A Simulation-Based Optimization Method for Warehouse Worker Assignment

The general assignment problem is a classical NP-hard (non-deterministic polynomial-time) problem. In a warehouse, the constraints on the equipment and the characteristics of consecutive processes make it even more complicated. To overcome the difficulty in calculating the benefit of an assignment and in finding the optimal assignment plan, a simulation-based optimization method is introduced. We first built a simulation model of the warehouse with the object-oriented discrete-event simulation (O2DES) framework, and then implemented a random neighborhood search method utilizing the simulation output. With this method, the throughput and service level of the warehouse can be improved, while keeping the number of workers constant. Numerical results with real data demonstrate the reduction of discrepancy between inbound and outbound service level performance. With a less than 10% reduction in inbound service level, we can achieve an over 30% increase in outbound service level. The proposed decision support tool assists the warehouse manager in dealing with warehouse worker allocation problem under conditions of random daily workload.