Optimal Routing Schedules for Robots Operating in Aisle-Structures

In this paper, we consider the Constant-cost Orienteering Problem (COP) where a robot, constrained by a limited travel budget, aims at selecting a path with the largest reward in an aisle-graph. The aisle-graph consists of a set of loosely connected rows where the robot can change lane only at either end, but not in the middle. Even when considering this special type of graphs, the orienteering problem is known to be NP-hard. We optimally solve in polynomial time two special cases, COP-FR where the robot can only traverse full rows, and COP-SC where the robot can access the rows only from one side. To solve the general COP, we then apply our special case algorithms as well as a new heuristic that suitably combines them. Despite its light computational complexity and being confined into a very limited class of paths, the optimal solutions for COP-FR turn out to be competitive even for COP in both real and synthetic scenarios. Furthermore, our new heuristic for the general case outperforms state-of-art algorithms, especially for input with highly unbalanced rewards

Task Planning on Stochastic Aisle Graphs for Precision Agriculture

This work addresses task planning under uncertainty for precision agriculture applications whereby task costs are uncertain and the gain of completing a task is proportional to resource consumption (such as water consumption in precision irrigation). The goal is to complete all tasks while prioritizing those that are more urgent, and subject to diverse budget thresholds and stochastic costs for tasks. To describe agriculture-related environments that incorporate stochastic costs to complete tasks, a new Stochastic-Vertex-Cost Aisle Graph (SAG) is introduced. Then, a task allocation algorithm, termed Next-Best-Action Planning (NBA-P), is proposed. NBA-P utilizes the underlying structure enabled by SAG, and tackles the task planning problem by simultaneously determining the optimal tasks to perform and an optimal time to exit (i.e. return to a base station), at run-time. The proposed approach is tested with both simulated data and real-world experimental datasets collected in a commercial vineyard, in both single- and multi-robot scenarios. In all cases, NBA-P outperforms other evaluated methods in terms of return per visited vertex, wasted resources resulting from aborted tasks (i.e. when a budget threshold is exceeded), and total visited vertices.Comment: To appear in Robotics and Automation Letter

A Drone-based Application for Scouting Halyomorpha halys Bugs in Orchards with Multifunctional Nets

In this work, we consider the problem of using a drone to collect information within orchards in order to scout insect pests, i.e., the stink bug Halyomorpha halys. An orchard can be modeled as an aisle-graph, which is a regular and constrained data structure formed by consecutive aisles where trees are arranged in a straight line. For monitoring the presence of bugs, a drone flies close to the trees and takes videos and/or pictures that will be analyzed offline. As the drone's energy is limited, only a subset of locations in the orchard can be visited with a fully charged battery. Those places that are most likely to be infested should be selected to promptly detect the pest. We implemented the proposed approach on a DJI drone and evaluated its performance in the real-world environment

A Drone-Based Application for Scouting Halyomorpha Halys Bugs in Orchards with Multifunctional Nets

In this work, we consider the problem of using a drone to collect information within orchards in order to scout insect pests, i.e., the stink bug Halyomorpha halys. An orchard can be modeled as an aisle-graph, which is a regular and constrained data structure formed by consecutive aisles where trees are arranged in a straight line. For monitoring the presence of bugs, a drone flies close to the trees and takes videos and/or pictures that will be analyzed offline. As the drone\u27s energy is limited, only a subset of locations in the orchard can be visited with a fully charged battery. Those places that are most likely to be infested should be selected to promptly detect the pest. We implemented the proposed approach on a DJI drone and evaluated its performance in the real-world environment

Optimization of storage and picking systems in warehouses

La croissance du commerce électronique exige une hausse des performances des systèmes d'entreposage, qui sont maintenant repensés pour faire face à un volume massif de demandes à être satisfait le plus rapidement possible. Le système manuel et le système à robots mobile (SRM) sont parmi les plus utilisés pour ces activités. Le premier est un système centré sur l'humain pour réaliser des opérations complexes que les robots actuels ne peuvent pas effectuer. Cependant, les nouvelles générations de robots autonomes mènent à un remplacement progressif par le dernier pour augmenter la productivité. Quel que soit le système utilisé, plusieurs problèmes interdépendants doivent être résolus pour avoir des processus de stockage et de prélèvement efficaces. Les problèmes de stockage concernent les décisions d'où stocker les produits dans l'entrepôt. Les problèmes de prélèvement incluent le regroupement des commandes à exécuter ensemble et les itinéraires que les cueilleurs et les robots doivent suivre pour récupérer les produits demandés. Dans le système manuel, ces problèmes sont traditionnellement résolus à l'aide de politiques simples que les préparateurs peuvent facilement suivre. Malgré l'utilisation de robots, la même stratégie de solution est répliquée aux problèmes équivalents trouvés dans le SRM. Dans cette recherche, nous étudions les problèmes de stockage et de prélèvement rencontrés lors de la conception du système manuel et du SRM. Nous développons des outils d'optimisation pour aider à la prise de décision pour mettre en place leurs processus, en améliorant les mesures de performance typiques de ces systèmes. Certains problèmes traditionnels sont résolus avec des techniques améliorées, tandis que d'autres sont intégrés pour être résolus ensemble au lieu d'optimiser chaque sous-système de manière indépendante. Nous considérons d'abord un système manuel avec un ensemble connu de commandes et intégrons les décisions de stockage et de routage. Le problème intégré et certaines variantes tenant compte des politiques de routage communes sont modélisés mathématiquement. Une métaheuristique générale de recherche de voisinage variable est présentée pour traiter des instances de taille réelle. Des expériences attestent de l'efficience de la métaheuristique proposée par rapport aux modèles exacts et aux politiques de stockage communes. Lorsque les demandes futures sont incertaines, il est courant d'utiliser une stratégie de zonage qui divise la zone de stockage en zones et attribue les produits les plus demandés aux meilleures zones. Les tailles des zones sont à déterminer. Généralement, des dimensions arbitraires sont choisies, mais elles ignorent les caractéristiques de l'entrepôt et des demandes. Nous abordons le problème de dimensionnement des zones pour déterminer quels facteurs sont pertinents pour choisir de meilleures tailles de zone. Les données générées à partir de simulations exhaustives sont utilisées pour trainer quatre modèles de régression d'apprentissage automatique - moindres carrés ordinaire, arbre de régression, forêt aléatoire et perceptron multicouche - afin de prédire les dimensions optimales des zones en fonction de l'ensemble de facteurs pertinents identifiés. Nous montrons que tous les modèles entraînés suggèrent des dimensions sur mesure des zones qui performent meilleur que les dimensions arbitraires couramment utilisées. Une autre approche pour résoudre les problèmes de stockage pour le système manuel et pour le SRM considère les corrélations entre les produits. L'idée est que les produits régulièrement demandés ensemble doivent être stockés près pour réduire les coûts de routage. Cette politique de stockage peut être modélisée comme une variante du problème d'affectation quadratique (PAQ). Le PAQ est un problème combinatoire traditionnel et l'un des plus difficiles à résoudre. Nous examinons les variantes les plus connues du PAQ et développons une puissante métaheuristique itérative de recherche tabou mémétique en parallèle capable de les résoudre. La métaheuristique proposée s'avère être parmi les plus performantes pour le PAQ et surpasse considérablement l'état de l'art pour ses variantes. Les SRM permettent de repositionner facilement les pods d'inventaire pendant les opérations, ce qui peut conduire à un processus de prélèvement plus économe en énergie. Nous intégrons les décisions de repositionnement des pods à l'attribution des commandes et à la sélection des pods à l'aide d'une stratégie de prélèvement par vague. Les pods sont réorganisés en tenant compte du moment et de l'endroit où ils devraient être demandés au futur. Nous résolvons ce problème en utilisant la programmation stochastique en tenant compte de l'incertitude sur les demandes futures et suggérons une matheuristique de recherche locale pour résoudre des instances de taille réelle. Nous montrons que notre schéma d'approximation moyenne de l'échantillon est efficace pour simuler les demandes futures puisque nos méthodes améliorent les solutions trouvées lorsque les vagues sont planifiées sans tenir compte de l'avenir. Cette thèse est structurée comme suit. Après un chapitre d'introduction, nous présentons une revue de la littérature sur le système manuel et le SRM, et les décisions communes prises pour mettre en place leurs processus de stockage et de prélèvement. Les quatre chapitres suivants détaillent les études pour le problème de stockage et de routage intégré, le problème de dimensionnement des zones, le PAQ et le problème de repositionnement de pod. Nos conclusions sont résumées dans le dernier chapitre.The rising of e-commerce is demanding an increase in the performance of warehousing systems, which are being redesigned to deal with a mass volume of demands to be fulfilled as fast as possible. The manual system and the robotic mobile fulfillment system (RMFS) are among the most commonly used for these activities. The former is a human-centered system that handles complex operations that current robots cannot perform. However, newer generations of autonomous robots are leading to a gradual replacement by the latter to increase productivity. Regardless of the system used, several interdependent problems have to be solved to have efficient storage and picking processes. Storage problems concern decisions on where to store products within the warehouse. Picking problems include the batching of orders to be fulfilled together and the routes the pickers and robots should follow to retrieve the products demanded. In the manual system, these problems are traditionally solved using simple policies that pickers can easily follow. Despite using robots, the same solution strategy is being replicated to the equivalent problems found in the RMFS. In this research, we investigate storage and picking problems faced when designing manual and RMFS warehouses. We develop optimization tools to help in the decision-making process to set up their processes and improve typical performance measures considered in these systems. Some classic problems are solved with improved techniques, while others are integrated to be solved together instead of optimizing each subsystem sequentially. We first consider a manual system with a known set of orders and integrate storage and routing decisions. The integrated problem and some variants considering common routing policies are modeled mathematically. A general variable neighborhood search metaheuristic is presented to deal with real-size instances. Computational experiments attest to the effectiveness of the metaheuristic proposed compared to the exact models and common storage policies. When future demands are uncertain, it is common to use a zoning strategy to divide the storage area into zones and assign the most-demanded products to the best zones. Zone sizes are to be determined. Commonly, arbitrary sizes are chosen, which ignore the characteristics of the warehouse and the demands. We approach the zone sizing problem to determine which factors are relevant to choosing better zone sizes. Data generated from exhaustive simulations are used to train four machine learning regression models - ordinary least squares, regression tree, random forest, and multilayer perceptron - to predict the optimal zone sizes given the set of relevant factors identified. We show that all trained models suggest tailor-made zone sizes with better picking performance than the arbitrary ones commonly used. Another approach to solving storage problems, both in the manual and RMFS, considers the correlations between products. The idea is that products constantly demanded together should be stored closer to reduce routing costs. This storage policy can be modeled as a quadratic assignment problem (QAP) variant. The QAP is a traditional combinatorial problem and one of the hardest to solve. We survey the most traditional QAP variants and develop a powerful parallel memetic iterated tabu search metaheuristic capable of solving them. The proposed metaheuristic is shown to be among the best performing ones for the QAP and significantly outperforms the state-of-the-art for its variants. The RMFS allows easy repositioning of inventory pods during operations that can lead to a more energy-efficient picking process. We integrate pod repositioning decisions with order assignment and pod selection using a wave picking strategy such that pods are parked after being requested considering when and where they are expected to be requested next. We solve this integrated problem using stochastic programming considering the uncertainty about future demands and suggest a local search matheuristic to solve real-size instances. We show that our sample average approximation scheme is effective to simulate future demands since our methods improve solutions found when waves are planned without considering the future demands. This thesis is structured as follows. After an introductory chapter, we present a literature review on the manual and RMFS, and common decisions made to set up their storage and picking processes. The next four chapters detail the studies for the integrated storage and routing problem, the zone sizing problem, the QAP, and the pod repositioning problem. Our findings are summarized in the last chapter

A Special Case of the Multiple Traveling Salesmen Problem in End-of-Aisle Picking Systems

This study focuses on the problem of sequencing requests for an end-of-aisle automated storage and retrieval system in which each retrieved load must be returned to its earlier storage location after a worker has picked some products from the load. At the picking station, a buffer is maintained to absorb any fluctuations in speed between the worker and the storage/retrieval machine. We show that, under conditions, the problem of optimally sequencing the requests in this system with a buffer size of m loads forms a special case of the multiple traveling salesmen problem in which each salesman visits the same number of cities. Several interesting structural properties for the problem are mathematically shown. In addition, a branch-and-cut method and heuristics are proposed. Experimental results show that the proposed simulated annealing-based heuristic performs well in all circumstances and significantly outperforms benchmark heuristics. For instances with negligible picking times for the worker, we show that this heuristic provides solutions that are, on average, within 1.8% from the optimal value

Workforce Scheduling with Order-Picking Assignments in Distribution Facilities

Scheduling the availability of order pickers is crucial for effective operations in a distribution facility with manual order pickers. When order-picking activities can only be performed in specific time windows, it is essential to jointly solve the order picker shift scheduling problem and the order picker planning problem of assigning and sequencing individual orders to order pickers. This requires decisions regarding the number of order pickers to schedule, shift start and end times, break times, as well as the assignment and timing of order-picking activities. We call this the order picker scheduling problem and present two formulations. A branch-and-price algorithm and a metaheuristic are developed to solve the problem. Numerical experiments illustrate that the metaheuristic finds near-optimal solutions at 80% shorter computation times. A case study at the largest supermarket chain in The Netherlands shows the applicability of the solution approach in a real-life business application. In particular, different shift structures are analyzed, and it is concluded that the retailer can increase the minimum compensated duration for employed workers from six hours to seven or eight hours while reducing the average labor cost with up to 5% savings when a 15-minute flexibility is implemented in the scheduling of break times

Order picking optimization with order assignment and multiple workstations in KIVA warehouses

We consider the problem of allocating orders and racks to multiple stations and sequencing their interlinked processing flows at each station in the robot-assisted KIVA warehouse. The various decisions involved in the problem, which are closely associated and must be solved in real time, are often tackled separately for ease of treatment. However, exploiting the synergy between order assignment and picking station scheduling benefits picking efficiency. We develop a comprehensive mathematical model that takes the synergy into consideration to minimize the total number of rack visits. To solve this intractable problem, we develop an efficient algorithm based on simulated annealing and dynamic programming. Computational studies show that the proposed approach outperforms the rule-based policies used in practice in terms of solution quality. Moreover, the results reveal that ignoring the order assignment policy leads to considerable optimality gaps for real-world-sized instances

Intelligent Simulation Modeling of a Flexible Manufacturing System with Automated Guided Vehicles

Although simulation is a very flexible and cost effective problem solving technique, it has been traditionally limited to building models which are merely descriptive of the system under study. Relatively new approaches combine improvement heuristics and artificial intelligence with simulation to provide prescriptive power in simulation modeling. This study demonstrates the synergy obtained by bringing together the "learning automata theory" and simulation analysis. Intelligent objects are embedded in the simulation model of a Flexible Manufacturing System (FMS), in which Automated Guided Vehicles (AGVs) serve as the material handling system between four unique workcenters. The objective of the study is to find satisfactory AGV routing patterns along available paths to minimize the mean time spent by different kinds of parts in the system. System parameters such as different part routing and processing time requirements, arrivals distribution, number of palettes, available paths between workcenters, number and speed of AGVs can be defined by the user. The network of learning automata acts as the decision maker driving the simulation, and the FMS model acts as the training environment for the automata network; providing realistic, yet cost-effective and risk-free feedback. Object oriented design and implementation of the simulation model with a process oriented world view, graphical animation and visually interactive simulation (using GUI objects such as windows, menus, dialog boxes; mouse sensitive dynamic automaton trace charts and dynamic graphical statistical monitoring) are other issues dealt with in the study

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