Picker Assignment Algorithm Optimizes Warehouse Fulfillment
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Solution Overview
Problem
Traditional computerized systems for order fulfillment are inefficient in assigning items to pickers, leading to increased picking time, higher costs, and reduced customer satisfaction due to algorithmic inefficiencies, particularly in high-volume and complex order fulfillment operations.
Innovation Solution
A computerized system that assigns items to pickers by determining their physical locations, calculating distances, and selecting the closest picker to minimize transit time, while also considering item priorities and queue thresholds to optimize picker routes and assignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional computerized methods are used for order fulfillment, then systems can handle basic operations, but computing inefficiencies negate efficiencies gained by volume and cannot plan complex high-volume operations quickly enough
Solution Approach 1:
The system segments the order fulfillment problem into discrete item-level assignments rather than treating orders as monolithic units. Each item is independently evaluated and assigned to the optimal picker based on real-time location data, allowing the system to handle complex high-volume operations through modular decision-making that scales efficiently
Solution Approach 2:
The system implements dynamic picker assignment where pickers are not fixed to specific orders but are continuously reassigned to the nearest unassigned item based on their current location. This dynamic approach allows the system to adapt to changing conditions in real-time, enabling rapid processing of complex order fulfillment operations
2Loss of substance
If a single picker is assigned to items of a single order to simplify packaging, then shipping costs are reduced, but picking time increases and other nearby items from other orders are bypassed
Solution Approach 1:
The system allows pickers to partially fulfill multiple orders by assigning them to individual items from different orders based on proximity. Instead of requiring complete order fulfillment by a single picker, the system takes a partial approach where each item is independently assigned, enabling pickers to collect items from multiple orders during a single routing path
Solution Approach 2:
The system transitions from order-centric thinking to item-centric thinking, adding a spatial dimension to the assignment problem. By considering picker location coordinates and item location coordinates, the system optimizes assignments based on physical proximity rather than order boundaries, allowing efficient collection of items from multiple orders
3Ease of operation
If traditional algorithms provide simple unoptimized picking lists, then implementation is straightforward, but picking operation efficiency is reduced and delivery time increases
Solution Approach 1:
The system implements self-service through automated real-time optimization where the algorithm continuously calculates optimal picker assignments based on current locations without human intervention. The system serves itself by automatically reassigning items to pickers as they move through the warehouse, eliminating the need for manual list creation while maintaining operational simplicity for workers
Data Source
AI summary
The present disclosure provides a computerized method for assigning items to pickers including: determining a priority of an ordered item; inserting the item into an ordered data structure based on the priority of the item; iteratively, for items in the ordered data structure: determining an item physical location corresponding to a first unassigned item in the ordered data structure; determining a plurality of picker physical locations corresponding to locations of user devices of pickers; calculating a plurality of distances between the item physical location and picker physical locations among the plurality of picker physical locations; assigning the first unassigned item by: identifying a closest picker corresponding to a shortest distance of the plurality of distances; selecting the identified picker; correlating the first unassigned item with the selected picker in a data structure; and sending information of the item and physical location to the user device of the picker.