分區式揀貨倉庫系統之訂單批次化問題研究

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呂柏嫻(Lu-Po-Hsien) 查詢紙本館藏

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工業管理研究所

論文名稱

分區式揀貨倉庫系統之訂單批次化問題研究

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摘要(中)

近年來，因網路購物的迅速發展，促使消費模式改變，消費管道由實體店面轉移至電商平台，更因COVID-19（新冠肺炎）疫情的關係，網路零售業銷售額創新高，網購商家所主打的24小時快速到貨及免運費等促銷活動，使得配送量與日俱增，也考驗著物流中心的效率與產能。因此，如何在迅速滿足客戶的需求下，同時降低成本，儼然成為物流中心需面對的一大挑戰。
物流中心的作業流程可歸類為以下九項：進貨、搬運、儲存、盤點、訂單、揀貨、補貨、出貨、輸配送，其中揀貨作業為最具客戶敏感度的一環，同時也是人力消耗以及作業量最大的一項工作。目前大多數的物流中心是屬於「勞力密集」的產業，揀貨作業占物流中心運營總成本的50到75%，為物流中心「成本最高的作業流程」，且揀貨作業時間約佔整個物流作業時間的30到40%。因此，優化揀貨流程成為物流中心的首要目標。
以往，物流中心常見的揀貨方式為「個別揀取」，即一位揀貨員一次揀取一張訂單，此方法的優點為簡單明瞭，缺點是效率較低。對此，常見的解決方式為「批次揀取」，意即將相似訂單做合併處理，一個揀貨員同時對多張相似訂單進行揀貨，減少所需揀貨時間與行走距離。由此可知，訂單批次化方法的優劣對揀貨效率有關鍵的影響，若能找到適合的訂單批次化方法能對揀貨效率有顯著的提升。
然而，過往的訂單批次化文獻，鮮少探討物流業常見的「分區式揀貨系統」。此揀貨系統的優點為揀貨行走路線流暢，相對的動線較為複雜，因此搭配優良的揀貨策略顯得格外重要。基於上述原因，本研究將針對分區式揀貨系統中的批次化問題進行研究，並搭配揀貨路徑方法，期望透過完整的模擬實驗與績效分析，找出最適合的訂單批次化方法，並能對此類問題有更深入的了解，亦對未來類似的研究能有所貢獻。

摘要(英)

In recent years, due to the rapid development of online shopping, consumption patterns have changed, and consumption channels have shifted from physical stores to e-commerce platforms. Due to COVID-19, online retail sales have reached a new high point. Online shopping merchants focus on 24-hour fast arrival free shipping and free shipping make the distribution volume increase day by day, and also test the efficiency and production capacity of the distribution center. Therefore, how to meet the needs of customers while reducing costs has become a major challenge for distribution centers.
In the operation of the distribution center, the picking operation is the most customer-sensitive part, and it is also the work that consumes the most manpower and the largest amount of operation. At present, most distribution centers are "labor-intensive" industries. Picking operations account for 50 to 75% of the total distribution center operating costs, and the picking operation time accounts for about 30 to 40% of the entire distribution operation time. Therefore, optimizing the picking process becomes the primary goal of the distribution center.
The common picking method in the distribution center is "individual picking". The advantage of this method is that it is simple and clear, but the disadvantage is that it is less efficient. The solution to this is "batch picking", which means combining similar orders to reduce the required picking time and travel distance. It can be seen that the quality of the order batching method has a key impact on the picking efficiency. If a suitable order batching method can be found, the picking efficiency can be significantly improved.
In the past literature, there is little discussion on the common "partition picking system" in the distribution industry. The advantage of this picking system is that the picking route is smooth, but the relative moving line is relatively complicated. Therefore, this research will study the batching problem in the partition picking system, and with the picking path method, it is hoped that through a complete Simulation experiments and performance analysis can find out the most suitable order batching method, and can have a deeper understanding of such problems, and can also contribute to similar research in the future.

關鍵字(中)

★ 物流中心
★ 分區式揀貨系統
★ 訂單批次化
★ 固定式揀貨路徑

關鍵字(英)

★ Distribution Center
★ Zone Picking System
★ Order Batching
★ Order Batch Selection
★ Fixed Order Picking Route

論文目次

目錄
摘要 I
Abstract II
目錄 III
圖目錄 VI
表目錄 VIII
第一章緒論 1
1.1 背景研究 1
1.2 研究動機 2
1.3 研究目的 4
1.4 研究環境 4
1.5 論文架構 8
第二章文獻探討 10
2.1 倉儲規劃（Warehouse planning） 10
2.1.1 倉儲設計（Warehouse design） 10
2.1.2 走道設計（Aisle design） 15
2.2 儲位規劃（Storage planning） 18
2.2.1 儲位指派（Storage assignment） 18
2.2.2 儲區佈置（Warehouse layout） 21
2.3 訂單揀貨規劃（Order picking planning） 27
2.3.1 訂單批次化（Order batching） 27
2.3.2 揀貨政策（Picking policy） 36
2.3.3 路徑策略（Routing strategy） 41
第三章研究方法 49
3.1 問題說明 49
3.2 方法架構與流程 49
3.3 訂單批次化問題 51
3.3.1 種子訂單+配合訂單批次化法 52
3.3.2 種子訂單選擇法 54
3.3.2.1 揀貨區域數最少法 56
3.3.2.2 最小方形揀貨覆蓋區域法 56
3.3.2.3 揀貨區域中心點與 I/O 點之平均直線距離最短法 58
3.3.2.4 隨機選取法則 61
3.3.3 配合訂單選擇法 62
3.3.3.1 額外增加揀貨區域數最少法 63
3.3.3.2 最大揀貨覆蓋區域重疊面積法 64
3.3.3.3 訂單間至最鄰近揀貨區域中心點之平均直線距離最短法 66
3.3.3.4 候選訂單與批次訂單所有揀貨區域中心點直線距離最短法 71
3.3.3.5 隨機選取法 75
3.4 訂單批次選取問題 76
3.4.1 隨機選取法 76
3.5 揀貨區域拜訪順序法 77
3.5.1.固定揀貨區域拜訪順序法 78
3.5.1.1. 鄰近揀貨區域優先演算法 80
3.5.1.2. 模擬退火演算法 80
3.5.1.3. 模擬退火演算法設置 82
第四章模擬實驗與分析 83
4.1 模擬實驗設計 83
4.1.1 揀貨環境設定 83
4.1.2 實驗訂單設定 85
4.1.3 揀貨環境假設 85
4.1.4 實驗因子組合 86
4.2 績效評估指標 89
4.3 統計分析 89
4.3.1 分析說明 90
4.3.2 依「揀貨系統總執行時間（TST）」為績效評估指標 90
4.3.2.1 個別因子之說明（依TST績效值） 91
4.3.2.2 兩因子交互作用之說明（依TST績效值） 93
4.3.2.3 最佳因子組合與績效 98
4.3.3 依「揀貨員總揀貨距離（TTD）」為績效評估指標 100
4.3.3.1 個別因子之說明（依TTD績效值） 101
4.3.3.2 兩因子交互作用之說明（依TTD績效值） 103
4.3.3.3 最佳因子組合與績效 109
4.3.4 依「揀貨員總忙碌時間（TBT）」為績效評估指標 111
4.3.4.1 個別因子之說明（依TBT績效值） 112
4.3.4.2 兩因子交互作用之說明（依TBT績效值） 114
4.3.4.3 最佳因子組合與績效 120
4.4 實驗結論 122
第五章研究結論與建議 123
5.1. 研究結論 123
5.2. 未來研究建議 124
參考文獻 125
中文文獻 125
英文文獻 126

參考文獻

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2023-7-14

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