In this study we consider a pick-to-pack orderpicking system, in which batches of orders are picked simultaneously from different (work) zones by a group of order pickers. After picking, the orders are transported by a conveyor to the next station for packing. Our aim is to determine the optimal number of zones such that the overall (picking and packing) time to finish a batch is minimized. We solve this problem by optimally assigning items to pick routes in each zone. We illustrate the method with data taken from a distribution center of one of the largest online retailers in the Netherlands.
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