Abstract
This study investigates an integrated optimization problem on the three main types of equipment used in a new design of multi-tier automated warehouse: automated guided vehicles, lifts and shuttles. A mixed-integer programming model is proposed to optimize the assignment of pallets to the related equipment and the storage locations during inbound process, as well as the sequencing handling activities of these equipment. As the problem considers a number of various types of equipment as well as the interaction among them, the formulated model is comprehensive but complex, which is intractable for some commercial solvers to solve under large-scale instances. Thus, an algorithm based on variable neighborhood search is developed to solve the model efficiently. By conducting extensive numerical experiments, our results show that the tailored algorithm can solve the instances with million integer variables and ten million constraints in ten minutes. Some managerial implications are also obtained based on sensitivity analysis, which may be potentially useful for warehouse operators to increase the operational efficiency in automated warehouse management.
Similar content being viewed by others
References
Azadeh, K., de Koster, R., & Roy, D. (2019). Robotized and automated warehouse systems: review and recent developments. Transportation Science, 53(4), 917–945. https://doi.org/10.1287/trsc.2018.0873
Boysen, N., Briskorn, D., & Emde, S. (2017). Parts-to-picker based order processing in a rack-moving mobile robots environment. European Journal of Operational Research, 262(2), 550–562. https://doi.org/10.1016/j.ejor.2017.03.053
Boysen, N., de Koster, R., & Weidinger, F. (2019). Warehousing in the e-commerce era: A survey. European Journal of Operational Research, 277(2), 396–411. https://doi.org/10.1016/j.ejor.2018.08.023
Boysen, N., & Stephan, K. (2016). A survey on single crane scheduling in automated storage/retrieval systems. European Journal of Operational Research, 254(3), 691–704. https://doi.org/10.1016/j.ejor.2016.04.008
Boywitz, D., & Boysen, N. (2018). Robust storage assignment in stack- and queue-based storage systems. Computers & Operations Research, 100, 189–200. https://doi.org/10.1016/j.cor.2018.07.014
Boywitz, D., Schwerdfeger, S., & Boysen, N. (2019). Sequencing of picking orders to facilitate the replenishment of A-Frame systems. IISE Transactions, 51(4), 368–381. https://doi.org/10.1080/24725854.2018.1513672
Chen, Z. X., Li, X. P., & Gupta, J. N. D. (2016). Sequencing the storages and retrievals for flow-rack automated storage and retrieval systems with duration-of-stay storage policy. International Journal of Production Research, 54(4), 984–998. https://doi.org/10.1080/00207543.2015.1035816
Cheng, Z. M., Fu, X., Wang, J., & Xu, X. H. (2019). Research on robot charging strategy based on the scheduling algorithm of minimum encounter time. Journal of the Operational Research Society, 72(1), 237–245. https://doi.org/10.1080/01605682.2019.1654941
Dong, W. Q., Jin, M. Z., Wang, Y. Y., & Kelle, P. (2021). Retrieval scheduling in crane-based 3D automated retrieval and storage systems with shuttles. Annals of Operations Research, 302(1), 111–135. https://doi.org/10.1007/s10479-021-03967-8
Ekren, B. Y. (2017). Graph-based solution for performance evaluation of shuttle-based storage and retrieval system. International Journal of Production Research, 55(21), 6521–6526. https://doi.org/10.1080/00207543.2016.1203076
Ekren, B. Y., Akpunar, A., Sari, Z., & Lerher, T. (2018). A tool for time, variance and energy related performance estimations in a shuttle-based storage and retrieval system. Applied Mathematical Modelling, 63, 109–127. https://doi.org/10.1016/j.apm.2018.06.037
Emde, S., Polten, L., & Gendreau, M. (2020). Logic-based benders decomposition for scheduling a batching machine. Computers & Operations Research, 113, 104777. https://doi.org/10.1016/j.cor.2019.104777
Fragapane, G., de Koster, R., Sgarbossa, F., & Strandhagen, J. O. (2021). Planning and control of autonomous mobile robots for intralogistics: Literature review and research agenda. European Journal of Operational Research, 294(2), 405–426. https://doi.org/10.1016/j.ejor.2021.01.019
Gong, Y. M., Jin, M. Z., & Yuan, Z. (2021). Robotic mobile fulfilment systems considering customer classes. International Journal of Production Research, 59(16), 5032–5049. https://doi.org/10.1080/00207543.2020.1779370
He, Z. J., Aggarwal, V., & Nof, S. Y. (2018). Differentiated service policy in smart warehouse automation. International Journal of Production Research, 56(22), 6956–6770. https://doi.org/10.1080/00207543.2017.1421789
Jerald, J., Asokan, P., Saravanan, R., & Rani, A. D. C. (2006). Simultaneous scheduling of parts and automated guided vehicles in an FMS environment using adaptive genetic algorithm. The International Journal of Advanced Manufacturing Technology, 29(5), 584–589. https://doi.org/10.1007/s00170-005-2529-9
Jiang, M., Leung, K. H., Lyu, Z. Y., & Huang, G. Q. (2020). Picking-replenishment synchronization for robotic forward-reserve warehouses. Transportation Research Part E-Logistics and Transportation Review, 144, 102138. https://doi.org/10.1016/j.tre.2020.102138
Jiang, Z. Z., Wan, M. Z., Pei, Z., & Qin, X. W. (2021). Spatial and temporal optimization for smart warehouses with fast turnover. Computers & Operations Research, 125, 105091. https://doi.org/10.1016/j.cor.2020.105091
Kress, D., Boysen, N., & Pesch, E. (2016). Which items should be stored together? a basic partition problem to assign storage space in group-based storage systems. IISE Transactions, 49(1), 13–30. https://doi.org/10.1080/0740817x.2016.1213469
Kumawat, G. L., & Roy, D. (2021). A new solution approach for multi-stage semi-open queuing networks: An application in shuttle-based compact storage systems. Computers & Operations Research, 125, 105086. https://doi.org/10.1016/j.cor.2020.105086
Lee, C. W., Wong, W. P., Ignatius, J., Rahman, A., & Tseng, M. L. (2020). Winner determination problem in multiple automated guided vehicle considering cost and flexibility. Computers & Industrial Engineering, 142, 106337. https://doi.org/10.1016/j.cie.2020.106337
Lerher, T. (2018). Aisle changing shuttle carriers in autonomous vehicle storage and retrieval systems. International Journal of Production Research, 56(11–12), 3859–3879. https://doi.org/10.1080/00207543.2018.1467060
Liu, W. H., Hou, J. H., Yan, X. Y., & Tang, O. (2021). Smart logistics transformation collaboration between manufacturers and logistics service providers: A supply chain contracting perspective. Journal of Management Science and Engineering, 6(1), 25–52. https://doi.org/10.1016/j.jmse.2021.02.007
Man, X. Y., Zheng, F. F., Chu, F., Liu, M., & Xu, Y. F. (2021). Bi-objective optimization for a two-depot automated storage/retrieval system in container terminals. Annals of Operations Research, 296(1–2), 243–262. https://doi.org/10.1007/s10479-019-03222-1
Muter, I., & Oncan, T. (2021). Order batching and picker scheduling in warehouse order picking. IISE Transactions, 54(5), 435–447. https://doi.org/10.1080/24725854.2021.1925178
Nia, A. R., Haleh, H., & Saghaei, A. (2017). Dual command cycle dynamic sequencing method to consider ghg efficiency in unit-load multiple-rack automated storage and retrieval systems. Computers & Industrial Engineering, 111, 89–108. https://doi.org/10.1016/j.cie.2017.07.007
Roy, D., Nigam, S., de Koster, R., Adan, I., & Resing, J. (2019). Robot-storage zone assignment strategies in mobile fulfillment systems. Transportation Research Part E Logistics and Transportation Review, 122, 119–142. https://doi.org/10.1016/j.tre.2018.11.005
Sadati, M. E. H., & Catay, B. (2021). A hybrid variable neighborhood search approach for the multi-depot green vehicle routing problem. Transportation Research Part E Logistics and Transportation Review, 149(4), 102293. https://doi.org/10.1016/j.tre.2021.102293
Tostani, H. H., Haleh, H., Molana, S., & Sobhani, F. M. (2020). A bi-level bi-objective optimization model for the integrated storage classes and dual shuttle cranes scheduling in AS/RS with energy consumption, workload balance and time windows. Journal of Cleaner Production, 257, 120409. https://doi.org/10.1016/j.jclepro.2020.120409
Wang, Y. Y., Liu, Z. W., Huang, K., Mou, S. D., & Zhang, R. X. (2020). Model and solution approaches for retrieval operations in a multi-tier shuttle warehouse system. Computers & Industrial Engineering, 141, 106283. https://doi.org/10.1016/j.cie.2020.106283
Weidinger, F., Boysen, N., & Briskorn, D. (2018). Storage assignment with rack-moving mobile robots in kiva warehouses. Transportation Science, 52(6), 1479–1495. https://doi.org/10.1287/trsc.2018.0826
Yuan, R., Graves, S. C., & Cezik, T. (2019). Velocity-based storage assignment in semi-automated storage systems. Production and Operations Management, 28(2), 354–373. https://doi.org/10.1111/poms.12925
Yuan, Z., & Gong, Y. M. (2017). Bot-in-time delivery for robotic mobile fulfillment systems. IEEE Transactions on Engineering Management, 64(1), 83–93. https://doi.org/10.1109/Tem.2016.2634540
Zaerpour, N., Yu, Y. G., & de Koster, R. (2017a). Optimal two-class-based storage in a live-cube compact storage system. IISE Transactions, 49(7), 53–68. https://doi.org/10.1080/24725854.2016.1273564
Zaerpour, N., Yu, Y. G., & de Koster, R. (2017b). Response time analysis of a live-cube compact storage system with two storage classes. IISE Transactions, 49(5), 461–480. https://doi.org/10.1080/24725854.2016.1273563
Zou, B. P., de Koster, R., & Xu, X. H. (2018). Operating policies in robotic compact storage and retrieval systems. Transportation Science, 52(4), 788–811. https://doi.org/10.1287/trsc.2017.0786
Funding
The funding was provided by National Natural Science Fundation of China, (Grant No. 72025103), Lu ZHEN
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Zhen, L., Wu, J., Li, H. et al. Scheduling multiple types of equipment in an automated warehouse. Ann Oper Res 322, 1119–1141 (2023). https://doi.org/10.1007/s10479-022-04935-6
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10479-022-04935-6