Optimizing Rack Locations in the Mobile-Rack Picking System: A Method of Integrating Rack Heat and Relevance

Abstract

The flexible movement of racks in the mobile-rack picking system (MRPS) significantly improves the picking efficiency of e-commerce orders with the characteristics of “one order multi–items” and creates a challenging problem of how to place racks in the warehouse. This is because the placement of each rack in the MRPS directly influences the distance that racks need to be moved during order picking, which in turn affects the order picking efficiency. To handle the rack location optimization problem (RLOP), this work introduces a novel idea and methodology, taking into account the heat degree and the relevance degree of racks, to enhance the efficiency of rack placements in the MRPS. Specifically, a two-stage solution strategy is implemented. In stage 1, an integer programming model (Model 1) is developed to determine the heat and relevance degree of racks, and it can be solved quickly by the Gurobi. Stage 2 entails developing a bi-objective integer programming model (Model 2) with the objective to minimize the travel distances of robots in both heavy load and no-load conditions, using the rack heat and relevance degree as inputs. In light of the challenge of decision coupling and the vast solution space in stage 2, we innovatively propose two lower bounds by slacking off the distance between storage locations. A matheuristic algorithm based on Benders decomposition (MABBD) is designed, which utilizes Benders-related rules to reconstruct Model 2, introduces an enhanced cut and an improved optimal cut with RLOP characteristics, and designs the warm start strategy and the master variable fixed strategy. Given the substantial size of real-life problems, the Memetic algorithm (MA) is specifically devised to address them. Instances of varying sizes are also employed to validate the science and efficacy of the model and algorithm.