Title: An order picking operation improvement in a cross-docking distribution centre using simulation: a case study of a chilled distribution centre in Thailand

Authors: Pham Duc Tai; Jirachai Buddhakulsomsiri; Parthana Parthanadee

Addresses: School of Manufacturing Systems and Mechanical Engineering, Sirindhorn International Institute of Technology, Thammasat University, Pathum Thani, Thailand ' School of Manufacturing Systems and Mechanical Engineering, Sirindhorn International Institute of Technology, Thammasat University, Pathum Thani, Thailand ' Department of Agro-Industrial Technology, Faculty of Agro-Industry, Kasetsart University, 50 Ngamwongwan Rd., Lad Yao, Chatuchak, Bangkok 10900, Thailand

Abstract: This article involves a study to improve the cross-docking operation at a chilled distribution centre, owned by a retail conglomerate in Thailand. Among activities of cross-docking, order picking is identified as a bottleneck. Therefore, exploring operational policies that improves the performance of order picking in terms of makespan and operating cost of is the objective of this study. To facilitate the exploration, a simulation model is developed. The model is experimented with various sets of operational policies. Each set represents a combination of options for resource management, (i.e., dedicating and sharing of picking operators) and order splitting, (i.e., split no batch, only the first batch, and the first and the last two batches of orders). Statistical analysis of the simulation indicates that implementing resource sharing with splitting the first and the last two batches minimises both the makespan and operating cost of the order picking activity.

Keywords: simulation; order picking; put-to-light; cross-docking; chilled distribution centre; CDC; Thailand.

DOI: 10.1504/IJLSM.2025.149885

International Journal of Logistics Systems and Management, 2025 Vol.52 No.3, pp.410 - 432

Received: 27 Jan 2023
Accepted: 12 Mar 2023
Published online: 17 Nov 2025 *

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