Mixed-width aisle configurations for order picking in distribution centers

Space required for the order picking area and labor required to perform the picking activity are two significant costs for a distribution center (DC). Traditionally, DCs employ either entirely wide or entirely narrow aisles in their picking systems. Wide aisles allow pickers to pass each other, which reduces blocking, and requires fewer pickers than their narrow-aisle counterpart for the same throughput. However, the amount of space required for wide-aisle configurations is high. Narrow aisles utilize less space than wide aisles, but are less efficient because of the increased likelihood of congestion experienced by pickers. We propose a variation to the traditional orthogonal aisle designs where both wide and narrow aisles are mixed within the configuration, with a view that mixed-width aisles may provide a compromise between space and labor. To analyze these new mixed-width aisle configurations, we develop analytical models for space and travel time considering randomized storage and traversal routing policies. Through a cost-based optimization model, we identify system parameters for which mixed-width aisle configurations are optimal. Experimental results indicate that annual cost savings of up to $48,000 can be realized over systems with pure wide or narrow aisle configurations.     

A fast simulated annealing method for batching precedence-constrained customer orders in a warehouse

Batching customer orders in a warehouse can result in considerable savings in order pickers’ travel distances. Many picker-to-parts warehouses have precedence constraints in picking a customer order. In this paper a joint order-batching and picker routing method is introduced to solve this combined precedence-constrained routing and order-batching problem. It consists of two sub-algorithms: an optimal A^∗-algorithm for the routing; and a simulated annealing algorithm for the batching which estimates the savings gained from batching more than two customer orders to avoid unnecessary routing. For batches of three customer orders, the introduced algorithm produces results with an error of less than 1.2% compared to the optimal solution. It also compares well to other heuristics from literature. A data set from a large Finnish order picking warehouse is rerouted and rebatched resulting in savings of over 5000 kilometres or 16% in travel distance in 3 months compared to the current method.     

Using a TSP heuristic for routing order pickers in warehouses

In this paper, we deal with the sequencing and routing problem of order pickers in conventional multi-parallel-aisle warehouse systems. For this NP-hard Steiner travelling salesman problem (TSP), exact algorithms only exist for warehouses with at most three cross aisles, while for other warehouse types literature provides a selection of dedicated construction heuristics. We evaluate to what extent reformulating and solving the problem as a classical TSP leads to performance improvements compared to existing dedicated heuristics. We report average savings in route distance of up to 47% when using the LKH (Lin–Kernighan–Helsgaun) TSP heuristic. Additionally, we examine if combining problem-specific solution concepts from dedicated heuristics with high-quality local search features could be useful. Lastly, we verify whether the sophistication of ‘state-of-the-art’ local search heuristics is necessary for routing order pickers in warehouses, or whether a subset of features suffices to generate high-quality solutions.     

A clustering algorithm for item assignment in a synchronized zone order picking system

In a synchronized zone order picking system, all the zones process the same order simultaneously. There may be some idle time when the zone pickers wait until all the pickers complete the current order. This paper develops a heuristic algorithm to balance the workload among all pickers so that the utilization of the order picking system is improved and to reduce the time needed for fulfilling each requested order. A similarity measurement, using customer orders, of any two items is first presented for measuring the co-appearance of both items in the same order. With this similarity measurement, a natural cluster model, which is a relaxation of the well-studied NP-hard homogeneous cluster model, is constructed. The heuristic algorithm is then proposed to solve the model for locating all the items into distinct zones. Finally, empirical data and simulation experiments verify that the objectives of the item cluster model are achieved.     

分类存储返回型与S型拣选路径随机模型的比较研究

物流配送中心中,减小订单拣选行走距离进而优化人工拣选作业系统可有效提高客户满意度,降低成本.货位指派和拣选方式是影响拣选行走距离的两个重要因素.作者在分类存储的货位指派策略下、分别对返回型和S型拣选方式,建立了拣选距离随机模型.仿真结果表明,模型结果能在误差允许条件下较好地与仿真逼近.通过在4种物品订购频率和货位分配情况下对返回型和S型拣选方式的比较,得出两种拣选方式各自适用的情况.     

Optimizing a dynamic order-picking process

This research studies the problem of batching orders in a dynamic, finite-horizon environment to minimize order tardiness and overtime costs of the pickers. The problem introduces the following trade-off: at every period, the picker has to decide whether to go on a tour and pick the accumulated orders, or to wait for more orders to arrive. By waiting, the picker risks higher tardiness of existing orders on the account of lower tardiness of future orders. We use a Markov decision process (MDP) based approach to set an optimal decision making policy. In order to evaluate the potential improvement of the proposed approach in practice, we compare the optimal policy with two naïve heuristics: (1) “Go on tour immediately after an order arrives”, and, (2) “Wait as long as the current orders can be picked and supplied on time”. The optimal policy shows a considerable improvement over the naïve heuristics, in the range of 7–99%, where the specific values depend on the picking process parameters. We have found that one measure, the slack percentage of the picking process, associated with the difference between the promised lead time and the single item picking time, predicts quite accurately the cost reduction generated by the optimal policy. Since relatively small-scale problems could be solved by the optimal algorithm, a heuristic was developed, based on the structure and properties of the optimal solutions. Numerical results show that the proposed heuristic, MDP-H, outperforms the naïve heuristics in all experiments. As compared to the optimal solution, MDP-H provides close to optimal results for a slack of up to 40%.     

Routing order pickers in a warehouse with a middle aisle

This paper considers a parallel aisle warehouse, where order pickers can change aisles at the ends of every aisle and also at a cross aisle halfway along the aisles. An algorithm is presented that can find shortest order picking tours in this type of warehouses. The algorithm is applicable in warehouse situations with up to three aisle changing possibilities. Average tour length is compared for warehouses with and without a middle aisle. It appears that in many cases the average order picking time can be decreased significantly by adding a middle aisle to the layout.     

On-line order batching and sequencing problem with multiple pickers: A hybrid rule-based algorithm

Existing on-line order batching rules, namely fixed time window batching (FTWB) and variable time window batching (VTWB), try to choose the fixed time window in the case of FTWB or the fixed number of orders in the case of VTWB. However, these solutions are not appropriate for the fluctuating order environment. The reasonable assignment of batches to order pickers is also an important issue in order picking systems. Motivated by these issues, we study the problem of integrating on-line order batching and the assignment of the batches, which is called the on-line order batching and sequencing problem with multiple pickers (OOBSPMP). The objective is to minimize the turnover time. To solve the problem, a hybrid rule-based algorithm, referred to FTWB, is proposed in order to form batches and assign them to appropriate pickers under a fluctuating order environment. Three batching situations (off-peak, normal and peak arrival time) and two assigning situations (assigning to one busy picker and assigning to one idle picker) are distinguished. Through a series of experiments, we discover several enlightening findings: (i) the rule-based algorithm demonstrates high effectiveness and efficiency in turnover time with multiple pickers; (ii) the rule-based algorithm leads to an impressive improvement in both saving time and wage costs under different arrival rates, picking devices and time intervals compared with VTWB; (iii) to obtain both good warehouse performance and a reasonable workload distribution, the factors, such as the fixed time window, the average workload per picker and the average idle time per picker are also important issues in analysing the efficiency of order picking systems.     

基于聚类和动态规划的组合路径策略

为提高电商仓库的拣货作业效率,本文提出了基于聚类和动态规划的组合路径策略,实现了生成路径消耗时间和路径长度之间的平衡,并将这一策略成功地应用到多区型仓库。该策略分四步:首先,根据待拣储位分布特征,运用聚类分析法对其进行分类;然后,以各类的首末储位作为节点,运用动态规划法对已得分类进行排序,得到相应的类序;其次,得到各类内部路径;最后,依次拣取待拣商品,并返回出发点完成拣货作业。在提出新的路径策略后,通过仿真方法将新策略与三种传统路径策略(穿越策略、最大间隙策略和混合策略)和一种优质算法(蚁群算法)进行了对比分析,结果表明:该策略具备良好的适用性和实用性。     

Research on the vehicle routing problem with interval demands

In this paper, a vehicle routing problem with interval demands is investigated based on the motivation of dispatching vehicles to deliver perishable products in practice. A nonlinear interval-based programming method is used to build a model for the vehicle routing problem with interval demands, which assumes that demands of customers are uncertain but fall in given intervals and actual demand of a customer becomes known only when the vehicle visited the customer. A vehicle-coordinated strategy was designed to solve the service failure problem. A hybrid algorithm based on the artificial immune system is also proposed to solve the model for vehicle routing problem with interval demands. The validity of methods and sensitivity analysis are illustrated by conducting some numerical examples. We find that the tolerant possibility degree of interval number has significant impacts on the distances. The planned distance strictly increased, while the additional distance strictly decreased and the total distance after coordinated transport has a U-typed relationship with the tolerant possibility degree of interval number.     

B2C电子商务仓库拣货路径优化策略应用研究

当前国内B2C电子商务仓库多为人至物的拣货模式,拣货作业成为其核心作业之一,占据仓库大量时间成本和资金成本,拣货路径优化成为企业亟需解决的问题。本文基于TSP对拣货路径进行建模,利用蚁群算法、模拟退火算法和禁忌搜索对该NP-hard问题进行求解,并同当前企业普遍采用的S型启发式策略进行对比,拣货时间节约13.35%。进一步得出当拣货品数量较少时应采用模拟退火算法求解,而当拣货品数量较大时采用蚁群算法仅进行一次迭代,则可以实现短时间得到相对较优的解。所得结果已应用于某大型电子商务企业,效果明显。     

Prioritizing replenishments of the piece picking area

Having sufficient inventories in the forward or piece picking area of a warehouse is an essential condition for warehouse operations. As pickers consume the inventory in the piece racks, there is a risk of stockout. This can be reduced by the timely replenishment of products from the bulk reserve area to the forward area. We develop and compare three policies for prioritizing replenishments for the case where order picking and replenishments occur concurrently because of time restrictions. The first policy, based on the ratio of available inventory to wave demand, reduces the number of stockouts considerably. The other two more sophisticated policies reduce the number of stockouts even more but require much more computation time, and are more costly in terms of implementation, maintenance and software updates. We present the results of implementing one of these policies in the warehouse of a large cosmetics firm.     

考虑完全拆分的拣选分批与拣选路径集成优化模型

在电商海量订单背景下,在线订单拣选作业难度加大,因此设计了基于订单完全拆分的拣选分批与拣选路径综合优化模型解决此问题.模型共分两阶段.第一阶段,基于种子算法,设计考虑订单完成度、等待时间与拣选路径的拣选分批模型;第二阶段以拣选单流为单队列,设计多拣选员并行服务的拣选系统.行走策略为基于返回型和遍历型的综合策略,拣选路径优化模型采用模拟退火算法求解.算例分析表明,与传统的不拆分拣选分批模型相比,构建的综合优化模型能够显著提高拣选系统效率.拣选员为4人时,模型能够使总服务时间减少58.79%,订单完成率提高10.09%.     

基于改进粒子群算法V型非传统布局仓库通道优化设计

V型仓储布局是一种典型的非传统布局方式,针对V型布局主通道设计的问题,将主通道抽象为若干个点连接而成的折线通道,每条拣货通道按物动量大小对仓库进行分区,采用更加符合实际的存取货物作业的概率不相等的非完全随机存储策略,建立最小化平均拣货距离的仓库主通道设计数学优化模型。其次,设计了基于极值扰动算子的改进粒子群优化算法(EDO-PSO)进行算法求解,利用极值扰动算子解决易陷入局部最优问题,采用并行深度搜索策略,提高算法性能,并用Benchmark函数与其他改进PSO算法对比验证算法性能。最后,结合具体实验数据仿真分析,计算结果表明,该方法在相同货位分配策略下,能有效缩短总拣货距离,验证了方法的有效性。     

考虑缺货的闭环供应链选址-库存-路径集成优化

再制造是企业实现环境友好、提升经济效益的重要策略之一;再制造的发展推动了新商业模式的出现,即产品服务系统;高效的再制造物流网络对于成功实施再制造十分重要。本文研究了基于产品服务系统下的再制造物流网络集成优化问题,即闭环供应链的选址-库存-路径的集成优化决策问题,且在库存策略中允许库存出现缺货的情况;论文基于产品服务系统模式构建了混合非线性规划模型来最小化生产、选址、配送、库存以及缺货成本,并采用了改进的禁忌搜索算法进行求解。通过与传统禁忌搜索算法的计算结果进行对比,表明本文中的算法能在可接受的时间内得到较优解。通过算例的敏感性分析得出,企业所服务的顾客如果接受再制造产品,提高回收率可以节约成本;在回收率一定时,客户在缺货情形下的制造和再制造批量比不允许缺货时要大,企业总成本比不允许缺货时要小。     

Tabu search heuristics for the order batching problem in manual order picking systems

In a manual order picking system, order pickers walk or ride through a distribution warehouse in order to collect items requested by (internal or external) customers. In order to perform these operations efficiently, it is usually required that customer orders be combined into (more substantial) picking orders that are limited in size. The order batching problem considered in this paper deals with the question of how a given set of customer orders should be combined into picking orders such that the total length of all picker tours necessary for all of the requested items to be collected is minimized. For the solution of this problem the authors suggest two approaches based on the tabu search principle. The first is a (classic) tabu search (TS), and the second is the attribute-based hill climber (ABHC). In a series of extensive numerical experiments, these approaches are benchmarked against other solution methods put forward in the current literature. It is demonstrated that the proposed methods are superior to the existing methods and provide solutions which may allow distribution warehouses to operate more efficiently.     

Location-aided routing with uncertainty in mobile ad hoc networks: A stochastic semidefinite programming approach

We study location-aided routing under mobility in wireless ad hoc networks. Due to node mobility, the network topology changes continuously, and clearly there exists an intricate tradeoff between the message passing overhead and the latency in the route discovery process. Aiming to obtain a clear understanding of this tradeoff, we use stochastic semidefinite programming (SSDP), a newly developed optimization model, to deal with the location uncertainty associated with node mobility. In particular, we model both the speed and the direction of node movement by random variables and construct random ellipses accordingly to better capture the location uncertainty and the heterogeneity across different nodes. Based on SSDP, we propose a stochastic location-aided routing (SLAR) strategy to optimize the tradeoff between the message passing overhead and the latency. Our results reveal that in general SLAR can significantly reduce the overall overhead than existing deterministic algorithms, simply because the location uncertainty in the routing problem is better captured by the SSDP model.     

成品油配送多车舱车辆指派及路径优化问题研究

针对成品油配送中多车型、多车舱的车辆优化调度难题,综合考虑多车型车辆指派、多车舱车辆装载及路径安排等决策,以派车成本与油耗成本之和的总成本最小为目标,建立了多车型多车舱的车辆优化调度模型。为降低模型求解的复杂性,本文提出一种基于C-W节约算法的“需求拆分→合并装载”的车辆装载策略,并综合利用Relocate和Exchange算子进行并行邻域搜索改进,获得优化的成品油配送方案。最后,通过算例验证了本文提出的模型与算法用于求解大规模成品油配送问题的有效性。并通过数据实验揭示了以下规律:1)多车舱车辆相对于单车舱车辆在运营成本上具有优越性;2)大型车辆适合远距离配送,小型车辆适合近距离配送;3)多车型车辆混合配送相对于单车型车辆配送在运营成本上具有优越性。这些规律可为成品油配送公司的车辆配置提供决策参考。     

考虑横向整合战略的库存路径动态区域定价

库存路径和定价是供货商管理库存(Vendor Management Inventory, VMI)中三个互相制约和影响的决策问题,是降低供货商成本,提高其利润的关键。针对VMI拉式供应链中多供货商、多商品和多区域的库存路径定价问题,提出了对不同区域客户、在不同时段进行商品差异化定价策略,并设计一种共同配送车辆司机成本和燃油成本分摊方案,据此构建基于横向整合战略的库存路径动态区域定价模型。算例结果显示,在横向整合战略下,供货商商品定价会有所降低,配送车辆行驶距离显著缩短,各时段配货量更为均衡,期末库存数量显著降低。研究表明,无论供货商之间供货规模比例差异多大,开展库存路径动态区域定价,供货商联盟成员的利润均能得到显著提高,实现合作共赢的目标。     

Solving school bus routing problems through integer programming

In this paper, an exact solution approach is described for solving a real-life school bus routing problem (SBRP) for transporting the students of an elementary school throughout central Ankara, Turkey. The problem is modelled as a capacitated and distance constrained open vehicle routing problem and an associated integer linear program is presented. The integer program borrows some well-known inequalities from the vehicle routing problem, which are also shown to be valid for the SBRP under consideration. The optimal solution of the problem is computed using the proposed formulation, resulting in a saving of up to 28.6% in total travelling cost as compared to the current implementation.