With the rise of personalized demands, mass customization has gained popularity in manufacturing. This mode, marked by diverse products, mixed batch sizes, and dynamic orders, often results in low efficiency in picking areas due to manual operations. To enhance material flow and assembly efficiency, seamless coordination between replenishment and picking is crucial. This study proposes a human-centric replenishment-picking coordination method (HCRPCM) that incorporates ergonomic principles to balance efficiency and worker well-being. Using the Non-Dominated Sorting Genetic Algorithm II (NSGA-II), HCRPCM significantly improves picking efficiency and reduces ergonomic risks compared to traditional methods, with average total order operation time reduced by 9%–35% and ergonomic risks by 8%–50%.

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Human-Centric Replenishment-Picking Coordination for Mass Customization Manufacturing Workshops Considering Ergonomic Risk

  • Fen Liu,
  • Qu Zhou,
  • Mingxing Li,
  • Xiaoguang Sun,
  • Fangtong Liu,
  • Mian Yan,
  • Jieyi Hu

摘要

With the rise of personalized demands, mass customization has gained popularity in manufacturing. This mode, marked by diverse products, mixed batch sizes, and dynamic orders, often results in low efficiency in picking areas due to manual operations. To enhance material flow and assembly efficiency, seamless coordination between replenishment and picking is crucial. This study proposes a human-centric replenishment-picking coordination method (HCRPCM) that incorporates ergonomic principles to balance efficiency and worker well-being. Using the Non-Dominated Sorting Genetic Algorithm II (NSGA-II), HCRPCM significantly improves picking efficiency and reduces ergonomic risks compared to traditional methods, with average total order operation time reduced by 9%–35% and ergonomic risks by 8%–50%.