The impact of sorting strategies on automated sortation system performance

In this paper, we develop an analytical model of an order sortation system used in automated distribution centers. In such systems, groups of orders are delivered to a recirculating conveyor system where they are sorted into shipping lanes for final preparation and loaded onto waiting trucks. We develop a model of the sorting process, which incorporates the stochastic elements of these systems, to determine the relative merits of two common categories of sorting strategies found in industry: fixed priority schemes and the next available rule. Fixed priority schemes include such popular rules as ‘sort the largest (or smallest) orders first’. We show that in systems with little lane blocking, a rule which assigns the next available order to a shipping lane will outperform any fixed priority scheme in terms of sorting time and system throughput while in systems with significant lane blocking, the sorting rule has little impact.