IDEAS home Printed from https://ideas.repec.org/a/eee/transe/v194y2025ics1366554524004666.html
   My bibliography  Save this article

Operating policies for robotic cellular warehousing systems

Author

Listed:
  • Ma, Benedict Jun
  • Pan, Shenle
  • Zou, Bipan
  • Kuo, Yong-Hong
  • Huang, George Q.

Abstract

Robotic Cellular Warehousing Systems provide an innovative robot-to-goods picking approach designed to improve robot transportation efficiency, where robots move to pick items and transport the picked items to workstations. In this study, we investigate the optimal operating policies for such a system by comparing two picking strategies (pick-while-sort and pick-then-sort) and three robot-to-workstation assignment rules (random, closest, and dedicated). Specifically, we develop dedicated closed queuing networks to model robot-to-goods picking and estimate warehouse throughput under different policies through single-class and multi-class models. The effectiveness of these analytical models is validated through numerical simulations, with an average gap of 5.53% between simulation and analytical results. Additionally, we conduct a series of numerical experiments to examine the impact of various factors on warehouse performance, including the numbers of robots and workstations, robot capacity, order size, and sorting efficiency. Based on the experimental findings, we provide managerial implications that offer insights into optimizing resource allocation and system configuration. These insights enable warehouse managers to improve operational efficiency and overall performance.

Suggested Citation

  • Ma, Benedict Jun & Pan, Shenle & Zou, Bipan & Kuo, Yong-Hong & Huang, George Q., 2025. "Operating policies for robotic cellular warehousing systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 194(C).
  • Handle: RePEc:eee:transe:v:194:y:2025:i:c:s1366554524004666
    DOI: 10.1016/j.tre.2024.103875
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S1366554524004666
    Download Restriction: Full text for ScienceDirect subscribers only

    File URL: https://libkey.io/10.1016/j.tre.2024.103875?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Sonja Otten & Ruslan Krenzler & Lin Xie & Hans Daduna & Karsten Kruse, 2022. "Analysis of semi-open queueing networks using lost customers approximation with an application to robotic mobile fulfilment systems," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 44(2), pages 603-648, June.
    2. He, Jing & Liu, Xinglu & Duan, Qiyao & Chan, Wai Kin (Victor) & Qi, Mingyao, 2023. "Reinforcement learning for multi-item retrieval in the puzzle-based storage system," European Journal of Operational Research, Elsevier, vol. 305(2), pages 820-837.
    3. Zou, Bipan & Xu, Xianhao & Gong, Yeming (Yale) & De Koster, René, 2018. "Evaluating battery charging and swapping strategies in a robotic mobile fulfillment system," European Journal of Operational Research, Elsevier, vol. 267(2), pages 733-753.
    4. 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).
    5. Roy, Debjit & Nigam, Shobhit & de Koster, René & Adan, Ivo & Resing, Jacques, 2019. "Robot-storage zone assignment strategies in mobile fulfillment systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 122(C), pages 119-142.
    6. Tim Lamballais Tessensohn & Debjit Roy & René B.M. De Koster, 2020. "Inventory allocation in robotic mobile fulfillment systems," IISE Transactions, Taylor & Francis Journals, vol. 52(1), pages 1-17, January.
    7. Debjit Roy & Ananth Krishnamurthy & Sunderesh Heragu & Charles Malmborg, 2015. "Stochastic models for unit-load operations in warehouse systems with autonomous vehicles," Annals of Operations Research, Springer, vol. 231(1), pages 129-155, August.
    8. repec:hal:journl:hal-02313400 is not listed on IDEAS
    9. Tsan‐Ming Choi & Subodha Kumar & Xiaohang Yue & Hau‐Ling Chan, 2022. "Disruptive Technologies and Operations Management in the Industry 4.0 Era and Beyond," Production and Operations Management, Production and Operations Management Society, vol. 31(1), pages 9-31, January.
    10. Xiao Cai & Sunderesh S. Heragu & Yang Liu, 2014. "Modeling and evaluating the AVS/RS with tier-to-tier vehicles using a semi-open queueing network," IISE Transactions, Taylor & Francis Journals, vol. 46(9), pages 905-927, September.
    11. Soondo Hong & Andrew Johnson & Brett Peters, 2012. "Large-scale order batching in parallel-aisle picking systems," IISE Transactions, Taylor & Francis Journals, vol. 44(2), pages 88-106.
    12. Roy, Debjit & Krishnamurthy, Ananth & Heragu, Sunderesh & Malmborg, Charles, 2015. "Queuing models to analyze dwell-point and cross-aisle location in autonomous vehicle-based warehouse systems," European Journal of Operational Research, Elsevier, vol. 242(1), pages 72-87.
    13. 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.
    14. Julia Wahlen & Timo Gschwind, 2023. "Branch-Price-and-Cut-Based Solution of Order Batching Problems," Transportation Science, INFORMS, vol. 57(3), pages 756-777, May.
    15. Nils Boysen & David Füßler & Konrad Stephan, 2020. "See the light: Optimization of put‐to‐light order picking systems," Naval Research Logistics (NRL), John Wiley & Sons, vol. 67(1), pages 3-20, February.
    16. Martin Epp & Simon Wiedemann & Kai Furmans, 2017. "A discrete-time queueing network approach to performance evaluation of autonomous vehicle storage and retrieval systems," International Journal of Production Research, Taylor & Francis Journals, vol. 55(4), pages 960-978, February.
    17. Wanying Amanda Chen & René de Koster & Yeming Gong, 2023. "Warehouses without aisles : Layout design of a multi-deep rack climbing robotic system," Post-Print hal-04343870, HAL.
    18. Ronald Buitenhek & Geert‐Jan van Houtum & Henk Zijm, 2000. "AMVA‐based solution procedures for open queueing networks with population constraints," Annals of Operations Research, Springer, vol. 93(1), pages 15-40, January.
    19. Li, Xiaowei & Hua, Guowei & Huang, Anqiang & Sheu, Jiuh-Biing & Cheng, T.C.E. & Huang, Fengquan, 2020. "Storage assignment policy with awareness of energy consumption in the Kiva mobile fulfilment system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 144(C).
    20. Peng Yang & Guang Jin & Guofang Duan, 2022. "Modelling and analysis for multi-deep compact robotic mobile fulfilment system," International Journal of Production Research, Taylor & Francis Journals, vol. 60(15), pages 4727-4742, August.
    21. Chen, Ran & Yang, Jingjing & Yu, Yugang & Guo, Xiaolong, 2023. "Retrieval request scheduling in a shuttle-based storage and retrieval system with two lifts," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 174(C).
    22. Wanying Chen & René De Koster & Yeming Gong, 2022. "Analysis and Design of Rack-Climbing Robotic Storage and Retrieval Systems," Transportation Science, INFORMS, vol. 56(6), pages 1658-1676, November.
    23. Lamballais, T. & Merschformann, M. & Roy, D. & de Koster, M.B.M. & Azadeh, K. & Suhl, L., 2022. "Dynamic policies for resource reallocation in a robotic mobile fulfillment system with time-varying demand," European Journal of Operational Research, Elsevier, vol. 300(3), pages 937-952.
    24. repec:hal:journl:hal-02312005 is not listed on IDEAS
    25. Mirzaei, Masoud & Zaerpour, Nima & de Koster, René, 2021. "The impact of integrated cluster-based storage allocation on parts-to-picker warehouse performance," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 146(C).
    26. Zheng Wang & Jiuh‐Biing Sheu & Chung‐Piaw Teo & Guiqin Xue, 2022. "Robot Scheduling for Mobile‐Rack Warehouses: Human–Robot Coordinated Order Picking Systems," Production and Operations Management, Production and Operations Management Society, vol. 31(1), pages 98-116, January.
    27. Boysen, Nils & de Koster, René & Weidinger, Felix, 2019. "Warehousing in the e-commerce era: A survey," European Journal of Operational Research, Elsevier, vol. 277(2), pages 396-411.
    28. 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).
    29. Shashank Kumar & Balkrishna E. Narkhede & Karuna Jain, 2021. "Revisiting the warehouse research through an evolutionary lens: a review from 1990 to 2019," International Journal of Production Research, Taylor & Francis Journals, vol. 59(11), pages 3470-3492, June.
    30. 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-01892897, HAL.
    31. Rouwenhorst, B. & Reuter, B. & Stockrahm, V. & van Houtum, G. J. & Mantel, R. J. & Zijm, W. H. M., 2000. "Warehouse design and control: Framework and literature review," European Journal of Operational Research, Elsevier, vol. 122(3), pages 515-533, May.
    32. Bipan Zou & René De Koster & Yeming Gong & Xianhao Xu & Guwen Shen, 2021. "Robotic Sorting Systems: Performance Estimation and Operating Policies Analysis," Transportation Science, INFORMS, vol. 55(6), pages 1430-1455, November.
    33. Lamballais, T. & Roy, D. & De Koster, M.B.M., 2017. "Estimating performance in a Robotic Mobile Fulfillment System," European Journal of Operational Research, Elsevier, vol. 256(3), pages 976-990.
    34. Bipan Zou & Yeming (Yale) Gong & Xianhao Xu & Zhe Yuan, 2017. "Assignment rules in robotic mobile fulfilment systems for online retailers," International Journal of Production Research, Taylor & Francis Journals, vol. 55(20), pages 6175-6192, October.
    35. Wanying Amanda Chen & Yeming Gong & Qi Chen & Hongwei Wang, 2024. "Does battery management matter? Performance evaluation and operating policies in a self-climbing robotic warehouse," Post-Print hal-04337021, HAL.
    36. Zhe Yuan & Yeming Gong, 2017. "Bot-In-Time Delivery for Robotic Mobile Fulfillment Systems," Post-Print hal-02311982, HAL.
    37. Jiuh‐Biing Sheu & Tsan‐Ming Choi, 2023. "Can we work more safely and healthily with robot partners? A human‐friendly robot–human‐coordinated order fulfillment scheme," Production and Operations Management, Production and Operations Management Society, vol. 32(3), pages 794-812, March.
    38. Jiang, Min & Huang, George Q., 2022. "Intralogistics synchronization in robotic forward-reserve warehouses for e-commerce last-mile delivery," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 158(C).
    39. Elena Tappia & Debjit Roy & René de Koster & Marco Melacini, 2017. "Modeling, Analysis, and Design Insights for Shuttle-Based Compact Storage Systems," Transportation Science, INFORMS, vol. 51(1), pages 269-295, February.
    40. Zou, Bipan & Xu, Xianhao & (Yale) Gong, Yeming & De Koster, René, 2016. "Modeling parallel movement of lifts and vehicles in tier-captive vehicle-based warehousing systems," European Journal of Operational Research, Elsevier, vol. 254(1), pages 51-67.
    41. Yaohan Shen & Xianhao Xu & Bipan Zou & Hongwei Wang, 2021. "Operating policies in multi-warehouse drone delivery systems," International Journal of Production Research, Taylor & Francis Journals, vol. 59(7), pages 2140-2156, April.
    42. Kaveh Azadeh & René De Koster & Debjit Roy, 2019. "Robotized and Automated Warehouse Systems: Review and Recent Developments," Transportation Science, INFORMS, vol. 53(4), pages 917-945, July.
    43. Boysen, Nils & de Koster, René & Weidinger, Felix, 2019. "Warehousing in the e-commerce era: A survey," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 126185, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    44. Bipan Zou & Xianhao Xu & Yeming Gong & René de Koster, 2018. "Evaluating battery charging and swapping strategies in a robotic mobile fulfillment system," Post-Print hal-02312110, HAL.
    45. 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.
    46. Bipan Zou & René De Koster & Xianhao Xu, 2018. "Operating Policies in Robotic Compact Storage and Retrieval Systems," Transportation Science, INFORMS, vol. 52(4), pages 788-811, August.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Zhang, Zhengmin & Gong, Yeming & Yuan, Zhe & Chen, Wanying, 2024. "Robotic warehouse systems considering dynamic priority," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 192(C).
    2. Qin, Zhizhen & Kang, Yuexin & Yang, Peng, 2024. "Making better order fulfillment in multi-tote storage and retrieval autonomous mobile robot systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 192(C).
    3. Boysen, Nils & de Koster, René, 2025. "50 years of warehousing research—An operations research perspective," European Journal of Operational Research, Elsevier, vol. 320(3), pages 449-464.
    4. Zhuang, Yanling & Zhou, Yun & Yuan, Yufei & Hu, Xiangpei & Hassini, Elkafi, 2022. "Order picking optimization with rack-moving mobile robots and multiple workstations," European Journal of Operational Research, Elsevier, vol. 300(2), pages 527-544.
    5. 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).
    6. Lamballais, T. & Merschformann, M. & Roy, D. & de Koster, M.B.M. & Azadeh, K. & Suhl, L., 2022. "Dynamic policies for resource reallocation in a robotic mobile fulfillment system with time-varying demand," European Journal of Operational Research, Elsevier, vol. 300(3), pages 937-952.
    7. Ding, Tianrong & Zhang, Yuankai & Wang, Zheng & Hu, Xiangpei, 2024. "Velocity-based rack storage location assignment for the unidirectional robotic mobile fulfillment system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 186(C).
    8. Gharehgozli, Amir & Zaerpour, Nima, 2020. "Robot scheduling for pod retrieval in a robotic mobile fulfillment system," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 142(C).
    9. Justkowiak, Jan-Erik & Pesch, Erwin, 2023. "Stronger mixed-integer programming-formulations for order- and rack-sequencing in robotic mobile fulfillment systems," European Journal of Operational Research, Elsevier, vol. 305(3), pages 1063-1078.
    10. 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.
    11. Yang, Jingjing & Guo, Xiaolong & Chen, Ran & Wang, Zhaotong, 2025. "Retrieval request sequencing in a novel tier-captive AVS/RS with a double-capacity lift," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 194(C).
    12. Chen, Wanying & Wu, Peng & Gong, Yeming & Zhang, Zhengmin & Wang, Kun, 2025. "The role of energy consumption in robotic mobile fulfillment systems: Performance evaluation and operating policies with dynamic priority," Omega, Elsevier, vol. 130(C).
    13. Zhuang, Yanling & Zhou, Yun & Hassini, Elkafi & Yuan, Yufei & Hu, Xiangpei, 2022. "Rack retrieval and repositioning optimization problem in robotic mobile fulfillment systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 167(C).
    14. 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).
    15. Dong, Wenquan & Jin, Mingzhou, 2024. "Automated storage and retrieval system design with variant lane depths," European Journal of Operational Research, Elsevier, vol. 314(2), pages 630-646.
    16. 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).
    17. Jiang, Min & Leung, K.H. & Lyu, Zhongyuan & Huang, George Q., 2020. "Picking-replenishment synchronization for robotic forward-reserve warehouses," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 144(C).
    18. Kaveh Azadeh & René De Koster & Debjit Roy, 2019. "Robotized and Automated Warehouse Systems: Review and Recent Developments," Transportation Science, INFORMS, vol. 53(4), pages 917-945, July.
    19. 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.
    20. Jiang, Min & Huang, George Q., 2022. "Intralogistics synchronization in robotic forward-reserve warehouses for e-commerce last-mile delivery," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 158(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:transe:v:194:y:2025:i:c:s1366554524004666. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/600244/description#description .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.