Planning and consolidating shipments from a warehouse

A typical warehouse or distribution centre ships material to various customer locations across the country, using various modes of transportation. Each mode has different constraints on size of shipment, different cost structures and different transportation times. Typically, for a given warehouse there are certain customer locations that receive frequent shipments of material. It is often possible, therefore, for the warehouse to consolidate different orders for the same customer location into a single shipment. The transportation mode and the day of shipment must be chosen such that the consolidated shipment meets the size constraints and arrives within an agreed-upon ‘delivery window’. In preparing a warehouse distribution plan, a planner seeks to achieve transportation economies of scale (by consolidating two or more orders into fewer shipments) while levelling the workload on warehouse resources and ensuring that material arrives at a customer location during the acceptable delivery window. The problem of deciding what shipments to make daily can be formulated as a set partitioning problem with side constraints. This paper describes an heuristic solution approach for this problem. Computational experiments using actual warehouse select activity indicate that, for moderate-size problems, the heuristic produces solutions with transportation costs that are within a few percent of optimal. Larger problems found in practice are generally too large to be solved by optimal algorithms; the heuristic easily handles such problems. The heuristic has been integrated into the transportation planning system of a leading distributor of telecommunications products.