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Design, Modeling, and Analysis of Vertical Robotic Storage and Retrieval Systems

Author

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  • Kaveh Azadeh

    (Rotterdam School of Management, Erasmus University, 3062 PA Rotterdam, Netherlands)

  • Debjit Roy

    (Indian Institute of Management Ahmedabad, Ahmedabad, 380015 Gujarat, India)

  • René De Koster

    (Rotterdam School of Management, Erasmus University, 3062 PA Rotterdam, Netherlands)

Abstract

Autonomous vehicle-based storage and retrieval systems are commonly used in many fulfillment centers (e.g., e-commerce warehouses), because they allow a high- and flexible-throughput capacity. In these systems, roaming robots transport loads between a storage location and a workstation. Two main variants exist: horizontal , where the robots only move horizontally and use lifts for vertical transport, and a new variant vertical , where the robots can also travel vertically in the rack. This paper builds a framework to analyze the performance of the vertical system and compare its throughput capacity with the horizontal system. We build closed queueing network models for this that, in turn, are used to optimize the design. The results show that the optimal height-to-width ratio of a vertical system is around one. Because a large number of system robots may lead to blocking and delays, we compare the effects of different robot blocking protocols on the system throughput: robot Recirculation and Wait-on-Spot. The Wait-on-Spot policy produces a higher system throughput when the number of robots in the system is small. However, for a large number of robots in the system, the Recirculation policy dominates the Wait-on-Spot policy. Finally, we compare the operational costs of the vertical and horizontal transport systems. For systems with one load/unload (L/U) point, the vertical system always produces a similar or higher system throughput with a lower operating cost compared with the horizontal system with a discrete lift. It also outperforms the horizontal system with a continuous lift in systems with two L/U points.

Suggested Citation

  • Kaveh Azadeh & Debjit Roy & René De Koster, 2019. "Design, Modeling, and Analysis of Vertical Robotic Storage and Retrieval Systems," Transportation Science, INFORMS, vol. 53(5), pages 1213-1234, September.
    • Handle: RePEc:inm:ortrsc:v:53:y:2019:i:5:p:1213-1234
    DOI: 10.1287/trsc.2018.0883
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    References listed on IDEAS

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    1. Debjit Roy & Ananth Krishnamurthy & Sunderesh Heragu & Charles Malmborg, 2012. "Performance analysis and design trade-offs in warehouses with autonomous vehicle technology," IISE Transactions, Taylor & Francis Journals, vol. 44(12), pages 1045-1060.
    2. Bipan Zou & Xianhao Xu & Yeming Gong & René de Koster, 2016. "Modeling parallel movement of lifts and vehicles in tier-captive vehicle-based warehousing systems," Post-Print hal-02313400, HAL.
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    Cited by:

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    2. Chen, Wanying & Gong, Yeming & Chen, Qi & Wang, Hongwei, 2024. "Does battery management matter? Performance evaluation and operating policies in a self-climbing robotic warehouse," European Journal of Operational Research, Elsevier, vol. 312(1), pages 164-181.
    3. Kumar, Suryakant & Sheu, Jiuh-Biing & Kundu, Tanmoy, 2023. "Planning a parts-to-picker order picking system with consideration of the impact of perceived workload," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 173(C).
    4. Fragapane, Giuseppe & de Koster, René & Sgarbossa, Fabio & Strandhagen, Jan Ola, 2021. "Planning and control of autonomous mobile robots for intralogistics: Literature review and research agenda," European Journal of Operational Research, Elsevier, vol. 294(2), pages 405-426.
    5. Emilio Moretti & Elena Tappia & Martina Mauri & Marco Melacini, 2022. "A performance model for mobile robot-based part feeding systems to supermarkets," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 580-613, September.
    6. Xu, Xianhao & Chen, Yuerong & Zou, Bipan & Gong, Yeming, 2022. "Assignment of parcels to loading stations in robotic sorting systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 164(C).
    7. Yi Li & Zhiyang Li, 2022. "Shuttle-Based Storage and Retrieval System: A Literature Review," Sustainability, MDPI, vol. 14(21), pages 1-18, November.
    8. Chen, Wanying (Amanda) & De Koster, René & Gong, Yeming, 2023. "Warehouses without aisles: Layout design of a multi-deep rack climbing robotic system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 179(C).
    9. Dong, Wenquan & Jin, Mingzhou, 2021. "Travel time models for tier-to-tier SBS/RS with different storage assignment policies and shuttle dispatching rules," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 155(C).

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