Bi-Objective Job-Shop Scheduling Considering Human Fatigue in Cobotic Order Picking Systems: A Case of an Online Grocer

Increasing online retail has resulted in increased automation in order picking systems, leading to new challenges and opportunities in task scheduling. The job-shop scheduling problem is an optimization problem essential in such systems, but existing JSP literature often overlooks workplace fatigue, which harms employees’ well-being and costs U.S. employers up to €127 billion annually. In this work, we propose fatigue consideration in the job-shop scheduling problem in a cobotic order picking system to mitigate its negative effects. We present a new bi-objective mixed integer nonlinear programming problem formulation that considers worker fatigue and productivity during schedule optimisation. To put the results of simulated optimisation in perspective, we experimentally validate the fatigue model and scheduling results in a real operation. The mathematical model finds solutions that conventional single-objective optimisation cannot, allowing fractional fatigue distribution improvements more than 4x larger than the decrease in productivity they require in 53% of the considered virtual cases. The experiments show that our predictive fatigue model has an average RMSE of 2.20 kcal/min in estimating energy expenditure rates compared to heart rate measurements. It also shows a low correlation, meaning it is unfit for application. On the other hand, fatigue-conscious schedules show no clear benefit regarding measured and perceived fatigue. However, the scheduling model could also use heart rate measurements that do not show these inaccuracies. Our study highlights the need to further develop and validate the mathematical formulation and fatigue model and extend to other human factors and indirect fatigue effects.