Throughput time distribution analysis for a one-block warehouse

We develop discrete time models for the throughput time distribution of orders arriving to a one-block warehouse. The models accommodate single- or multi-line orders, and we show how to use them to determine the optimal batch size, given a desired probability of on-time order fulfillment. Experiments suggest that the optimal batch size is slightly higher than one would choose if minimizing average throughput time.

► We present a new methodology to analyze order fulfillment processes in a warehouse. ► We use discrete time queues to calculate the order throughput time distribution. ► The models provide a fast way to predict the percentage of successfully filled orders. ► Input parameters can be easily derived by empirical data. ► Batch sizes optimizing service level are different than those optimizing throughput.