Enhancing Human–System Interaction in Order Picking through Ergonomics-Based Decision Support

Abstract

Human-centered decision-making is becoming increasingly important in logistics systems where operational performance relies heavily on manual labor. In food distribution centers, for example, order picking is one of the most physically demanding activities. However, task allocation practices often neglect worker-related characteristics, which can lead to imbalances in manual handling demands, physical overload, and long-term fatigue. An industrial case study revealed significant variability among operators in daily load handling and item manipulation, underscoring the necessity of decision-support tools that consider ergonomic factors. This study proposes a human-centered framework for order-picking task allocation that incorporates measurable worker characteristics, such as handling exposure and manipulation counts, into planning processes. By moving beyond the assumption of homogeneous operators, the framework enables more transparent and balanced decision-making while maintaining productivity. From a human factors and systems interaction perspective, this work represents workers as key system components rather than interchangeable resources. Embedding ergonomics requirements in ex-ante planning enhances interpretability, trust, and the overall quality of operational decision-making. Grounded in a real-world application at a large food distribution center, the approach aims to promote sustainable interactions between planning systems, decision-makers, and frontline workers in physically demanding environments.

Keywords: Human Factors, Ergonomics-based Decision Support, Human Factors And Systems Interaction, Order Picking, Workload Balancing, Order Picking Task Allocation

DOI: 10.54941/ahfe1007981