播種式揀貨系統之規劃

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姓名

劉忠政(Jhong-jheng Liou) 查詢紙本館藏

畢業系所

工業管理研究所

論文名稱

播種式揀貨系統之規劃
(A Planning of Put-to-light Based Picking System)

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摘要(中)

物流中心的電子標籤輔助揀貨系統可分成「摘取式(Pick-to-light)」與「播種式(Put-to-light)」兩種，所謂「摘取式揀貨系統」即貨架上安裝的標籤所對應的是商品，揀貨人員依標籤的指示，自貨架上將商品取下以滿足手上的客戶訂單；至於「播種式揀貨系統」跟「摘取式揀貨系統」正好相反，貨架上安裝的標籤所對應的是客戶訂單，揀貨人員將批次匯總後之商品，依標籤的指示，並分發至訂購客戶架上。
本研究主要針對「播種式揀貨系統」內部訂單揀貨作業為主要探討重點，針對多橫向走道（cross-aisle）環境，配合吾人提出的揀貨方式模擬出不同的結果，本研究主要可分為四個階段：第一階段為輸入訂單之集中型態、第二階段為品項分群，包括使用先前學者提出的相似係數以及群集分析法、第三階段為備料區品項指派、最後一階段為訂單指派儲位順序，前一階段必須完成後才做下一個階段；本研究即是用以3種不同的訂單型態水準、4種相似係數水準、3種聚群法則水準、2種備料區指派水準，及13種訂單儲位配置水準，共有936種組合進行實驗，並以揀貨作業總行走距離為績效，求取最佳效果組合。結果發現訂單愈呈集中型態，吾人所提出之因子法則對節省行走距離愈有效，在此訂單型態下相似係數計算法、品項聚群法則及備料區指派法則有顯著影響，但在品項平均需求型態或品項需求平均數大的訂單型態下，相似係數計算法、品項聚群法則及訂單指派準則有顯著差異，備料區指派法則反而沒有顯著差異。相似係數計算法、品項聚群法則、備料區指派法則與訂單指派準則各因子的最佳水準分別為SC1、CA3、AL2與OC11。

摘要(英)

According to the picking operation in Distribution Centers, the Computer Aided Picking Systems could be divided into “Pick-to-light” and “Put-to-light”. In the “Pick-to-light” system, the digital tags on racks correspond to items and indicate pickers to pick items. In the other hand, the tags correspond to customers’ orders in the “Put-to-light” system. Pickers batch the necessary items of these orders and then assort the needed items to orders by the indication of tags.
The study is based on the picking operation of “Put-to-light” systems and experimented with simulation by the proposed methods under multiple cross-aisles warehouses environment. There are four phases in the study: the first phase is types of input orders, the second phase is item grouping, including the similar coefficients and the cluster analysis which proposed in previous research, the third phase is assignment of assorting zones, and the last is sequence of the orders that have be allocated to bins. Once the previous one phase has finished, the next phase will begin. The study is experimented with three different order type levels, four similar coefficient levels, three cluster rule levels, two assignment of assorting zone levels, and thirteen order allocation criterion levels. There are totally 936 combinations and the pickers’ total traveling distance is used as performance measurement to measure every combination. The result is as concentrated as consisting of orders, the proposed methods are more efficacy in saving traveling distance. When the system under the concentrated order type level, the similar coefficient, cluster rule and assignment of assorting zone factors are significant. But when it under uniform order type level, the similar coefficient, cluster rule and order allocation criterion factors are significant. Finally, the best level of similar coefficient, cluster rule, assignment of assorting zone and order allocation criterion are SC1, CA3, AL2 and OC11.

關鍵字(中)

★ 物流中心
★ 播種式揀貨系統
★ 品項聚群

關鍵字(英)

★ Distribution Center
★ Put-to-light System
★ item grouping

論文目次

摘　要.................................................I
目　錄................................................IV
圖目錄................................................VI
表目錄...............................................VII
第一章　緒論...........................................1
1.1 研究背景與動機................................1
1.2 研究目的......................................2
1.3 研究環境與假設................................2
1.4 研究方法與流程................................4
1.5 論文架構......................................6
第二章　文獻回顧.......................................7
2.1 物流..........................................7
2.1.1 物流的定義.......................................7
2.1.2 物流的領域.......................................8
2.1.3 物流中心介紹.....................................8
2.1.4 物流中心揀貨設備................................10
2.1.5 物流中心揀貨作業程序............................14
2.2 倉儲管理（Warehouse Management）.............14
2.2.1倉庫規劃（Warehousing）..........................15
2.2.2走道設計（Aisle Design）.........................15
2.3 儲位設計（Storage Design）...................16
2.3.1 儲位管理方法（Storage Management）..............16
2.4.2 儲位指派策略（Storage Assign Strategy）.........17
2.4 揀貨策略與方法（Order Picking Strategy）.....18
2.4.1分區揀貨（Zone Picking）.........................18
2.4.2 訂單分批（Order Batching）......................19
2.4.3 訂單分割（Order Splitting）.....................21
2.4.4 播種式揀貨系統（Put-to-light System）...........22
2.5 揀貨路徑策略（Route Strategy）...............22
2.5.1銷售員旅行問題（Traveling Salesman Problem）.....22
2.5.2 揀貨路徑政策（Routing Policy）..................23
第三章　研究問題與方法................................25
3.1 研究流程與架構...............................25
3.2 問題說明與環境假設...........................28
3.3 訂單產生依據.................................29
3.4 相似係數與品項聚群...........................32
3.5 品項群指派（備料區佈置）.....................35
3.5.1 PLANET-Based演算法..............................37
3.5.2 模擬退火法（Simulated Annealing, SA）...........39
3.5.3 數學模型........................................41
3.6 訂單儲位配置.................................45
3.6.1 儲位配置法則....................................45
3.6.2 訂單指派準則....................................47
3.7 揀貨員行走路徑...............................53
第四章　模擬實驗與分析................................55
4.1 模擬實驗設計.................................55
4.1.1 揀貨環境設計....................................56
4.1.2 備料區個數、揀貨員個數..........................57
4.1.3 總品項種類數....................................57
4.1.4 總實驗訂單張數..................................58
4.2 實驗因子組合.................................58
4.3 績效評估準則.................................58
4.4 模擬實驗分析.................................58
4.4.1 原始數據資料....................................59
4.4.2 基本假設檢定....................................63
4.4.3 個別因子之假設..................................64
4.5 ANOVA統計分析................................65
4.5.1主要效果項分析...................................65
4.5.2 二因子交互作用分析..............................70
4.6 訂單大小與變異分析...........................79
4.6.1 需求品項平均數..................................79
4.6.2 需求品項變異數..................................81
4.7 實驗結論.....................................83
第五章　結論與建議....................................87
5.1 研究結論.....................................87
5.2 後續研究建議.................................87
參考文獻..............................................89
附錄..................................................93

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中文部份
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電子媒體
[1] 「94年全球商業鏈整合及物流運籌e計畫」，全國商工行政服務入口網。http://gcis.nat.gov.tw
[2] MaterialHandlingInfo.com網站。http://www.mhinfo.com
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指導教授

何應欽(Y.C. Ho)

審核日期

2007-7-14

推文