IDEAS home Printed from https://ideas.repec.org/a/eee/transe/v194y2025ics1366554524005210.html
   My bibliography  Save this article

Joint optimization of order picking and replenishment in robotic mobile fulfillment systems

Author

Listed:
  • Wu, Jingwen
  • Yang, Zhiyuan
  • Zhen, Lu
  • Li, Wenxin
  • Ren, Yiran

Abstract

Advancements in intelligent warehousing have spotlighted the robotic mobile fulfillment system as a transformative solution for modern logistics challenges. This paper introduces a five-stage mixed-integer programming model designed to optimize the robotic mobile fulfillment system (RMFS) by minimizing the longest completion time, a critical metric in warehouse efficiency. Our comprehensive model strategically integrates the assignment of orders to stations and pods, the deployment of pods to robots, and the intricate details of route planning, order picking, and replenishment. Utilizing a variable neighborhood search algorithm, we not only tackle the complex scheduling decisions among orders, robots, stations, and pods but also demonstrate the model’s effectiveness through rigorous numerical experiments. The results provide pivotal insights, revealing significant potential for enhancing the RMFS efficiency and offering practical guidance for warehouse managers.

Suggested Citation

  • Wu, Jingwen & Yang, Zhiyuan & Zhen, Lu & Li, Wenxin & Ren, Yiran, 2025. "Joint optimization of order picking and replenishment in robotic mobile fulfillment systems," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 194(C).
  • Handle: RePEc:eee:transe:v:194:y:2025:i:c:s1366554524005210
    DOI: 10.1016/j.tre.2024.103930
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S1366554524005210
    Download Restriction: Full text for ScienceDirect subscribers only

    File URL: https://libkey.io/10.1016/j.tre.2024.103930?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. Boysen, Nils & Briskorn, Dirk & Emde, Simon, 2017. "Parts-to-picker based order processing in a rack-moving mobile robots environment," European Journal of Operational Research, Elsevier, vol. 262(2), pages 550-562.
    2. Masae, Makusee & Glock, Christoph H. & Grosse, Eric H., 2020. "Order picker routing in warehouses: A systematic literature review," International Journal of Production Economics, Elsevier, vol. 224(C).
    3. Boysen, Nils & Schwerdfeger, Stefan & W. Ulmer, Marlin, 2023. "Robotized sorting systems: Large-scale scheduling under real-time conditions with limited lookahead," European Journal of Operational Research, Elsevier, vol. 310(2), pages 582-596.
    4. 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.
    5. 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.
    6. Nicolas, Lenoble & Yannick, Frein & Ramzi, Hammami, 2018. "Order batching in an automated warehouse with several vertical lift modules: Optimization and experiments with real data," European Journal of Operational Research, Elsevier, vol. 267(3), pages 958-976.
    7. Çağla Cergibozan & A. Serdar Tasan, 2019. "Order batching operations: an overview of classification, solution techniques, and future research," Journal of Intelligent Manufacturing, Springer, vol. 30(1), pages 335-349, January.
    8. van Gils, Teun & Ramaekers, Katrien & Braekers, Kris & Depaire, Benoît & Caris, An, 2018. "Increasing order picking efficiency by integrating storage, batching, zone picking, and routing policy decisions," International Journal of Production Economics, Elsevier, vol. 197(C), pages 243-261.
    9. Makusee Masae & Christoph H. Glock & Panupong Vichitkunakorn, 2020. "Optimal order picker routing in the chevron warehouse," IISE Transactions, Taylor & Francis Journals, vol. 52(6), pages 665-687, June.
    10. Jiajia Dou & Chunlin Chen & Pei Yang, 2015. "Genetic Scheduling and Reinforcement Learning in Multirobot Systems for Intelligent Warehouses," Mathematical Problems in Engineering, Hindawi, vol. 2015, pages 1-10, December.
    11. repec:hal:journl:hal-02312005 is not listed on IDEAS
    12. Bingqian WANG & Xiuqing YANG & Mingyao QI, 2023. "Order and rack sequencing in a robotic mobile fulfillment system with multiple picking stations," Flexible Services and Manufacturing Journal, Springer, vol. 35(2), pages 509-547, June.
    13. 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.
    14. 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.
    15. 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.
    16. Xie, Lin & Thieme, Nils & Krenzler, Ruslan & Li, Hanyi, 2021. "Introducing split orders and optimizing operational policies in robotic mobile fulfillment systems," European Journal of Operational Research, Elsevier, vol. 288(1), pages 80-97.
    17. Lenoble Nicolas & Frein Yannick & Hammami Ramzi, 2018. "Order batching in an automated warehouse with several vertical lift modules: Optimization and experiments with real data," Post-Print hal-01999890, HAL.
    18. 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).
    19. Boysen, Nils & Briskorn, Dirk & Emde, Simon, 2017. "Parts-to-picker based order processing in a rack-moving mobile robots environment," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 85774, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    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. 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).
    2. 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.
    3. 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.
    4. 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).
    5. 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).
    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. 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).
    8. Giorgi Tadumadze & Julia Wenzel & Simon Emde & Felix Weidinger & Ralf Elbert, 2023. "Assigning orders and pods to picking stations in a multi-level robotic mobile fulfillment system," Flexible Services and Manufacturing Journal, Springer, vol. 35(4), pages 1038-1075, December.
    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. 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.
    11. Zhuang, Yanling & Zhou, Yun & Hassini, Elkafi & Yuan, Yufei & Hu, Xiangpei, 2024. "Improving order picking efficiency through storage assignment optimization in robotic mobile fulfillment systems," European Journal of Operational Research, Elsevier, vol. 316(2), pages 718-732.
    12. Boysen, Nils & Schwerdfeger, Stefan & Stephan, Konrad, 2023. "A review of synchronization problems in parts-to-picker warehouses," European Journal of Operational Research, Elsevier, vol. 307(3), pages 1374-1390.
    13. 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).
    14. 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).
    15. 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).
    16. Jiang, Zhong-Zhong & Zhao, Jinlong & Sun, Minghe, 2024. "Joint optimization of order picking and delivery in ergonomic picking systems with due dates for sustainability and resilience," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 191(C).
    17. 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).
    18. 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.
    19. 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).
    20. 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).

    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:s1366554524005210. 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.