The Multi-AMR Buffer Storage, Retrieval, and Reshuffling Problem: Exact and Heuristic Approaches
Organizations: Karlsruhe Institute of Technology, Zirkel 2, 76131 Karlsruhe, Germany
Abstract
Buffer zones are essential in production systems to decouple sequential processes. In dense floor storage environments, such as space-constrained brownfield facilities, manual operation is increasingly challenged by severe labor shortages and rising operational costs. Automating these zones requires solving the Buffer Storage, Retrieval, and Reshuffling Problem (BSRRP). While previous work has addressed scenarios where the focus is limited to reshuffling and retrieving a fixed set of items, real-world manufacturing necessitates an adaptive approach that also incorporates arriving unit loads. This paper introduces the Multi-AMR BSRRP, coordinating a robot fleet to manage concurrent reshuffling, alongside time-windowed storage and retrieval tasks, within a shared floor area. We formulate a Binary Integer Programming (IP) model to obtain exact solutions for benchmarking purposes. As the problem is NP-hard, rendering exact methods computationally intractable for industrial scales, we propose a hierarchical heuristic. This approach decomposes the problem into an A* search for task-level sequence planning of unit load placements, and a Constraint Programming (CP) approach for multi-robot coordination and scheduling. Experiments demonstrate orders-of-magnitude computation time reductions compared to the exact formulation. These results confirm the heuristic's viability as responsive control logic for high-density production environments.
Figures & tables
| Reference | Handling Operations | Access Mode | Fleet | Temporal Representation | Method |
|---|---|---|---|---|---|
| Caserta et al. (2012) | Perimeter | 1 Crane | Moves | IP | |
| Borjian et al. (2015) | ● | Perimeter | 1 Crane | Continuous | IP |
| Ji et al. (2015) | Perimeter | n Cranes | Moves | Genetic Algo. | |
| Bömer et al. (2024) | Perimeter | n AMRs | Moves | CP | |
| Disselnmeyer et al. (2024) | Perimeter | 1 AMR | Continuous | IP | |
| Hu et al. (2025) | In-Grid | n AMRs | Steps | CBS Search |
| Notation | Description |
| Sets of unit loads, AMRs, and time steps. | |
| Sets of all lanes (incl. I/O), Set of all buffer lanes (excl. I/O). | |
| Slot at lane and position ( is deepest in the lane). | |
| Distance between slots and . | |
| Travel and handling time (cost) between slots and . | |
| Handling time for picking up or dropping a unit load. |
| Symbol | Description |
| Sets and Indices | |
| Set of storage and retrieval orders ( ) | |
| Subsets of storage and retrieval orders | |
| Indices for specific orders ( ) | |
| Set of dependency groups formed during priority assignment | |
| Set of moves generated by A* search | |
| Parameter | Category | Small ( ) | Large ( ) |
| Fleet Size ( ) | 1 AMR | 151 | 0 |
| 2 AMRs | 288 | 48 | |
| 3 AMRs | 277 | 46 | |
| Access Directions | 1 Side | 72 | 1 |
| 2 Sides | 373 | 54 | |
| 4 Sides | 271 | 39 |
| Solve Rate Heuristic | Computational Efficiency (Median) | Median Opt. | ||||||
| Layout | Fleet ( ) | Number of Instances | Solved | Rate | EF Runtime | Heur. Runtime | Speedup | Gap (%) |
| 1 AMR | 151 | 139 | 92.1% | 515.5 s | 0.05 s | 10,310x | 2.56% | |
| 2 AMRs | 288 | 284 | 98.6% | 253.0 s | 0.08 s | 3,163x | 10.20% | |
| 3 AMRs | 277 | 275 | 99.3% | 307.2 s | 0.09 s | 3,413x | 14.58% | |
| 2 AMRs | 48 | 44 | 91.7% | 1,524.3 s | 3.37 s | 452x | 4.70% | |
| 3 AMRs | 46 | 45 | 97.8% | 2,927.9 s | 2.52 s | 1,162x | 10.63% | |
| Layout Topology | Ratio | Access Directions | Solve Rate | |||
| 1 | 2 | 3 | 4 | |||
| Rectangle ( ) | 0.7 | 30/50 | 50/50 | – | – | 80.0% |
| 0.8 | 15/50 | 50/50 | – | – | 65.0% | |
| 0.9 | 5/50 | 50/50 | – | – | 55.0% | |
| 1.0 | 0/50 | 45/50 | – | – | 45.0% | |
| Block ( ) | 0.7 | 0/50 | 85/100 | – | 50/50 | 67.5% |
Appendix figures & tables1 asset
Supplementary material from the paper’s appendix.
Appendix
| Element | Notation | Description |
| Sets and Indices | ||
| Set of unit loads | , | Range: |
| Set of time steps | , | Range: |
| Set of all lanes | , | Range: |
| Set of buffer lanes | Range: (excluding sink and source) | |
| Set of slots | , | Range: |
Industrial Robotics
Industrial robotics develops robots, control systems, and planning methods for manufacturing, assembly, inspection, and material handling.
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