Enhancing picking-by-line operations: a simulation-based approach

Effective warehouse management plays a pivotal role in optimizing supply chain performance, particularly in high-demand, time-sensitive environments. This study introduces a simulation-based decision support system designed to improve the management of Picking-By-Line (PBL) operations in cross-docking distribution centres. Developed in FlexSim and calibrated with empirical data from an industrial case study, the model replicates real-world warehouse conditions and is validated against observed operational performance. The tool supports warehouse managers in evaluating and comparing operational strategies, such as dynamic storage allocation policies and picker routing constraints, with the goal of reducing operator travel distances, mitigating congestion, and enhancing overall efficiency. A key contribution of this work is the integration of congestion-sensitive performance indicators that allow for a detailed analysis of the trade-offs between travel efficiency and localized congestion—an aspect often overlooked in traditional optimization methods. This study demonstrates the value of simulation as a scalable and realistic decision-support tool for optimizing PBL operations in complex and variable environments where human movement is a major cost and performance driver. The proposed tool bridges the gap between theoretical modelling and practical implementation, offering actionable insights for warehouse layout, space utilization, and resource allocation.