Storage layout optimization with Order Oriented Slotting (OOS) and Interaction Frequency Heuristic (IFH) for improved picking efficiency: a case study at Toserba Selamat Cipanas Cianjur
DOI:
https://doi.org/10.35194/jmtsi.v10i1.6131Keywords:
Order oriented slotting, Interaction frequency heuristic, Storage, Layout, OptimizationAbstract
At the Toserba Selamat Cipanas Cianjur warehouse, product placement is frequently determined by the availability of empty space rather than by demand levels or inter-product relationships. This unstructured warehouse layout has consequently resulted in order fulfillment delays, averaging 6.5% of total overall orders. This study aims to propose a more optimal storage layout and product arrangement to enhance picking efficiency within the warehouse. Layout optimization was carried out through the Order Oriented Slotting (OOS) and Interaction Frequency Heuristic (IFH) approaches, applied to the medium-sized (M) Non-Food Stock Keeping Unit (SKU) category, which exhibited the highest delay rate at 20%. These methods were implemented by analyzing Work Order List (WOL) data over the period of March 2024 to March 2025, based on the frequency of occurrence and inter-product interaction. The proposed layout was redesigned by prioritizing slots closest to the Inbound/Outbound (I/O) point for high-demand and highly interactive SKUs. Implementation results demonstrated a reduction in average Cycle Time from 4.03 minutes to 1.20 minutes per WOL, representing a time efficiency improvement of 70.27%. Furthermore, all WOLs in the new layout were successfully processed without any delays. These findings confirm that the OOS–IFH method is effective in enhancing picking performance and reducing travel time through demand-data-driven slot arrangement.
References
[1] Z. Zain, A. Farezan, M. Ghufron, and S. Sahara, “Manajemen gudang di era industri 4.0: Tinjauan literatur dan arah penelitian ke masa depan”, jiwp, vol. 9, no. 12, pp. 587-592, June, 2023.
[2] U.M. Sugeng. ”Perancangan Tata Letak Warehouse Baru Untuk Meningkatkan Kapasitas Penyimpanan Material Dengan Metode Dedicated Storage Di Pt.Xx”. JISI : Jurnal Integrasi Sistem Industri, 3(1), 23–28, Feb, 2016.
[3] B. Sugara and K. Kusmayanti, “Analisis Manajemen Pergudangan Pada PT. Anugrah Persada Alam”, IKRAITH-EKONOMIKA, vol. 6, no. 2, pp. 358-363, Nov, 2022.
[4] H.W.W. Pitoy, A.B.H. Jan, and J.S.B. Sumarauw. “Analisis manajemen pergudangan pada gudang Paris Superstore Kotamobagu”. Jurnal EMBA, 8(3), 252–260, July, 2020.
[5] S. E. McInerney and S. Yadavalli, “S. E. McInerney and S. Yadavalli. “Increasing warehouse throughput through the develoment of dynamic class-based storage assigment algorithm”, S AFR J IND ENG, vol. 33, no. 2, pp. 157–167, Jul. 2022.
[6] C. Purwanto and R. Oktarina, “Application of heuristic algorithms in warehouse order picking routes”, Journal Industrial Servicess, vol. 10, no. 2, pp. 361–369, October, 2024.
[7] Y. Li, R. Zhang, and D. Jiang. “Order-picking efficiency in e-Commerce warehouses: A literature review”. Journal of Theoretical and Applied Electronic Commerce Research 17(4):1812-1830, December, 2022.
[8] S. Zhong, & V. Giannikas, J. Merino, D. McFarlane, J. Cheng, W. Shao. "Evaluating the benefits of picking and packing planning integration in e-commerce warehouses". European Journal of Operational Research, Elsevier, vol. 301(1), pages 67-81. 2022.
[9] F. Dongo-Rivero, A.M. Pineda-Moreno, and M.C. Diaz. "Lean warehousing optimization in the Peruvian plastic sector: Reducing returns and costs”. In 5th Asia Pacific Conference on Industrial Engineering and Operations Management, September, 2024.
[10] J.C. Duque-Jaramillo, J.M. Cogollo-Flórez, C.G. Gómez-Marín, and A.A. Correa-Espinal. “Warehouse management optimization using a sorting-based slotting approach”. Journal of Industrial Engineering and Management, 17(1), 133-150. 2024.
[11] A.K. Putra, A.Y. Ridwan, and R. Aurrachman. “Design of storage allocation using interaction frequency heuristic-order oriented slotting approach to reduce delay time on traveling searching activities in Refinery Unit V Warehouse PT XYZ”. Jurnal Rekayasa Sistem Industri Vol. 7 No. 1, April, 2018.
[12] R. Wolniak. “The concept of descriptive analysis”. Scientific Papers of Silesian University of Technology - Organization and Management Series No. 172, 2023.
[13] D. Frazzetto, T.D. Nielsen, T.B. Pedersen, and L. Šikšnys. “Prescriptive analytics: a survey of emerging trends and technologies”. The VLDB Journal 28, 575–595, May, 2019.
[14] A. Görener. “Picker routing and batching in multi-block parallel-aisle warehouses: An application from the logistics service provider. Logistics 9, 40, March, 2025.
[15] J.A. Cano, A.A. Correa-Espinal, and R.A. Gómez-Montoya. “An evaluation of picking routing policies to improve warehouse efficiency”. International Journal of Industrial Engineering and Management (IJIEM), Vol.8 No 4, pp. 229-238, Nov, 2017.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2026 Anita Ilmaniati, M. Abdee Teguh Putra
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
