Warehouse Layouts in Picker-to-Parts Order Picking Systems: An Overview of Design Alternatives and Planning Problems

Order picking is among the most time- and cost-intensive internal logistics processes. One prerequisite for an efficient order picking process is an optimised warehouse layout that defines the general structure of the warehouse, type and position of the shelves, and dimensions and locations of the aisles. The framework conditions established by the warehouse layout determine the available options for storage assignment and order picker routing, and they also influence the order pickers’ well-being at work. This chapter provides an overview of alternative warehouse layouts discussed in the order picking literature, outlines optimisation problems associated with layout design, and presents a selection of solution methodologies. The chapter concludes with an outlook for future research opportunities.