Design and control of a flexible order picking system (FOPS): a new integrated approach to the implementation of an expert system

Purpose – To present an innovative approach to the design of a flexible order-picking systems (OPS). The proposed conceptual framework is the first step to the development of an expert system created in a rapid and innovative manner, i.e. based on the integration of simulation, genetic algorithms and factorial analysis. Design/methodology/approach – The impact of alternative policies and configurations of both picker-to-part and part-to-picker OPS is quantified, with the aim of designing and optimising robust facilities capable of minimising global costs and maximising their performances in terms of efficiency and customer service quality. Findings – The importance of validation analysis and both virtual and on-field data collection emerges. Originality/value – Compared with the studies found in the literature, this article presents an innovative approach with original results that will be of use in the design and control of a flexible OPS.