A new mathematical model and meta-heuristic algorithm for order batching, depot selection, and assignment problem with multiple depots and pickers

Abstract

The ‘order picking problem’ involves the efficient and organized retrieval of items from shelves to fulfill customer orders. In this study, we consider a new configuration of warehouse system with multiple pickers and depots (m-pickers & n-depots) for manually operated ‘picker-to-parts’ warehouses. The efficiency of the process is measured based on two metrics: i- total order picking distance of each picker ii- total number of pickers assigned to each of depots. The handled problem is called as ‘Order Batching, Depot Selection and Assignment Problem with Multiple Depots and Multiple Pickers (OBDSAPMDMP)11OBDSAPMDMP = Order Batching, Depot Selection, and Assignment Problem with Multiple Depots and Multiple Pickers.’. To solve this complex problem, a new bi-objective Mixed-Integer Linear Programming (MILP) formulation for small-sized problems and a meta-heuristic called ‘Dependent Harmony Search (DHS)22DHS = Dependent Harmony Search.’ for large-sized problems are proposed. The performance of DHS algorithm is evaluated by comparing the optimal results attained by MILP model. For the problem size of 10 orders, the average gap (%) in distance between the solution of DHS and MILP is 4.22%, although in some experiments DHS can find the optimal solution in a very short time. Also, in related analysis, it is seen that constructing multiple depots instead of one left-most located depot decreases total order picking distance by 7.11% on average.