-parts warehousing systems

Abstract The rapid and severe outbreak of COVID-19 caused by SARS-CoV-2 has heavily impacted warehouse operations around the world. In particular, picker-to-parts warehousing systems, in which human pickers collect requested items by moving from picking location to picking location, are very susceptible to the spread of infection among pickers because the latter generally work close to each other. This paper aims to mitigate the risk of infection in manual order picking. Given multiple pickers, each associated with a given sequence of picking tours for collecting the items specified by a picking order, we aim to execute the tours in a way that minimizes the time pickers simultaneously spend in the same picking aisles, but without changing the distance traveled by the pickers. To achieve this, we exploit the degrees of freedom induced by the fact that picking tours contain cycles which can be traversed in both directions, i.e., at the entry to each of these cycles, the decision makers can decide between the two possible directions. We formulate the resulting picking tour execution problem as a mixed integer program and propose an efficient iterated local search heuristic to solve it. In extensive numerical studies, we show that an average reduction of 50% of the total temporal overlap between pickers can be achieved compared to randomly executing the picking tours. Moreover, we compare our approach to a zone picking approach, in which infection risk between pickers can be almost eliminated. However, compared to our approach, the results show that the zone picking approach increases the makespan by up to 1066%.