Prerequisites for Black Box Picking Identification of Prerequisites for the Black Box Order Picking Method in Warehousing

Abstract

Consolidation of orders is a time-consuming process in a warehouse. The company of collaboration for this master’s thesis, DB Schenker Logistics, wants to eliminate the process of consolidation by transitioning to the black box order picking method. Black box picking is a version of pick-and-pass where goods are picked in secondary warehouse zones before they are placed, and later picked, in a main zone. DB Schenker Logistics needs to understand what prerequisites are important for a successful black box system. The aim of this master’s thesis is therefore to identify the prerequisites needed for a black box picking system in a warehouse. Thereby, the thesis will provide support for warehouse designers to facilitate the implementation of a black box system. Data collection for the master’s thesis was conducted using a literature review, visits to DB Schenker Logistics’ warehouses, and visits to four case companies’ warehouses. During the warehouse visits, interviews and observations took place. Interviews were also performed with personnel working at DB Schenker Logistics. The literature review was used to develop a framework for assessing prerequisites for black box picking, which thereafter was used for data analysis of the collected empirical data. The framework focused on the three categories of system factors, product and order factors, and inventory factors, which were then further broken down into several subfactors. The identified factors were classified as prerequisites, simplifying but not necessary, and not prerequisites. The findings have implications for DB Schenker Logistics and for warehouses in general. For DB Schenker Logistics, the framework can be used to evaluate if prerequisites exist for black box picking, in order to avoid consolidation in the warehouse. Furthermore, the developed framework can be used by warehouse designers in general to assess if black box picking is suitable for application in a certain warehouse setting.