A Comparative Study of Bayesian Contextual Bandits for Real-Time Warehouse Sorter Optimization
Authors: Tina Dongxu Li, Mouhacine Benosman, Ken Meszaros, Trevor Dardik
Organizations: Amazon.com, USA
Abstract
Efficient sorter diversion control of automated material handling systems (MHS) is critical for optimizing operational efficiency in large-scale warehouse environments. In this study, we use an inbound receiving sorter at a high-volume e-commerce warehouse as our primary use case, where the sorter diversion system relies on cost functions with static weight configurations that fail to adapt to highly dynamic system contexts, such as volume mode, congestion level, equipment physical status, and upstream/downstream dependencies. To address this real-time sorter diversion optimization challenge, we conducted a comparative study of three candidate hybrid machine learning frameworks: Linear Regression with Gradient Descent Optimization (LR+GDO), XGBoost with Bayesian Optimization (XGB+BO), and Bayesian Contextual Bandits (BCB). Model training and evaluation were enabled by leveraging a high-fidelity physics-aware emulator to overcome the cold-start problem and allow a safe transition from offline to online learning. We performed comprehensive evaluations including reward model predictive accuracy, contextual sensitivity, action distribution, and projected reward uplift. Our results demonstrate that while tree-based reward models offer slightly better predictive power, the BCB framework achieved overall higher performance with 2.03% reward uplift over the heuristic baseline. Furthermore, BCB exhibits several superior characteristics, such as its decisive time-optimal policy backed by Bang-Bang control theory, continuous online learning capability, strategic balance between exploration and exploitation, and significantly shorter inference latency. These results demonstrate the potential of the BCB framework for real-time control optimization in large-scale warehouse environments, motivating further investigation toward operational deployment.
We present an offline reinforcement learning (RL) framework for optimizing SLAM throughput control in a warehouse fulfillment environment. SLAM (Scan/Label/Apply/Manifest) throughput directly influences system congestion and operational efficiency. Our RL-based control approach dynamically recommends SLAM throughput settings that adaptively balance throughput maximization with downstream stability through intelligent adjustment of throttling behavior. We include a history-informed state representation, action space abstraction for delayed-impact control, and a reward function that captures both upstream and downstream operational metrics. Our approach is algorithm-agnostic, enabling integration of multiple offline RL methods under a unified architecture. We instantiate our framework with three state-of-the-art offline RL algorithms, and trained the models offline using de-identified historical operational logs from a large-scale warehouse. Policy performance is evaluated using a comprehensive multi-method strategy. These include model-free approaches including immediate reward estimation via regression models and long-horizon Fitted Q Evaluation (FQE), as well as model-based Deep Koopman dynamics evaluation. Empirical results reveal that the CQL policy consistently outperforms alternatives, improving system health by 22.97% and reducing average throttling duration by 3.18%. These findings demonstrate the potential of offline RL for safe and scalable warehouse throughput control optimization.
Tina Dongxu Li, Mouhacine Benosman, Rajat Kumar +3
Discovering optimal designs through sequential data collection is essential in many real-world applications. While Bayesian Optimization (BO) has achieved remarkable success in this setting, growing attention has recently turned to context-specific optimal design, formalized as Contextual Bayesian Optimization (CBO). Unlike BO, CBO is inherently more challenging as it must approximate an entire mapping from the context space to its corresponding optimal design, requiring simultaneous exploration across contexts and exploitation within each. In many modern applications, such tasks arise across multiple potentially heterogeneous but related clients, where collaboration can significantly improve learning efficiency. We propose CCBO, Collaborative Contextual Bayesian Optimization, a unified framework enabling multiple clients to jointly perform CBO with controllable contexts, supporting both online collaboration and offline initialization from peers' historical beliefs, with an optional privacy-preserving communication mechanism. We establish sublinear regret guarantees and demonstrate, through extensive simulations and a real-world hot rolling application, that CCBO achieves substantial improvements over existing approaches even under client heterogeneity. The code to reproduce the results can be found at https://github.com/cchihyu/Collaborative-Contextual-Bayesian-Optimization
We study new algorithms for Contextual Bandits with Knapsack. In these problems, there are finitely many types of customers, products, and resources. Each product is made from a fixed combination of resources, and resources have finite capacity. A decision maker must assign each arriving customer one out of a set of multiple possible products. Every assignment of a customer to a product will generate a random reward, which equals an unknown linear function of customer and product features, plus a noise term. The objective is to jointly learn the mean reward function, and to make online assignments to minimize the expected revenue loss relative to an optimal policy that knows the reward function. We propose a natural and simple extension of the Upper-Confidence-Bound (UCB) family of algorithms and apply re-optimization techniques. We show that by taking advantage of re-optimization, our algorithm achieves an average regret of O(T(lnT)3) where T is the horizon length. Our bound significantly reduces the O(T1) bound in the literature for closely related dynamic-pricing problems that are based on re-optimization.