Order Allocation Strategy Optimization in a Goods-to-Person Robotic Mobile Fulfillment System with Multiple Picking Stations

• Published in: Applied sciences Vol. 15; no. 16; p. 9173
• Main Authors: Zhao, Junpeng, Zhang, Chu
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 20.08.2025
• Subjects: Automation; Decision making; Design; Efficiency; Electronic commerce; Genetic algorithms; Heuristic; Integer programming; Inventory; Inventory control; Inventory management; Logistics; Mathematical models; Optimization; Order picking; Order processing; Performance evaluation; Robotics; Robots; Strategic planning; Turnover; Workloads
• ISSN: 2076-3417; 2076-3417
• DOI: 10.3390/app15169173

The order picking process in Goods-to-Person (G2P) systems involves a set of interdependent yet often separately addressed decisions, such as order allocation, sequencing, and rack handling. This study focuses on the joint optimization of order allocation, order sequencing, rack selection, and rack sequencing in a G2P robotic mobile fulfillment system with multiple picking stations. To model this complex problem, we develop a mathematical formulation and propose a two-phase heuristic algorithm that combines simulated annealing, genetic algorithms, and beam search for efficient solution. In addition, we explore and compare two order allocation strategies—order similarity and order association—across a range of operational scenarios. Extensive computational experiments and sensitivity analyses demonstrate the effectiveness of the proposed approach and provide insights into how strategic order allocation can significantly improve picking efficiency. Computational experiments on small-scale instances show that our algorithm achieves near-optimal solutions with up to 93.3% reduction in computation time compared to exact optimization for small cases. In large-scale scenarios, the order similarity strategy reduces rack movements by up to 44.8% and the order association strategy by up to 33.5% relative to a first-come, first-served baseline. Sensitivity analysis reveals that the association strategy performs best with fewer picking stations and lower rack capacity, whereas the similarity strategy is superior in systems with more stations or higher rack capacity. The findings offer practical guidance for the design and operation of intelligent warehousing systems.