零散揀貨環境下之分區揀貨作業問題的探討

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姓名

李天傑(Tian-Jie Li) 查詢紙本館藏

畢業系所

工業管理研究所

論文名稱

零散揀貨環境下之分區揀貨作業問題的探討
(The Performance of Zone Picking under Piece Picking Environment)

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摘要(中)

供應鏈的競爭遍及各個層面，包括產品的訂價、銷售、策略行銷、物流等都是重要的環節。其中根據研究，在物流系統之中，揀貨所耗費的相關成本佔了總成本的15~20%；故揀貨相關的作業是一項相當值得研究的議題。
揀貨系統有許多形式，最為常見的揀貨系統稱作嚴格訂單揀貨系統，是指一個揀貨人員一次負責一張訂單的揀貨方式。這種揀貨方式最大的缺點，就是揀貨人員時常必須橫跨整個揀貨區域，以揀取訂單包含的品項。而分區揀貨(Zone Picking)，一般可分為同時分區揀貨(Synchronized Zone Picking)和順序分區揀貨(Sequential Zone Picking)；分區揀貨最大的好處便是固定揀貨人員，使得揀貨人員只需要在某個區域內揀取訂單上的品項，而不必在揀取品項的過程中，耗費太多行走時間。儘管分區揀貨大幅節省了揀貨人員的行走時間，但分隔區域便會造成各個揀貨區域的工作量不平衡問題。由於分區揀貨系統具有多條揀貨走道，因此在揀取訂單的時候，會先將訂單分成數個揀貨箱，再將揀貨箱送進不同的揀貨走道進行揀取作業。由於只有當全部的揀貨箱都完成揀取作業之後，才算完成一張訂單，因此區域工作量不平衡的問題將會嚴重影響訂單的揀取時間。
本研究針對分區揀貨環境的區域不平衡問題，以品項儲位設計及訂單選取控制兩個部份，各別提出數個法則，希望降低分區揀貨系統的系統總揀貨時間及平均每張訂單的揀貨時間。本研究最後以模擬軟體Arena 11.0驗證各法則的組合下，何者的系統績效指標最佳。

摘要(英)

The competitions in supply chain are common in pricing, sales, strategic marketing, logistics. According to researches, picking related costs take 15 to 20% of all costs in logistic system. It makes picking related operations as a valuable issue to study.
There are many types in picking system, the most common one is called strict picking system. The disadvantage of strict picking system is that pickers are likely cross the entire picking zone to pick items in orders. On the other hand, the greatest advantage of zone picking is that pickers are fixed with their picking zone. It makes pickers pick their items without crossing entire picking system thus saves time a lot. Though zone picking environment save walking time dramatically, it would cause workload balancing problem in every zones.
There are several picking aisles lie in zone picking system, and zone picking system would split an order into several picking box. The picking boxes would be taken into different picking aisles to complete the picking operations. An order is said to be finished only if its picking boxes are all finished, thus the unbalancing problem would effect order complete time dramatically.
The research proposes several rules in order to solve zone unbalancing problem in zone picking environment, hoping to decrease system picking time and average order picking time in zone picking system. In the study, we make use of Arena 11.0 coding the simulation and use statistical package SPSS 13.0 analyze and compare the variable combination experience outcomes.

關鍵字(中)

★ 物流中心
★ 訂單揀取
★ 分區揀貨
★ 品項儲位設計
★ 選取訂單法則

關鍵字(英)

★ Distribution Center
★ Order Picking
★ Zone Picking
★ Item Storage Design
★ Order selection Rule

論文目次

摘要 I
目錄 IV
圖目錄 VII
表目錄 VIII
第一章緒論 1
1.1 研究背景 1
1.2 研究動機與目的 2
1.3 研究環境 4
1.4 論文架構 7
第二章文獻回顧 9
2.1 揀貨策略問題 9
2.1.1 嚴格訂單揀貨 11
2.1.2 區域揀貨 11
2.2.1 儲位指派問題 15
2.2.2 黃金區域 17
2.3 揀貨路徑規劃問題 18
2.4訂單選取 19
第三章研究問題與方法 20
3.1 方法架構與流程 20
3.2 問題說明 20
3.2.1 揀貨系統績效評估準則 21
3.3 環境假設 22
3.4 訂單產生依據 22
3.5 訂單分流 23
3.6 揀貨人員揀貨流程 24
3.6.1「第一位揀貨人員」揀貨流程 25
3.6.2「中間揀貨人員」揀貨流程 27
3.6.3「最後一位揀貨人員」揀貨流程 29
3.7 訂單合流 30
3.8 品項儲位設計問題 31
3.8.1 品項儲位設計之設計原則 31
3.8.2 品項儲位優先排序 32
3.8.3 儲位黃金區 32
3.8.3 品項儲位法則 33
3.8.3.1 橫跨法則 33
3.8.3.2 S形橫跨法則 34
3.8.3.3 同列橫跨法則 35
3.8.3.4 S形同列橫跨法則 35
3.8.3.5 依序同列橫跨法則 36
3.8.3.6 S形依序同列橫跨法則 37
3.9 訂單選取控制問題 38
3.9.1 訂單選取控制流程 39
3.9.2 訂單選取控制法則 40
3.9.2.1 隨機法則 41
3.9.2.2最小平方和法則 43
3.9.2.3最小絕對值和法則 44
3.9.2.4最大訂單平衡值法則 45
第四章實驗結果與分析 47
4.1 模擬實驗設計 47
4.1.1 實驗環境 47
4.1.2 實驗目的與方法 47
4.1.3 模擬實驗因子 48
4.1.4 績效評估指標 49
4.2 模擬實驗結果 50
4.3 ANOVA統計檢定分析 51
4.3.1 變異數分析 51
4.3.1.1 系統總完成時間 51
4.3.1.2 平均訂單完成時間 52
4.3.2 主要效果項分析 53
4.3.2.1品項儲存策略 53
4.3.2.1.1 系統總完成時間 53
4.3.2.1.2 平均訂單完成時間 54
4.3.2.2 訂單選取策略 55
4.3.2.2.1 系統總完成時間 55
4.3.2.2.2 平均訂單完成時間 56
4.4 模擬實驗結果(續) 58
4.5 ANOVA統計分析檢定(續) 59
4.5.1 變異數分析 59
4.5.1.1 系統總完成時間 59
4.5.1.2 平均訂單完成時間 60
4.5.2 主要效果項分析 60
4.5.2.1 訂單選取策略 61
4.5.2.1.1 系統總完成時間 61
4.5.2.1.2 平均訂單完成時間 62
4.5 實驗結論 63
第五章結論與後續研究建議 64
5.1 研究結論 64
5.2未來研究建議 64
參考文獻 66

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指導教授

何應欽(Ying-Chin Ho)

審核日期

2009-7-21

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