Control systems and optimization methods for industrial logistics

Industry 4.0, is the well-known term used to represent the fourth industrial revolution, characterized by the integration of digital technologies, automation, and data-driven decision making into manufacturing and industrial processes. An important aspect, on which both researchers and companies are investigating, is the practical implementation of Industry 4.0 in logistics, considering case studies and best practices from leading companies. As a matter of fact, this doctoral thesis improve some of the most time-consuming and expansive operations in logistics by using the most promising control and optimization techniques. The thesis begins by providing a comprehensive overview of the Industry 4.0 framework and discusses the potential benefits of adopting Industry 4.0 principles (i.e., improved efficiency, reduced costs, and enhanced flexibility) in the logistic sector. Then, after the analysis of the main classification used for the logistic applications, the work is developed following two different functional contexts, that are the internal and the external logistics, applied to several application operational scenarios. In particular, for the first part, the two main problems tackled are the ones related to automated storage systems (i.e., systems designed to automate the process of storing and retrieving goods or materials within a warehouse or storage environment) that are the development of the automated bin packing algorithm and the optimization of the design of a particular kind of automated warehouse named Vertical Lift Module warehouse. On the other hand, the addressed in the second part are related to the management of the delivery planning and online replanning operations: starting with the enhancement of the cargo inside the container (i.e., the container loading problem), to the optimization of the vehicles routing both offline and in real-time, and finally with the design of a control systems for the application of drones in the last mile delivery of items. For each problem, after a deep analysis of the related state-of-the-art literature for the setting of the benchmarks to overcome and the choosing of the best resolution method, the related work has been developed also taking into account the company’s needs so as to formulate the most complete set of business rules, bridging the gap between companies and academia and satisfying the main requirements of innovations requested by the principles of Industry 4.0. Each problem is thus studied, formalized, and tested taking both the academics’ and companies’ points of view so as to provide the most complete solution possible. After the examination of the previous issues, the thesis is concluded by presenting a future outlook for logistics in the Industry 4.0 era. It highlights the importance of adaptability and continuous innovation to thrive in this digitally driven landscape. Overall,it is worth mentioning that this research contributes valuable insights for academics and industry professionals, aiming to navigate the transformation of logistics and supply chain management in the age of Industry 4.0 and has been rewarded of several prizes and publications international distinguished conferences, and journal articles.