Robotized Warehouse Systems: Developments and Research Opportunities

Robotized handling systems are increasingly applied in distribution centers. They require little space, provide flexibility in managing varying demand requirements, and are able to work 24/7. This makes them particularly fit for e-commerce operations. This paper reviews new categories of robotized handling systems, such as the shuttle-based storage and retrieval systems, shuttle-based compact storage systems, and robotic mobile fulfillment systems. For each system, we categorize the literature in three groups: system analysis, design optimization, and operations planning and control. Our focus is to identify the research issue and OR modeling methodology adopted to analyze the problem. We find that many new robotic systems and applications have hardly been studied in academic literature, despite their increasing use in practice. Due to unique system features (such as autonomous control, networked and dynamic operation), new models and methods are needed to address the design and operational control challenges for such systems, in particular, for the integration of subsystems. Integrated robotized warehouse systems will form the next category of warehouses. All vital warehouse design, planning and control logic such as methods to design layout, storage and order picking system selection, storage slotting, order batching, picker routing, and picker to order assignment will have to be revisited for new robotized warehouses

Planning and control of autonomous mobile robots for intralogistics: Literature review and research agenda

Autonomous mobile robots (AMR) are currently being introduced in many intralogistics operations, like manufacturing, warehousing, cross-docks, terminals, and hospitals. Their advanced hardware and control software allow autonomous operations in dynamic environments. Compared to an automated guided vehicle (AGV) system in which a central unit takes control of scheduling, routing, and dispatching decisions for all AGVs, AMRs can communicate and negotiate independently with other resources like machines and systems and thus decentralize the decision-making process. Decentralized decision-making allows the system to react dynamically to changes in the system state and environment. These developments have influenced the traditional methods and decision-making processes for planning and control. This study identifies and classifies research related to the planning and control of AMRs in intralogistics. We provide an extended literature review that highlights how AMR technological advances affect planning and control decisions. We contribute to the literature by introducing an AMR planning and control framework t

Advanced Storage and Retrieval Policies in Automated Warehouses

Warehouses are key components in supply chain. They facilitate the product flow from production to distribution. The performance of supply chains relies on the performance of warehouses and distribution centers. Being able to realize short order delivery lead times, in retail and ecommerce particularly, is important for warehouses. Efficient and responsive storage and retrieval operations can help in realizing a short order delivery lead time. Additionally, space scarcity has brought some companies to use high-density storage systems that increase space usage in the warehouse. In such storage systems, most of the available space is used for storing products, as little space is needed for transporting loads. However, the throughput capacity of high-density storage systems is typically low. New robotic and automated technologies help warehouses to increase their throughput and responsiveness. Warehouses adapting such technologies require customized storage and retrieval policies fit for automated operations. This thesis studies storage and retrieval policies in warehouses using several common and emerging automated technologies

Flexible high-density puzzle storage systems

In a traditional storage system, when one of the mechanical or electrical parts or the software fails to operate correctly, it may lead to the failure of the entire system imposing huge costs to the system (Gue et al., 2014). However, in a grid storage network, if a grid fails to operate, the system continues to operate. Therefore, failure of a system component will not jeopardize the whole system functionality. As such, reliability is one of the key advantages of grid storage networks. Another benefit of grid storage systems is flexibility. Various systems such as GridFlow, GridPick, GridStore, are developed that consist of multiple autonomous conveyors to store and move items in different directions. A unit module is capable to work independently. To retrieve an item, empty modules open a temporary aisle to move the item to the retrieval point. This study developed a tote retrieval algorithm for high-density storage systems (HDSS). The algorithm is capable of retrieving totes from all sides of a storage puzzle. This is novel since methodologies of prior studies were confined to retrieving items from a single grid or a single side of a puzzle. The algorithm was decentralized and agent-based where each grid acts as an agent. The study undertook developing algorithms that could minimize the number of movements in the network for tote retrievals and to prevent deadlocks. Deadlock prevention algorithms are capable to resolve a diverse range of situations that cause network deadlocks. An object-oriented software program was developed that implemented the algorithms. The software tool simulated puzzles of various sizes with different number of escorts available for retrieving requested totes. Thousands of iterations of the puzzle configurations were resolved for the analysis. It was found that incremental increase in the number of escorts in the puzzle reduces the number of movements for retrieving totes. However, depending on the puzzle size, there were increments that additional escorts had minimal impact. It was also found that average retrieval movements for 3 totes increase logarithmically with the number of cells in a puzzle. To validate the methodology and its software implementation, results from the simulation were compared with the results from other studies with mathematical solutions. The program replicated the optimum number of movements for a puzzle that contained one escort and retrieved one tote

Comparison of Alternative Configurations for Dense Warehousing Systems

In heavily constrained environments requiring very high density storage, traditional aisle-based warehousing may not provide viable options. One feasible manifestation of high density storage systems is the ‘puzzle-based’ system, in which unit loads are moved through the system via manipulation of empty (escort) locations to retrieve desired items. Another option would be the use of movable concentric rings, with escorts being utilized to enable lateral movements of unit loads between the rings. In this paper, the authors present analytical results to compare retrieval time performance for these two types of high density storage systems for randomly demanded items under various assumptions regarding the initial placement of escorts. The paper concludes that the use of movable concentric rings results in significant improvement to retrieval time performance in comparison to rectangular, puzzle-based systems, and further concludes that additional research is warranted

Modelling load retrievals in Puzzle-Based Storage systems

Puzzle-based storage systems are a new type of automated storage systems that allow storage of unit loads (e.g. cars, pallets, boxes) in a rack on a very small footprint with individual accessibility of all loads. They resemble the famous 15-sliding tile puzzle. Current models for such systems study retrieving loads one at a time. However, much time can be saved by considering multiple retrieval loads simultaneously. We develop an optimal method to do this for two loads and heuristics for three or more loads. Optimal retrieval paths are constructed for multiple load retrieval, which consists of moving multiple loads first to an intermediary ‘joining location’. We find that, compared to individual retrieval, optimal dual load retrieval saves on average 17% move time, and savings from the heuristic is almost the same. For three loads, savings are 23% on average. A limitation of our method is that it is valid only for systems with a very high space utilisation, i.e. only one empty locatio

Multi Agent Systems in Logistics: A Literature and State-of-the-art Review

Based on a literature survey, we aim to answer our main question: “How should we plan and execute logistics in supply chains that aim to meet today’s requirements, and how can we support such planning and execution using IT?†Today’s requirements in supply chains include inter-organizational collaboration and more responsive and tailored supply to meet specific demand. Enterprise systems fall short in meeting these requirements The focus of planning and execution systems should move towards an inter-enterprise and event-driven mode. Inter-organizational systems may support planning going from supporting information exchange and henceforth enable synchronized planning within the organizations towards the capability to do network planning based on available information throughout the network. We provide a framework for planning systems, constituting a rich landscape of possible configurations, where the centralized and fully decentralized approaches are two extremes. We define and discuss agent based systems and in particular multi agent systems (MAS). We emphasize the issue of the role of MAS coordination architectures, and then explain that transportation is, next to production, an important domain in which MAS can and actually are applied. However, implementation is not widespread and some implementation issues are explored. In this manner, we conclude that planning problems in transportation have characteristics that comply with the specific capabilities of agent systems. In particular, these systems are capable to deal with inter-organizational and event-driven planning settings, hence meeting today’s requirements in supply chain planning and execution.supply chain;MAS;multi agent systems

Intelligent Control of Vehicle-Based Internal Transport Systems

“Intelligent control of vehicle-based internal transport (VBIT) systems” copes with real-time dispatching and scheduling of internal-transport vehicles, such as forklifts and guided vehicles. VBIT systems can be found in warehouses, distribution centers, manufacturing plants, airport and transshipment terminals. Using simulation of two realworld environments, dispatching rules described in literature and several newly introduced rules are compared on performance. The performance evaluation suggests that in environments where queue space is not a restriction, distance-based dispatching rules such as shortest-travel-distance-first outperform time-based dispatching rules such as modified-first-come-first-served and using load prearrival information has a significant positive impact on reducing the average load waiting time. Experimental results also reveal that multi-attribute dispatching rules combining distance and time aspects of vehicles and loads are robust to variations in working conditions. In addition, multi-attribute rules which take vehicle empty travel distance and vehicle requirement at a station into account perform very well in heavy-traffic VBIT systems such as baggage handling systems. Besides dispatching rules, the potential contribution of dynamic vehicle scheduling for VBIT systems is investigated. Experiments using simulation in combination with optimization show that when sufficient pre-arrival information is available a dynamic scheduling approach outperforms the dispatching approach. This thesis also evaluates the impact of guide-path layout, load arrival rate and variance, and the amount of load pre-arrival information on different vehicle control approaches (scheduling and dispatching). Based on experimental results, recommendations for selecting appropriate vehicle control approaches for specific situations are presented