AI system learns to prevent warehouse robot traffic jams, boosting throughput 25%

"Inside a giant autonomous warehouse, hundreds of robots dart down aisles as they collect and distribute items to fulfill a steady stream of customer orders. In this busy environment, even small traffic jams or minor collisions can snowball into massive slowdowns. To avoid such an avalanche of inefficiencies, researchers from MIT and the tech firm Symbotic developed a new method that automatically keeps a fleet of robots moving smoothly.

Their method learns which robots should go first at each moment, based on how congestion is forming, and adapts to prioritize robots that are about to get stuck. In this way, the system can reroute robots in advance to avoid bottlenecks.

The hybrid system utilizes deep reinforcement learning, a powerful artificial intelligence method for solving complex problems, to figure out which robots should be prioritized. Then, a fast and reliable planning algorithm feeds instructions to the robots, enabling them to respond rapidly in constantly changing conditions.

In simulations inspired by actual e-commerce warehouse layouts, this new approach achieved about a 25% gain in throughput over other methods. Importantly, the system can quickly adapt to new environments with different quantities of robots or varied warehouse layouts.

"There are a lot of decision-making problems in manufacturing and logistics where companies rely on algorithms designed by human experts. But we have shown that, with the power of deep reinforcement learning, we can achieve super-human performance. This is a very promising approach, because in these giant warehouses even a 2% or 3% increase in throughput can have a huge impact," says Han Zheng, a graduate student in the Laboratory for Information and Decision Systems (LIDS) at MIT and lead author of a paper on this new approach.

Zheng is joined on the paper by Yining Ma, a LIDS postdoc; Brandon Araki and Jingkai Chen of Symbotic; and senior author Cathy Wu, the Class of 1954 Career Development Associate Professor in Civil and Environmental Engineering (CEE) and the Institute for Data, Systems, and Society (IDSS) at MIT, and a member of LIDS. The research is published in the Journal of Artificial Intelligence Research."