S. Fazi
Please Note
11 records found
1
Optimising Vehicle Routing for Skip Containers
A Waste Collection Case Study with Container Reuse and Stacking using LNS
First, a mixed-integer linear programming (MILP) benchmark model is developed to represent standard skip container operations under simplified assumptions. Second, an extended Large Neighbourhood Search (LNS) metaheuristic algorithm is proposed to incorporate more detailed stacking rules, direct container reuse, and multiple storage and disposal location options. The benchmark and metaheuristic models are evaluated using operational and algorithmic key performance indicators.
The validation experiments showed that the LNS algorithm generated solutions within an average deviation below 3% from the benchmark while requiring substantially shorter runtimes. Furthermore, the results show that exact optimisation becomes less practical as the number of customers increases. Across the larger experiments, vehicle configurations with limited full container capacity consistently performed worst, indicating that a primary operational bottleneck lies in the number of available positions for transporting full containers rather than in stacking height alone. In addition, reuse reduced total operational time and improved productivity mainly through reduced handling time, although the number of vehicles required remained unchanged. These findings show that detailed stacking constraints and direct container reuse can be incorporated successfully into skip container routing models and that these extensions improve the practical relevance of optimisation for chain-lift skip operations.
...
First, a mixed-integer linear programming (MILP) benchmark model is developed to represent standard skip container operations under simplified assumptions. Second, an extended Large Neighbourhood Search (LNS) metaheuristic algorithm is proposed to incorporate more detailed stacking rules, direct container reuse, and multiple storage and disposal location options. The benchmark and metaheuristic models are evaluated using operational and algorithmic key performance indicators.
The validation experiments showed that the LNS algorithm generated solutions within an average deviation below 3% from the benchmark while requiring substantially shorter runtimes. Furthermore, the results show that exact optimisation becomes less practical as the number of customers increases. Across the larger experiments, vehicle configurations with limited full container capacity consistently performed worst, indicating that a primary operational bottleneck lies in the number of available positions for transporting full containers rather than in stacking height alone. In addition, reuse reduced total operational time and improved productivity mainly through reduced handling time, although the number of vehicles required remained unchanged. These findings show that detailed stacking constraints and direct container reuse can be incorporated successfully into skip container routing models and that these extensions improve the practical relevance of optimisation for chain-lift skip operations.
Human vs. machine. Navigating the automation trade-offs
A methodology for evaluating automation level trade-offs in production line design
This research adopts a design science methodology to develop and refine a stepwise evaluation framework for automation trade-offs in production line design. The methodology begins with a thorough documentation of the production context, requirements, and constraints. It then systematically generates low, medium, and high automation scenarios for each production step, considering both cognitive and physical tasks. These scenarios are conceptualized using structured models (IDEF0 diagrams) and layout maps, followed by the development of dynamic models, to quantitatively assess system dynamics, throughput, and bottlenecks. Each scenario is evaluated across the five key factors using both model outcomes and expert review sessions, enabling a holistic comparison. The methodology is validated through a practical test case at Quooker, a company developing a new production line, and refined through feedback from industry experts and academic reviewers.
The final version of the designed automation evaluation methodology provides a structured and comprehensive approach for evaluating automation trade-offs in early stage production line design. Its main strengths include the integration of both quantitative and qualitative assessments, the explicit consideration of five key factors, and the ability to generate actionable insights that broaden perspectives beyond intuitive thinking. Application to the Quooker test case demonstrated that the methodology supports informed, data-driven discussions and enables the identification of balanced automation scenarios. Feedback from industry and academic experts confirmed its practical relevance and alignment with industry needs. However, limitations include the time-intensive nature of dynamic modeling, the dependency on expert input, and challenges in quantifying certain factors at early design stages. Despite these constraints, the methodology offers a robust foundation for making informed automation decisions and structuring early design discussions in manufacturing environment. ...
This research adopts a design science methodology to develop and refine a stepwise evaluation framework for automation trade-offs in production line design. The methodology begins with a thorough documentation of the production context, requirements, and constraints. It then systematically generates low, medium, and high automation scenarios for each production step, considering both cognitive and physical tasks. These scenarios are conceptualized using structured models (IDEF0 diagrams) and layout maps, followed by the development of dynamic models, to quantitatively assess system dynamics, throughput, and bottlenecks. Each scenario is evaluated across the five key factors using both model outcomes and expert review sessions, enabling a holistic comparison. The methodology is validated through a practical test case at Quooker, a company developing a new production line, and refined through feedback from industry experts and academic reviewers.
The final version of the designed automation evaluation methodology provides a structured and comprehensive approach for evaluating automation trade-offs in early stage production line design. Its main strengths include the integration of both quantitative and qualitative assessments, the explicit consideration of five key factors, and the ability to generate actionable insights that broaden perspectives beyond intuitive thinking. Application to the Quooker test case demonstrated that the methodology supports informed, data-driven discussions and enables the identification of balanced automation scenarios. Feedback from industry and academic experts confirmed its practical relevance and alignment with industry needs. However, limitations include the time-intensive nature of dynamic modeling, the dependency on expert input, and challenges in quantifying certain factors at early design stages. Despite these constraints, the methodology offers a robust foundation for making informed automation decisions and structuring early design discussions in manufacturing environment.
Damage-Aware Bin Packing for Online Grocery Delivery
Leveraging Customer Feedback Data to Improve Quality of Service
Therefore, we propose a novel two-part theoretical framework to process historical data of customer damage reports into quantifiable parameters that can be used by a bin packing model. In the first part, we formulate a predictive task and propose a classification machine learning model which provides a probability of damage for the bag, given a set of bag characteristics obtained from customer data. In the second part, we propose to integrate the machine learning component into a bin packing model as a weighted term in its objective function. This integrated model comprises our damage-aware bin packing model.
The proposed methodology was implemented and evaluated through a case study using real data from the daily operations of the online supermarket Picnic. As part of the experiments, we analysed over 60 million articles across 2.2 million deliveries. We started with a comprehensive data analysis to explore the relationships in the data and identify trends. We, then, developed and trained two machine learning variants, a logistic regression and an ensemble extreme gradient boost model (XGBoost) to fulfil the predicting task of bag-damage probability estimation. We applied random undersampling to the training dataset to mitigate the extreme class imbalance (0.41% damage rate). Then, we used the logistic regression model as the ML component and implemented a damage-aware bin packing model. We defined strategic empirical metrics to measure its performance and constructed an evaluation framework using counterfactual analysis on 6000 representative deliveries.
Our findings validate the technical feasibility of integrating customer feedback data into a bin packing algorithm. The damage-aware variant recorded a 14.1% relative reduction in the average probability of damage across all bags of the deliveries tested. On the other hand, extreme class imbalance severely limited the performance of the ML models trained (1% precision score in real operational conditions). As a result, a meaningful review of the economic impact of the model is not possible. The experiments illustrated sensible item movements across the bags tested, measured with some empirical key risk parameters, such as item categories, packaging types, and bag density. The implementation showed a tolerable computational overhead of around 18%, indicating that it is realistic to deploy an efficient model to real operations. ...
Therefore, we propose a novel two-part theoretical framework to process historical data of customer damage reports into quantifiable parameters that can be used by a bin packing model. In the first part, we formulate a predictive task and propose a classification machine learning model which provides a probability of damage for the bag, given a set of bag characteristics obtained from customer data. In the second part, we propose to integrate the machine learning component into a bin packing model as a weighted term in its objective function. This integrated model comprises our damage-aware bin packing model.
The proposed methodology was implemented and evaluated through a case study using real data from the daily operations of the online supermarket Picnic. As part of the experiments, we analysed over 60 million articles across 2.2 million deliveries. We started with a comprehensive data analysis to explore the relationships in the data and identify trends. We, then, developed and trained two machine learning variants, a logistic regression and an ensemble extreme gradient boost model (XGBoost) to fulfil the predicting task of bag-damage probability estimation. We applied random undersampling to the training dataset to mitigate the extreme class imbalance (0.41% damage rate). Then, we used the logistic regression model as the ML component and implemented a damage-aware bin packing model. We defined strategic empirical metrics to measure its performance and constructed an evaluation framework using counterfactual analysis on 6000 representative deliveries.
Our findings validate the technical feasibility of integrating customer feedback data into a bin packing algorithm. The damage-aware variant recorded a 14.1% relative reduction in the average probability of damage across all bags of the deliveries tested. On the other hand, extreme class imbalance severely limited the performance of the ML models trained (1% precision score in real operational conditions). As a result, a meaningful review of the economic impact of the model is not possible. The experiments illustrated sensible item movements across the bags tested, measured with some empirical key risk parameters, such as item categories, packaging types, and bag density. The implementation showed a tolerable computational overhead of around 18%, indicating that it is realistic to deploy an efficient model to real operations.
This research explores the integration of maglev technology into port logistics, focusing on connecting a dry port terminal to seaport terminals, with a direct connection to the berth. Using the Transport System Bögl (TSB) Cargo system as a reference, five different designs were developed for integration. These designs required a redesign of the dry port and terminal yard, as well as the design of the system’s berth connection and connections between all terminals.
Simulation modeling using Siemens Tecnomatix Plant Simulation software evaluated the performance of these designs under various scenarios based on Port of Hamburg demand input data. Results showed that all designs improved median berth times compared to the German benchmark of 18.96 hours, with Design 5 demonstrating the best performance together with Design 2.
Recommendations include continued collaboration with port authorities through simulation case studies, serving as proof of performance for potential integration projects, and exploration of collaboration opportunities with smaller scale ports facing space availability and road access issues. Further research should expand the model to accommodate new export container loading requirements and include all terminals, while studying new algorithms to balance the volumes and requests of all three terminals. This research demonstrates the feasibility of integrating maglev systems into port logistics, challenging the ’status quo’ and opening up new possibilities for improving port operations. Through a systematic approach, this study offers valuable insights for the integration of maglev technology into port logistics, paving the way for future advancements in the field. ...
This research explores the integration of maglev technology into port logistics, focusing on connecting a dry port terminal to seaport terminals, with a direct connection to the berth. Using the Transport System Bögl (TSB) Cargo system as a reference, five different designs were developed for integration. These designs required a redesign of the dry port and terminal yard, as well as the design of the system’s berth connection and connections between all terminals.
Simulation modeling using Siemens Tecnomatix Plant Simulation software evaluated the performance of these designs under various scenarios based on Port of Hamburg demand input data. Results showed that all designs improved median berth times compared to the German benchmark of 18.96 hours, with Design 5 demonstrating the best performance together with Design 2.
Recommendations include continued collaboration with port authorities through simulation case studies, serving as proof of performance for potential integration projects, and exploration of collaboration opportunities with smaller scale ports facing space availability and road access issues. Further research should expand the model to accommodate new export container loading requirements and include all terminals, while studying new algorithms to balance the volumes and requests of all three terminals. This research demonstrates the feasibility of integrating maglev systems into port logistics, challenging the ’status quo’ and opening up new possibilities for improving port operations. Through a systematic approach, this study offers valuable insights for the integration of maglev technology into port logistics, paving the way for future advancements in the field.
Hybrid warehouse optimisation
Improving warehouse performance through buffer allocation and manual picking configuration
The research identifies the key performance metrics for the system, including the number of late totes, average sojourn time, average stack throughput time, and picker productivity. Several factors impacting the system's performance are examined, such as buffer lane selection and group formation strategies, minimum and maximum group sizes, number of workers, pick times, and input data.
Through comprehensive experimentation and simulation modelling, the study reveals that prioritizing the deadline of totes for buffer lane selection and the IPB time for group formation results in the best system performance. The research also suggests that the configuration of the manual process should consider the group size should be adjusted based on the expected workload.
The study identifies the consolidation stations as a significant bottleneck in the system, and repairing them promptly on busy days is essential to maintain performance. The research provides practical implications for Picnic, emphasizing efficient buffer allocation and group formation strategies.
In conclusion, this research offers valuable insights into enhancing the performance of hybrid warehouse systems. Companies like Picnic can improve operational efficiency and customer satisfaction by optimizing buffer allocation, buffer lane selection, and group formation. The findings from this research can serve as a basis for further optimization and decision-making in similar warehouse setups. ...
The research identifies the key performance metrics for the system, including the number of late totes, average sojourn time, average stack throughput time, and picker productivity. Several factors impacting the system's performance are examined, such as buffer lane selection and group formation strategies, minimum and maximum group sizes, number of workers, pick times, and input data.
Through comprehensive experimentation and simulation modelling, the study reveals that prioritizing the deadline of totes for buffer lane selection and the IPB time for group formation results in the best system performance. The research also suggests that the configuration of the manual process should consider the group size should be adjusted based on the expected workload.
The study identifies the consolidation stations as a significant bottleneck in the system, and repairing them promptly on busy days is essential to maintain performance. The research provides practical implications for Picnic, emphasizing efficient buffer allocation and group formation strategies.
In conclusion, this research offers valuable insights into enhancing the performance of hybrid warehouse systems. Companies like Picnic can improve operational efficiency and customer satisfaction by optimizing buffer allocation, buffer lane selection, and group formation. The findings from this research can serve as a basis for further optimization and decision-making in similar warehouse setups.
Network integration with forward and returning product flows
A case study at Quooker
A lift-off investigation of next-generation offshore wind turbine generator components for feedering in the U.S.
Creating understanding in the release stage of a tower segment
In the first thesis of this double degree program, a lift/installation sequence called the direct installation method is deemed to be highly interesting with respect to the logistics and costs. However, this research misses a technical study in order to understand if it is technically reachable to directly install these components. In this offshore engineering thesis, a barge is used as a feeder vessel and tower segments of a 20 MW WTG are chosen as the to-be lifted components. This research focuses on the pre-tension phase before the lift-off. This contains the steps where the crane of the installation vessel is already attached to the tower, pre-tension is building up and the release of the sea-fastening. Here, pre-tension is a percentage of the load that is taken in the crane before the lift-off. This research aims to increase the understanding of whether a tower can be released safely on the floating barge and what can be done in order to realise the idea of a direct installation method.
Frequency, as well as time-domain simulations, are used to investigate the problem. The results show that snap loads occur for pre-tensions up to 10\%. From 30\% and higher, the tower will start toppling. Toppling is initiated due to the inertia of the large tower segment when it is released from its sea-fastening. Toppling the tower is not allowed since this could damage the tower itself, the sea-fastening and/or other components on deck of the feeder. Increasing the limiting wave height is a must in order to make the direct installation method more practicable. This can firstly be done by using more tower segments. Therefore, reducing the size of each segment. Another option is to implement a motion compensation tool that decouples the motions of the feeder and the tower. The third option is to design a seafastening system that reduces the moment after the release, a temporary counteracting toppling system. All in all, can be stated that safely releasing a 20 MW tower segment on a floating barge is highly challenging and more research is required to solve the issues that are found in this research. This is necessary to allow the direct feeder method to be used for future offshore wind installation projects in the U.S. ...
In the first thesis of this double degree program, a lift/installation sequence called the direct installation method is deemed to be highly interesting with respect to the logistics and costs. However, this research misses a technical study in order to understand if it is technically reachable to directly install these components. In this offshore engineering thesis, a barge is used as a feeder vessel and tower segments of a 20 MW WTG are chosen as the to-be lifted components. This research focuses on the pre-tension phase before the lift-off. This contains the steps where the crane of the installation vessel is already attached to the tower, pre-tension is building up and the release of the sea-fastening. Here, pre-tension is a percentage of the load that is taken in the crane before the lift-off. This research aims to increase the understanding of whether a tower can be released safely on the floating barge and what can be done in order to realise the idea of a direct installation method.
Frequency, as well as time-domain simulations, are used to investigate the problem. The results show that snap loads occur for pre-tensions up to 10\%. From 30\% and higher, the tower will start toppling. Toppling is initiated due to the inertia of the large tower segment when it is released from its sea-fastening. Toppling the tower is not allowed since this could damage the tower itself, the sea-fastening and/or other components on deck of the feeder. Increasing the limiting wave height is a must in order to make the direct installation method more practicable. This can firstly be done by using more tower segments. Therefore, reducing the size of each segment. Another option is to implement a motion compensation tool that decouples the motions of the feeder and the tower. The third option is to design a seafastening system that reduces the moment after the release, a temporary counteracting toppling system. All in all, can be stated that safely releasing a 20 MW tower segment on a floating barge is highly challenging and more research is required to solve the issues that are found in this research. This is necessary to allow the direct feeder method to be used for future offshore wind installation projects in the U.S.
Viability of the Dutch Inland Waterway Transport Sector
In The Context Of The Future Navigability Of The Rhine
Currently, Dutch IWT businesses benefit from increased demand for transport capacity during climate change induced periods of low river depth by being able to charge higher prices to shippers, thereby increasing short term profits. This thesis research project concludes that this behaviour is unsustainable due to the disregard for providing price competitive and reliable services to shippers, which will ultimately damage the reputation of the Dutch IWT sector. This can lead to shippers choosing other modes of transport, which will damage the long-term viability of IWT demand.
A lack of evident optimal climate adaptation measures that would better guarantee the long-term viability of an IWT business under any climate scenario is one of the reasons why IWT businesses have thus far been hesitant towards implementing climate adaptation measures. This thesis research project studies the potential of using a robust decision analysis in supporting IWT businesses’ decision-making on climate adaptation measures that could safeguard the long- term viability of the Dutch IWT sector. It conducts a robust decision analysis and then evaluates its potential using feedback from stakeholders of the Dutch IWT sector.
This thesis research project present the results from the robust decision analysis to IWT stakeholders to evaluate how these could impact their decision-making. Stakeholders noted that they believe that the produced influence diagram could be used as a standard communication object to produce a better consensus of how measures influence the long-term viability of IWT demand. Furthermore, stakeholders expressed that the robust decision analysis provided them a better understanding of which measures were able to better guarantee the long-term viability of IWT demand. Results from evaluation interviews with stakeholders therefore provide grounds to believe that robust decision analyses have potential to support IWT businesses’ decision- making on climate adaptation measures that could safeguard the long-term viability of the Dutch IWT sector. ...
Currently, Dutch IWT businesses benefit from increased demand for transport capacity during climate change induced periods of low river depth by being able to charge higher prices to shippers, thereby increasing short term profits. This thesis research project concludes that this behaviour is unsustainable due to the disregard for providing price competitive and reliable services to shippers, which will ultimately damage the reputation of the Dutch IWT sector. This can lead to shippers choosing other modes of transport, which will damage the long-term viability of IWT demand.
A lack of evident optimal climate adaptation measures that would better guarantee the long-term viability of an IWT business under any climate scenario is one of the reasons why IWT businesses have thus far been hesitant towards implementing climate adaptation measures. This thesis research project studies the potential of using a robust decision analysis in supporting IWT businesses’ decision-making on climate adaptation measures that could safeguard the long- term viability of the Dutch IWT sector. It conducts a robust decision analysis and then evaluates its potential using feedback from stakeholders of the Dutch IWT sector.
This thesis research project present the results from the robust decision analysis to IWT stakeholders to evaluate how these could impact their decision-making. Stakeholders noted that they believe that the produced influence diagram could be used as a standard communication object to produce a better consensus of how measures influence the long-term viability of IWT demand. Furthermore, stakeholders expressed that the robust decision analysis provided them a better understanding of which measures were able to better guarantee the long-term viability of IWT demand. Results from evaluation interviews with stakeholders therefore provide grounds to believe that robust decision analyses have potential to support IWT businesses’ decision- making on climate adaptation measures that could safeguard the long-term viability of the Dutch IWT sector.