Application of Machine Learning Methods for Pallet Loading Problem

Because of continuous competition in the corporate industrial sector, numerous companies are always looking for strategies to ensure timely product delivery to survive against their competitors. For this reason, logistics play a significant role in the warehousing, shipments, and transportation of the products. Therefore, the high utilization of resources can improve the profit margins and reduce unnecessary storage or shipping costs. One significant issue in shipments is the Pallet Loading Problem (PLP) which can generally be solved by seeking to maximize the total number of boxes to be loaded on a pallet. In many previous studies, various solutions for the PLP have been suggested in the context of logistics and shipment delivery systems. In this paper, a novel two-phase approach is presented by utilizing a number of Machine Learning (ML) models to tackle the PLP. The dataset utilized in this study was obtained from the DHL supply chain system. According to the training and testing of various ML models, our results show that a very high (>85%) Pallet Utilization Volume (PUV) was obtained, and an accuracy of >89% was determined to predict an accurate loading arrangement of boxes on a suitable pallet. Furthermore, a comprehensive analysis of all the results on the basis of a comparison of several ML models is provided in order to show the efficacy of the proposed methodology.

Complexity Constraint in the Distributor’s Pallet Loading Problem

This paper presents a study on the complexity of cargo arrangements in the pallet loading problem. Due to the diversity of perspectives that have been presented in the literature, complexity is one of the least studied practical constraints. In this work, we aim to refine and propose a new set of metrics to measure the complexity of an arrangement of cargo in a pallet. The parameters are validated using statistical methods, such as principal component analysis and multiple linear regression, using data retrieved from the company logistics. Our tests show that the number of boxes was the main variable responsible for explaining complexity in the pallet loading problem.

Solving a Real-Life Distributor’s Pallet Loading Problem

We consider the distributor’s pallet loading problem where a set of different boxes are packed on the smallest number of pallets by satisfying a given set of constraints. In particular, we refer to a real-life environment where each pallet is loaded with a set of layers made of boxes, and both a stability constraint and a compression constraint must be respected. The stability requirement imposes the following: (a) to load at level k+1 a layer with total area (i.e., the sum of the bottom faces’ area of the boxes present in the layer) not exceeding α times the area of the layer of level k (where α≥1), and (b) to limit with a given threshold the difference between the highest and the lowest box of a layer. The compression constraint defines the maximum weight that each layer k can sustain; hence, the total weight of the layers loaded over k must not exceed that value. Some stability and compression constraints are considered in other works, but to our knowledge, none are defined as faced in a real-life problem. We present a matheuristic approach which works in two phases. In the first, a number of layers are defined using classical 2D bin packing algorithms, applied to a smart selection of boxes. In the second phase, the layers are packed on the minimum number of pallets by means of a specialized MILP model solved with Gurobi. Computational experiments on real-life instances are used to assess the effectiveness of the algorithm.

Sequencing of Robot Packing

In the paper the problem of an automatic pallet loading with the usage of a robot is considered. In the logistic processes of trade business commodities are distributed from stores to retailers on pallets. In the paper the methods of pallet loading are analyzed in terms of the robot packing abilities. In order to put an item in a given place in a partially loaded pallet, robot needs to have free access to this place, so it cannot be blocked. A graph model is proposed to represent the relative positions of items on pallets and a method for sequencing of robot packing operations is formulated. It is also shown that not all patterns of pallet packing can be realized by a robot.

Improved layout structure with complexity measures for the Manufacturer’s Pallet Loading Problem (MPLP] using a Block approach

Purpose: The purpose of this paper is to study the Manufacturers pallet-loading problem (MPLP), by loading identical small boxes onto a rectangle pallet to maximise the pallet utilization percentage while reducing the Complexity of loading.Design/methodology/approach: In this research a Block approach is proposed using a Mixed integer linear programming (MILP) model that generates layouts of an improved structure, which is very effective due to its properties in grouping boxes in a certain orientation along the X and Y axis. Also, a novel complexity index is introduced to compare the complexity for different pallet loading, which have the same pallet size but different box arrangements.Findings: The proposed algorithm has been tested against available data-sets in literature and the complexity measure and graphical layout results clearly demonstrate the superiority of the proposed approach compared with literature Manufacturers pallet-loading problem layouts.Originality/value: This study aids real life manufactures operations when less complex operations are essential to reduce the complexity of pallet loading.