A Comparative Study of Bayesian Contextual Bandits for Real-Time Warehouse Sorter Optimization

Efficient sorter diversion control of automated material handling systems (MHS) is critical for optimizing operational efficiency in large-scale warehouse environments. In this study, we use an inbound receiving sorter at a high-volume e-commerce warehouse as our primary use case, where the sorter diversion system relies on cost functions with static weight configurations that fail to adapt to highly dynamic system contexts, such as volume mode, congestion level, equipment physical status, and upstream/downstream dependencies. To address this real-time sorter diversion optimization challenge, we conducted a comparative study of three candidate hybrid machine learning frameworks: Linear Regression with Gradient Descent Optimization (LR+GDO), XGBoost with Bayesian Optimization (XGB+BO), and Bayesian Contextual Bandits (BCB). Model training and evaluation were enabled by leveraging a high-fidelity physics-aware emulator to overcome the cold-start problem and allow a safe transition from offline to online learning. We performed comprehensive evaluations including reward model predictive accuracy, contextual sensitivity, action distribution, and projected reward uplift. Our results demonstrate that while tree-based reward models offer slightly better predictive power, the BCB framework achieved overall higher performance with 2.03% reward uplift over the heuristic baseline. Furthermore, BCB exhibits several superior characteristics, such as its decisive time-optimal policy backed by Bang-Bang control theory, continuous online learning capability, strategic balance between exploration and exploitation, and significantly shorter inference latency. These results demonstrate the potential of the BCB framework for real-time control optimization in large-scale warehouse environments, motivating further investigation toward operational deployment.

Offline Reinforcement Learning for Warehouse SLAM Throughput Control

We present an offline reinforcement learning (RL) framework for optimizing SLAM throughput control in a warehouse fulfillment environment. SLAM (Scan/Label/Apply/Manifest) throughput directly influences system congestion and operational efficiency. Our RL-based control approach dynamically recommends SLAM throughput settings that adaptively balance throughput maximization with downstream stability through intelligent adjustment of throttling behavior. We include a history-informed state representation, action space abstraction for delayed-impact control, and a reward function that captures both upstream and downstream operational metrics. Our approach is algorithm-agnostic, enabling integration of multiple offline RL methods under a unified architecture. We instantiate our framework with three state-of-the-art offline RL algorithms, and trained the models offline using de-identified historical operational logs from a large-scale warehouse. Policy performance is evaluated using a comprehensive multi-method strategy. These include model-free approaches including immediate reward estimation via regression models and long-horizon Fitted Q Evaluation (FQE), as well as model-based Deep Koopman dynamics evaluation. Empirical results reveal that the CQL policy consistently outperforms alternatives, improving system health by 22.97% and reducing average throttling duration by 3.18%. These findings demonstrate the potential of offline RL for safe and scalable warehouse throughput control optimization.

Enhancing Computer Vision Model Generalization in Warehouse Facilities: A Case Study on Anomaly Detection in Vertical Material Handling Systems

Deploying computer vision models in Warehouse Facilities traditionally requires extensive resources for camera mounting, image collection, annotation, training, and deployment - a process often needing repetition in each new environment due to camera mounting constraints and environmental variability. This paper explores an innovative approach to streamline this process by conducting the standard procedure solely in a laboratory setting, focusing on vertical material handling systems and anomaly detection in forks of the systems. Through extensive experimentation, we have found that combining optimal camera placement, strategic image triggering, careful model selection and model ensemble enables effective generalization from laboratory conditions to diverse warehouse facilities environments, potentially transforming warehouse automation implementation by simplifying warehouse facilities deployment to just camera mounting, image collection, and model deployment, thereby saving significant resources and time typically spent on image annotation and model retraining. This is an experimental research study and not a production deployment.