Picking system

Abstract

The present invention realizes a picking system capable of improving the efficiency of picking work. The control system executes a batch generation process for aggregating a set number of order information (In) and setting a picking job corresponding to the aggregated order information (In) as one batch job. In the batch generation process, the control system gathers order information (In) so that the number of target batch jobs can be set to be less than or equal to the total number of available stock-out in a case where the number of target batch jobs can be set to be less than or equal to the total number of available stock-out, and gathers order information (In) so that the number of target batch jobs cannot be set to be less than or equal to the total number of available stock-out. And executing a total number-of-ex-warehouse increase process for increasing the total number of ex-warehouse.

Description

Technical Field

[0001] The present invention relates to a picking system, comprising: an automatic warehouse for storing a plurality of carriers each carrying a plurality of articles; a plurality of work areas for performing picking operations, wherein the picking operations are to take out the articles of the type and quantity specified by the order information from the carriers that have been shipped out of the automatic warehouse based on order information that specifies the type and quantity of the articles required for each shipping destination; a conveying system for conveying the carriers between the automatic warehouse and the plurality of work areas; and a control system for controlling the automatic warehouse and the conveying system. Background Art

[0002] In a picking system used in a logistics center, etc., a carrier carrying articles of the type specified in order information is transported from an automatic warehouse to a work area. Then, a picking operation of taking out articles of the type and quantity specified in the order information is performed in the work area. A plurality of picking operations generated as tasks in the picking system are assigned to each of a plurality of work areas. An example of such a picking system is disclosed in Japanese Patent Application Laid-Open No. 2015-199562.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2015-199562.

[0004] However, there are many types of items stored in the automatic warehouse of the picking system, and the demand (such as the frequency and quantity of shipment) varies according to the type of item. Inventory management in the automatic warehouse is usually carried out according to demand, but the demand for items can change with changes in the market environment. For example, sometimes, if the demand exceeds the originally expected demand, the supply of items from the automatic warehouse to the work area will stagnate, and the picking operation cannot be carried out smoothly in the work area. Summary of the invention

[0005] In view of the above-mentioned actual situation, it is desired to realize a picking system which can improve the efficiency of picking work.

[0006] A picking system comprising:

[0007] An automatic warehouse storing a plurality of carriers each carrying a plurality of articles;

[0008] A plurality of work areas for performing picking operations, wherein the picking operations are to take out the articles of the type and quantity specified by the order information from the carriers that have been taken out of the automatic warehouse based on the order information that specifies the type and quantity of the articles required for each shipping destination;

[0009] A conveying system for conveying the carrier between the automatic warehouse and the plurality of working areas;

[0010] A control system controls the automatic warehouse and the conveying system, wherein:

[0011] The control system is configured to execute batch generation processing, job allocation processing, and transport processing.

[0012] The batch generation process aggregates a set number of the order information and treats the picking operations corresponding to the aggregated order information as a batch operation.

[0013] The job allocation process allocates each of the plurality of batch jobs generated by the batch generation process to any one of the plurality of job areas.

[0014] The transport process transports the carrier required for the batch work assigned by the work assignment process to each of the plurality of work areas,

[0015] Each of the plurality of categories is set as an object category, the carrier carrying the articles of the object category is set as an object carrier, the total number of the object carriers that can be shipped out of the automatic warehouse is set as the total number of shipments that can be shipped out, and the number of batch operations that include the articles of the object category in the objects of the picking operation is set as the number of object batch operations,

[0016] The control system, in the batch generation process,

[0017] When the number of target batch jobs can be set to be less than the total number that can be shipped out, the order information is aggregated so that the number of target batch jobs is set to be less than the total number that can be shipped out,

[0018] When the target batch job number cannot be set to be less than the total number that can be shipped, a total number that can be shipped increasing process is performed to increase the total number that can be shipped.

[0019] Effects of the Invention

[0020] According to this configuration, in the batch generation process, when the number of batch operations that include the object type of articles in the object of the picking operation, that is, the number of object batch operations, can be set to less than the total number of items that can be shipped, the order information of the items including the object type is collected in such a manner that the number of object batch operations is set to less than the total number of items that can be shipped. Thus, it is possible to avoid the number of object carriers being insufficient relative to the number of work areas where the picking operation on the object items is performed. Therefore, it is possible to suppress the occurrence of job waiting for the object carriers required for the picking operation waiting in the work area. In addition, according to this configuration, in the batch generation process, when the number of batch operations that include the object type of articles in the object of the picking operation, that is, the number of object batch operations, cannot be set to less than the total number of items that can be shipped, the total number of items that can be shipped is increased. Thus, since the total number of items that can be shipped can be increased according to the number of work areas where the picking operation on the object items is performed, it is possible to avoid the number of object carriers being insufficient relative to the number of work areas where the picking operation on the object items is performed. Therefore, even in this case, it is possible to suppress the occurrence of job waiting. As described above, according to this configuration, the efficiency of the picking operation can be improved.

[0021] Further features and advantages of the technology of the present disclosure will become more apparent from the following description of exemplary and non-limiting embodiments described with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a floor plan of the picking system.

[0023] Figure 2 It is the control block diagram of the picking system.

[0024] Figure 3 This is a diagram illustrating picking operations.

[0025] Figure 4 This is a diagram illustrating batch operations.

[0026] Figure 5 This is a diagram showing an example of the number of orders for each type of item.

[0027] Figure 6 This is a diagram for explaining the calculation of the repeated risk index.

[0028] Figure 7 This is a diagram to explain the process of increasing the total number of shipments that can be made. DETAILED DESCRIPTION

[0029] Hereinafter, embodiments of the picking system will be described with reference to the drawings.

[0030] like Figure 1 to Figure 3As shown, the picking system 100 comprises: an automatic warehouse 1 for storing a plurality of carriers 5 each carrying a plurality of articles W; a plurality of work areas 2 for performing picking operations, wherein the picking operations are based on order information In that specifies the types and quantities of articles W required for each shipping destination, and the articles W of the type and quantity specified by the order information In are taken out from the carriers 5 that have been shipped out of the automatic warehouse 1; a conveying system T for conveying the carriers 5 between the automatic warehouse 1 and the plurality of work areas 2; and a control system 3 for controlling the automatic warehouse 1 and the conveying system T.

[0031] Articles W include industrial products, daily necessities, foods, etc. In addition, finished products or semi-finished products may also be included. Articles W are stored in the automatic warehouse 1 and transported to various places by the transport system T while being placed on the carrier 5.

[0032] The carrier 5 includes a container and a tray. In addition, the container includes a folding container and a corrugated cardboard box. In this embodiment, the carrier 5 is composed of a storage container for pre-storing in the automatic warehouse 1 (see Figure 3 ). In this example, a single type of article W is placed on the carrier 5. However, a plurality of types of articles W may be placed on the carrier 5.

[0033] Although detailed illustrations are omitted, the automatic warehouse 1 includes a storage rack for storing the carrier 5 and an in-rack conveying device for conveying the carrier 5 in the automatic warehouse 1. Examples of the in-rack conveying device include a stacker crane, a lift, a conveying trolley arranged on each layer of the storage rack, a conveyor, and the like. The in-rack conveying device constitutes a part of the conveying system T. In the present embodiment, the picking system 100 includes a plurality of such automatic warehouses 1. In addition, in a case where the automatic warehouse 1 includes a conveyor as the in-rack conveying device, the carrier 5 may be stored on the conveyor. In this case, it is also possible to have a configuration without a stacker crane and a conveying trolley.

[0034] In the present embodiment, the conveying system T includes a conveyor Ta. The conveying path of the carrier 5 based on the conveyor Ta is formed in a manner connecting a plurality of automatic warehouses 1 and a plurality of work areas 2. The carrier 5 that has been taken out of one of the plurality of automatic warehouses 1 is conveyed to one of the plurality of work areas 2 through the conveying path of the conveyor Ta. The carrier 5 from which the required articles W are taken out through the picking operation in the work area 2 is conveyed to one of the plurality of automatic warehouses 1 through the conveying path of the conveyor Ta and stored. As a substitute for the conveyor Ta, or in addition to the conveyor Ta, the conveying system T may also include other types of conveying devices such as unmanned transport vehicles. In addition, as described above, the conveying system T includes an in-rack conveying device that conveys the carrier 5 in the automatic warehouse 1.

[0035] In this embodiment, the transport system T includes a first transport path T1 for transporting the carriers 5 between the automated warehouse 1 and the plurality of work areas 2 , and also includes a second transport path T2 for transporting the carriers 5 between the plurality of work areas 2 .

[0036] The second transport path T2 is a path not connected to each automated warehouse 1. In this example, the second transport path T2 is a path connecting only a plurality of work areas 2. As described later, the second transport path T2 is a path used for direct transport processing without passing through the automated warehouse 1.

[0037] like Figure 2 As shown, the control system 3 is configured to control the automatic warehouse 1, the work area 2, and the conveyor system T based on the order information In. In addition, the control system 3 also controls the work instruction output device (monitor, etc.) arranged in the work area 2, the picking robot, and the like.

[0038] The order information In is information that specifies the type and quantity of the article W required for each shipping destination. The order information In is information generated based on the customer's needs and is stored in the server 4. The control system 3 obtains the order information In from the server 4.

[0039] The control system 3 is configured to perform inventory management of articles W in the automated warehouse 1 . The control system 3 is configured to manage at least the types and quantities of articles W placed on each of the placing bodies 5 stored in the automated warehouse 1 .

[0040] The control system 3 selects multiple or single carriers 5 required for picking work in each work area 2 based on the order information In, and uses the conveying system T to convey the selected carriers 5 to each work area 2. The carriers 5 are conveyed from the automated warehouse 1 to the work area 2 using the first conveying path T1 described above.

[0041] The control system 3 can be configured by a plurality of hardware or a plurality of software. The control system 3 includes, for example, a processor such as a microcomputer, a peripheral circuit such as a memory, etc. And each function is realized by the cooperation of these hardware and a program executed on the processor such as a computer.

[0042] Next, the picking operation performed in the operation area 2 will be described.

[0043] like Figure 3 As shown, the picking operation is performed based on the order information In. In the picking operation, multiple or single items W specified in the order information In are collected. For example, the order information In is generated for each shipping destination. Therefore, the picking operation can also be called an operation of collecting the items W required for each shipping destination.

[0044] Multiple or a single carrier 5 carrying articles W of the type and quantity specified by the order information In is transported to a specific work area 2 , and during the picking operation, the articles W related to the order information In are taken out and put into a shipping container 6 .

[0045] When all articles W placed on the carrier 5 are taken out by the picking operation, the carrier 5 is empty. In the present embodiment, an empty carrier holding unit 20 for holding the empty carriers 5 generated by the picking operation is provided in the work area 2. Thus, the empty carriers 5 can be stored in advance in the work area 2. In the case where the carrier 5 is formed using a folding container, if a plurality of carriers 5 are stacked in a folded state, space efficiency is achieved. As described later, in the present example, the empty carriers 5 stored in the work area 2 are used in the carrier splitting operation.

[0046] exist Figure 3 In the example shown, three items W of type A (hereinafter, sometimes referred to as "items A"), two items W of type B (hereinafter, sometimes referred to as "items B"), and one item W of type C (hereinafter, sometimes referred to as "item C") are specified through the order information In. In this example, each carrier 5 is configured to carry a single type of item W, and a carrier 5 carrying at least three items A, a carrier 5 carrying at least two items B, and a carrier 5 carrying at least one item C are transported to the work area 2. And, in the picking operation in the work area 2, three items A, two items B, and one item C are collected in the shipping container 6. In addition, the picking operation can be performed by an operator or by a picking robot or the like in an unmanned environment. Alternatively, it can be performed by both the operator and the picking robot.

[0047] exist Figure 3 In the example shown in FIG. 1 , the carrier 5 for conveying the article C carries the same number of articles C (one article C in the example shown in the figure) as the number specified in the order information In. Therefore, when the carrier 5 is subjected to the picking operation, the carrier 5 is empty and is held in the empty carrier holding unit 20.

[0048] like Figure 4 As shown, the control system 3 (refer to Figure 2 ) is configured to perform the following processing: batch generation processing, aggregating a set number of order information In, and setting the picking operation corresponding to the aggregated order information In as a batch operation; job allocation processing, allocating each of the multiple batch operations generated by the batch generation processing to one of the multiple work areas 2; and transport processing, transporting the carrier 5 required for the batch operation allocated by the job allocation processing to each of the multiple work areas 2.

[0049] The batch operation includes picking operations related to a set number of order information In. That is, the batch operation includes a set number of picking operations. In the present embodiment, the "set number" is the maximum number of picking operations that can be included in one batch operation. In this example, the set number is set to 4. That is, in this case, the number of picking operations that can be included in one batch operation is set to 1 to 4. However, the set number can also be a number other than "4", for example, it can also be set to "1". In this way, in the present embodiment, the set number can be set to a fixed value or a value that changes according to the situation.

[0050] exist Figure 4 In the example shown, four batch jobs are illustrated. Each of the four batch jobs includes four picking jobs. Each of the four batch jobs is assigned to one of the four work areas 2 by the job assignment process. However, as described above, the number of picking jobs included in one batch job does not exceed the set number, and in this example, it can also be 1 to 3.

[0051] Among them, the types of articles W stored in the automatic warehouse 1 of the picking system 100 are various, and the demands are also various according to the types of articles W.

[0052] For example Figure 5 As shown, it is assumed that the types of items W are A to Z. The right column of the table shows the number of orders Na for each type of item W. The number of orders Na indicates the number of specific types of items W related to the order information In that should be processed within a unit period. In the example shown in the figure, type A is included in each of the 200 order information In. In other words, in the picking operation related to each of the 200 order information In, items W of type A are required. For types X, Y, and Z, the number of orders Na is relatively small, and the number of orders Na are "6", "5", and "4", respectively.

[0053] In the picking system 100, inventory management is performed in the automatic warehouse 1. In this inventory management, the inventory number of the high-demand type of articles W with a tendency of a large number of orders Na (i.e., the number of articles W stored in advance in the automatic warehouse 1) is increased, and the inventory number of the low-demand type of articles W with a tendency of a small number of orders Na is reduced. As a result, it is easy to improve the storage efficiency of the articles W in the automatic warehouse 1.

[0054] Here, each of a plurality of categories is set as an object category, a carrier 5 carrying an article W of the object category is set as an object carrier 5, the total number of object carriers 5 that can be shipped from the automatic warehouse 1 is set as the total number of shipments Nb, and the number of batch operations that include articles W of the object category in the objects of the picking operation is set as the number of object batch operations Nc. The total number of shipments Nb is, for example, the total number of object carriers 5 currently stored in the automatic warehouse 1. The number of object batch operations Nc is, for example, the number of batch operations required to process all orders for articles W of the object category. In addition, the "object category" refers to a part or all of the categories that are the objects of the batch generation process and the increase process of the total number of shipments described later among all the categories processed by the picking system 100.

[0055] Figure 6 It is a diagram showing the total number Nb that can be shipped out of the warehouse, the number of target batch operations Nc, and the duplication risk index Nd (described later) for each type of article W, especially each type X, Y, and Z with a relatively small number of orders Na. In addition, in the present embodiment, since the set number is "4", one batch operation includes four picking operations (order information In). The number of target batch operations Nc is the value obtained by dividing the number of orders Na by the set number ("4" in this example). In the case where the divided value includes a number after the decimal point, in order to ensure the number of batch operations required to process all orders of the specified object type of article W, the divided value is processed with the decimal point, and the value obtained by rounding the number after the decimal point is obtained. In the case where one batch operation is performed in one operation area 2, the above-mentioned number of target batch operations Nc can also be said to be the number of operation areas 2 where batch operations are performed.

[0056] As described above, the inventory quantity of the item W of the type with low demand, which tends to have a relatively small number of orders Na, is small. Figure 6 In the example shown, the total number Nb of object carriers 5 carrying items W of type X that can be taken out of the warehouse is "2", the total number Nb of object carriers 5 carrying items W of type Y that can be taken out of the warehouse is "1", and the total number Nb of object carriers 5 carrying items W of type Z that can be taken out of the warehouse is "1".

[0057] The number of orders Na for items W of type X is specified as "6". The number of target batch operations Nc, that is, the number of batch operations required to process 6 orders, is the value "2" obtained by dividing the number of orders Na "6" by the value of the set number "4" (1.5) and rounding the decimal point. That is, in this embodiment where the set number is "4", two work areas 2 are required to process 6 orders at the same time. Among the items W of type X, since the total number Nb that can be shipped out is "2", each of the two work areas 2 can be provided with a carrier 5 carrying items W of type X.

[0058] The number of orders Na for items W of type Y is specified to be "5". The number of target batch operations Nc, that is, the number of batch operations required to process 5 orders, is the value "2" obtained by rounding the number of orders Na "5" divided by the value of the set number "4" (1.25). That is, in this embodiment where the set number is "4", two work areas 2 are required to process 5 orders at the same time. Among the items W of type Y, since the total number Nb that can be shipped out is "1", it is impossible to provide a carrier 5 carrying items W of type Y to each of the two work areas 2. Therefore, one of the two work areas 2 will have a waiting operation for the target carrier 5 (here, the carrier 5 carrying items W of type Y) required for the picking operation.

[0059] The number of orders Na for the items W of category Z is specified to be "4". The number of target batch operations Nc, that is, the number of batch operations required to process 4 orders, is "1" obtained by dividing the number of orders Na "4" by the set number "4". That is, in this embodiment where the set number is "4", one work area 2 is required to process 4 orders at the same time. Among the items W of category Z, since the total number Nb that can be shipped out is "1", one work area 2 can be provided with a carrier 5 carrying the items W of category Z.

[0060] As described above, in this example, for articles W of type Y, the number of target placement bodies 5 is insufficient for the number of work areas 2 where picking work is performed on the articles W (a state where work waiting may occur).

[0061] The control system 3 is configured to change the number of aggregated order information In (hereinafter referred to as "order aggregate quantity") within a range not exceeding a set number to increase or decrease the number of target batch operations Nc. As shown in the following formula (1), the number of target batch operations Nc is calculated by dividing the number of orders Na by the order aggregate quantity.

[0062] Number of target batch jobs Nc = number of orders Na / total number of orders... (1)

[0063] ※The total order quantity is the value below the set quantity

[0064] Therefore, the larger the order aggregate quantity is, the smaller the target batch number Nc is, and the smaller the order aggregate quantity is, the larger the target batch number Nc is. The control system 3 can set an appropriate target batch number Nc relative to the total number Nb that can be shipped by controlling the increase or decrease of the target batch number Nc.

[0065] In the batch generation process, when the control system 3 can set the target batch operation number Nc to be less than the total number Nb that can be shipped, the order information In is aggregated so that the target batch operation number Nc is less than the total number Nb that can be shipped. In other words, the control system 3 sets the order aggregate quantity so that the target batch operation number Nc is less than the total number Nb that can be shipped. Thus, it is possible to suppress the occurrence of job waiting in the work area 2. In addition, the case where the target batch operation number Nc can be set to be less than the total number Nb that can be shipped refers to the case where the target batch operation number Nc can be set to be less than the total number Nb that can be shipped by increasing the order aggregate quantity by the limit of the set number and reducing the target batch operation number Nc.

[0066] In the batch generation process, when the control system 3 cannot set the target batch operation number Nc to be less than the total number Nb that can be shipped out, the total number Nb that can be shipped out is increased. That is, by setting the order aggregation number to the set number of the maximum number that can aggregate the order information In, even when the target batch operation number Nc is set to the minimum, when the target batch operation number Nc exceeds the total number Nb that can be shipped out, the control system 3 performs the total number increase process that can be shipped out. For example, in this example, for the items W of category Y, the minimum target batch operation number Nc that can be set for 5 orders is "2", which is greater than the total number Nb that can be shipped out (here "1"). In this case, as described above, the number of target carriers 5 that can be provided is insufficient relative to the number of work areas 2 for picking the items W of category Y, and a job wait occurs.

[0067] In this embodiment, the control system 3 performs index calculation processing for calculating the duplication risk index Nd for all categories, and the duplication risk index Nd indicates the possibility that the number of target carriers 5 is insufficient relative to the work area 2 for picking the articles W of the target category. In addition, the category whose duplication risk index Nd is lower than the predetermined judgment threshold is set as the duplication risk category, and the control system 3 performs batch generation processing with the order information In specifying the duplication risk category as the object, and at the same time, performs the processing of increasing the total number of items that can be shipped out with the target carrier 5 carrying the articles W of the duplication risk category as the object.

[0068] The duplication risk index Nd is calculated by dividing the total number of items that can be shipped out Nb by the number of target batch operations Nc. In this example, the determination threshold is "1.0".

[0069] exist Figure 6In the example shown, for category Y, the duplication risk index Nd is "0.5", which is lower than the determination threshold. Therefore, category Y is a duplication risk category. The control system 3 performs the total number of available warehouse increase processing on the target carrier 5 carrying the articles W of the duplication risk category, and can provide a suitable number of target carriers 5 relative to the target batch operation number Nc.

[0070] In addition, in the present embodiment, when the control system 3 cannot set the target batch operation number Nc to be less than the total number Nb that can be shipped in the batch generation process, the control system 3 performs the processing of increasing the total number Nb that can be shipped after aggregating the order information In in such a way as to minimize the target batch operation number Nc. Thus, even when the processing of increasing the total number Nb that can be shipped is performed, the degree of increase in the total number Nb that can be shipped can be suppressed to a small extent.

[0071] like Figure 7 As shown, in the present embodiment, the total number of items that can be shipped out increases includes a carrier dividing operation of dividing a plurality of articles W of a target type placed on one target carrier 5 and placing them on a plurality of carriers 5 .

[0072] In this embodiment, the carrier separation operation is performed in one of the multiple work areas 2. The control system 3 specifies one of the multiple work areas 2 and issues instructions to the operator or the picking robot that performs the operation in the specified work area 2. For example, the control system 3 uses the operation instruction output device (monitor, etc.) set in the work area 2 to instruct the operator. For the picking robot, an instruction signal is sent to the control device that controls the picking robot.

[0073] As described above, in the target operation area 2, the empty carriers 5 generated by the picking operation are held by the empty carrier holding unit 20. In the carrier separation operation, a plurality of articles W of the target type placed on the target carrier 5 are dispersed on the empty carriers 5 held in the empty carrier holding unit 20.

[0074] exist Figure 7 In the example shown, in addition to the target work area 2 where the picking operation is performed on the articles W of the type Y, which is the duplicate risk type, there is another work area 2 where the picking operation should be performed on the articles W of the type Y. In the target work area 2 where the target carrier 5 on which the articles W of the type Y are placed is provided, the carrier splitting operation is performed, and a part of the plurality of articles W placed on the target carrier 5 is transferred to the empty carrier 5 held in the target work area 2. As a result, the number of carriers 5 on which the articles W of the type Y whose total number Nb that can be shipped out is "1" is increased to two.

[0075] In the present embodiment, after the carrier splitting operation is completed in the target operation area 2, the control system 3 controls the conveying system T to use the second conveying path T2 to convey at least one of the carriers 5 carrying articles W of the target type to an operation area 2 for batch operation including articles W of the target type among the objects for picking operation other than the target operation area 2. The control system 3 conveys the carriers 5 generated by the carrier splitting operation along the second conveying path T2 by performing a direct conveying process of conveying the carriers 5 between different operation areas 2 without passing through the automatic warehouse 1.

[0076] exist Figure 7 In the illustrated example, one of the two carriers 5 on which articles W of the type Y are placed is transported from the target work area 2 to the other work area 2 via the second transport path T2.

[0077] In the present embodiment, in the carrier dividing operation, a required number of articles W of a target type in another work area 2 other than the target work area 2 are transferred to the carrier 5 .

[0078] exist Figure 7 In the example shown, in another operation area 2 other than the target operation area 2 in which the picking operation for the articles W of the category Y is performed, two articles W of the category Y are specified by the order information In. That is, the required number of articles W of the category Y in the other operation area 2 is "2". Therefore, in the carrier separation operation performed in the target operation area 2, two articles W are transferred from the target carrier 5 carrying 10 articles W of the category Y to the empty carrier 5. The carrier 5 carrying the two articles W of the category Y is transported from the target operation area 2 to the other operation area 2 via the second transport path T2. With this configuration, the picking operation for the articles W of the category Y can be performed simultaneously in both the target operation area 2 and the other operation area 2.

[0079] In the present embodiment, in the target operation area 2, after the carrier separation operation is performed, the picking operation of the articles W of the target type is performed. Figure 7 In the example shown, eight articles W placed on the target placing body 5 after the placing body separation operation are used to perform the picking operation in the target operation area 2. This allows the articles W of the target type to be provided to the other operation areas 2 at an early stage.

[0080] In the picking system 100 of the present disclosure, the algorithm described above is used to aggregate multiple order information In of at least one item W of a duplicate risk category into one batch. Order information In of items W of categories other than the duplicate risk category may also be aggregated into one batch using another algorithm, such as one based on the shipping frequency.

[0081] [Other implementation methods]

[0082] Next, other embodiments will be described.

[0083] (1) In the above-mentioned embodiment, an example is described in which an empty carrier 5 held by the empty carrier holding unit 20 in the target work area 2 where the operation is performed is used in the carrier splitting operation. However, the present invention is not limited to such an example, and the empty carrier 5 used in the carrier splitting operation may be transported to the target work area 2 from a place other than the target work area 2 (for example, an idle space of the automatic warehouse 1, etc.). In this case, in order to perform the carrier splitting operation in the target work area 2, which is one of the work areas 2 for batch operations in which the objects W of the target type are included in the objects of the picking operation, the control system 3 controls the automatic warehouse 1 and the conveying system T to transport the target carrier 5 and the carrier 5 without the object W to the target work area 2.

[0084] (2) In the above-mentioned embodiment, an example of increasing the total number of items that can be taken out of the warehouse Nb by dividing the items of ...

[0085] (3) In the above-mentioned embodiment, an example is described in which a part of the plurality of articles W placed on the target carrier 5 is transferred to the empty carrier 5 held in the target work area 2 in the carrier splitting operation performed in the target work area 2. However, the present invention is not limited to such an example, and the carrier splitting operation may be performed by transferring all the articles W placed on the target carrier W to a plurality of empty carriers 5 in a dispersed manner.

[0086] (4) In the above-mentioned embodiment, an example is described in which the carrier separation operation is performed in one of the plurality of work areas 2. However, the present invention is not limited to such an example, and the carrier separation operation may be performed in an area separate from the work area 2 where the picking operation is performed and dedicated to the carrier separation operation.

[0087] (5) In the above-mentioned embodiment, an example is described in which the carrier segmentation operation is performed in the target operation area 2 and then the picking operation of the target type of articles W is performed. However, the present invention is not limited to this example, and the carrier segmentation operation may be performed using the remaining number of articles W after the picking operation is performed.

[0088] (6) In the above-mentioned embodiment, the control system 3 performs a direct conveying process of conveying the carriers 5 between different work areas 2 without passing through the automatic warehouse 1, and conveys the carriers 5 generated by the carrier cutting operation along the second conveying path T2. However, the control system 3 is not limited to such an example, and the control system 3 may convey the carriers 5 generated by the carrier cutting operation along the first conveying path T1 to another work area 2 in a manner of relaying the automatic warehouse 1.

[0089] (7) In the above-mentioned embodiment, an example in which the determination threshold value of the duplication risk index Nd is "1.0" is described. However, the example is not limited to this, and the determination threshold value may be lower than "1.0". In this case, since the number of target batch operations Nc exceeds the total number of operations that can be shipped out of the warehouse Nb, all target batch operations cannot be performed at the same time, but by performing these target batch operations at different times, all target batch operations can be completed. However, even in this case, the determination threshold value may be "0.5", preferably a value larger than it, so that the time to complete all target batch operations will not be significantly increased. Accordingly, the degree of shortage of the total number of operations that can be shipped out of the warehouse Nb relative to the number of target batch operations Nc can be reduced as much as possible, and it is easy to minimize the time to complete all target batch operations.

[0090] (8) In addition, as long as no contradiction occurs, the configuration disclosed in the above-mentioned embodiment can also be combined with the configuration disclosed in other embodiments. Regarding other configurations, the embodiments disclosed in this specification are merely examples in all aspects. Therefore, various changes can be appropriately made without departing from the scope of the present disclosure.

[0091] [Summary of this embodiment]

[0092] Hereinafter, a summary of this embodiment will be described.

[0093] A picking system comprising:

[0094] An automatic warehouse storing a plurality of carriers each carrying a plurality of articles;

[0095] A plurality of work areas for performing picking operations, wherein the picking operations are based on order information specifying the types and quantities of the items required for each shipping destination, and taking out the items of the types and quantities specified in the order information from the carriers that have been shipped out of the automatic warehouse;

[0096] A conveying system for conveying the carrier between the automatic warehouse and the plurality of working areas;

[0097] A control system controls the automatic warehouse and the conveying system, wherein:

[0098] The control system is configured to execute batch generation processing, job allocation processing, and transport processing.

[0099] The batch generation process aggregates a set number of the order information and treats the picking operations corresponding to the aggregated order information as a batch operation.

[0100] The job allocation process allocates each of the plurality of batch jobs generated by the batch generation process to any one of the plurality of job areas.

[0101] The transport process transports the carrier required for the batch work assigned by the work assignment process to each of the plurality of work areas,

[0102] Each of the plurality of categories is set as an object category, the carrier carrying the articles of the object category is set as an object carrier, the total number of the object carriers that can be shipped out of the automatic warehouse is set as the total number of shipments that can be shipped out, and the number of batch operations that include the articles of the object category in the objects of the picking operation is set as the number of object batch operations,

[0103] The control system, in the batch generation process,

[0104] When the number of target batch jobs can be set to be less than the total number that can be shipped out, the order information is aggregated so that the number of target batch jobs is set to be less than the total number that can be shipped out,

[0105] When the target batch job number cannot be set to be less than the total number that can be shipped, a total number that can be shipped increasing process is performed to increase the total number that can be shipped.

[0106] According to this configuration, in the batch generation process, when the number of batch operations that include the object type of articles in the object of the picking operation, that is, the number of object batch operations, can be set to less than the total number of items that can be shipped, the order information of the items including the object type is collected in such a manner that the number of object batch operations is set to less than the total number of items that can be shipped. Thus, it is possible to avoid the number of object carriers being insufficient relative to the number of work areas where the picking operation on the object items is performed. Therefore, it is possible to suppress the occurrence of job waiting for the object carriers required for the picking operation waiting in the work area. In addition, according to this configuration, in the batch generation process, when the number of batch operations that include the object type of articles in the object of the picking operation, that is, the number of object batch operations, cannot be set to less than the total number of items that can be shipped, the total number of items that can be shipped is increased. Thus, since the total number of items that can be shipped can be increased according to the number of work areas where the picking operation on the object items is performed, it is possible to avoid the number of object carriers being insufficient relative to the number of work areas where the picking operation on the object items is performed. Therefore, even in this case, it is possible to suppress the occurrence of job waiting. As described above, according to this configuration, the efficiency of the picking operation can be improved.

[0107] Preferably, in the batch generation process, when the control system cannot set the target batch job number to less than the total number that can be shipped, the total number that can be shipped increase process is executed after aggregating the order information in a manner that minimizes the target batch job number.

[0108] According to this configuration, since order information is aggregated in the lot generation process so as to minimize the number of target lot jobs, even when the total number of shipment possible increase process is executed, the increase in the total number of shipment possible can be suppressed to a small level.

[0109] Preferably, the processing for increasing the total number of items that can be shipped out includes a carrier splitting operation, wherein the carrier splitting operation is an operation of separating a plurality of the articles of the target type placed on one target carrier and placing them on a plurality of carriers.

[0110] The object operation area is an operation area for the batch operation in which the objects of the picking operation include the items of the object type. In order to perform the carrier splitting operation in the object operation area, the control system controls the automatic warehouse and the conveying system to convey the object carrier and the carrier without the item to the object operation area.

[0111] According to this configuration, by performing the carrier splitting operation, the target article is dispersed to a plurality of carriers, and the number of carriers carrying the target article can be increased. Therefore, even if new target carriers are not added to the automatic warehouse, the total number of items that can be taken out of the warehouse can be increased. In addition, according to this configuration, since the carrier splitting operation can be performed in the work area where the target article is picked, the necessity of transporting the target carrier only for the carrier splitting operation can be reduced, and the necessity of adding new work areas and equipment can be reduced.

[0112] Preferably, the conveying system includes, in addition to a first conveying path for conveying the carrier between the automatic warehouse and the plurality of work areas, a second conveying path for conveying the carrier between the plurality of work areas.

[0113] After completing the carrier separation operation in the object operation area, the control system controls the conveying system to use the second conveying path to convey at least one of the carriers carrying the items of the object type to the operation area for the batch operation containing the items of the object type among the objects for the picking operation other than the object operation area.

[0114] According to this configuration, after the carrier splitting operation is performed, the carrier carrying the target object can be transported to other work areas that need the target object instead of returning it to the automatic warehouse. Therefore, the transport efficiency of the carrier can be improved, and at the same time, it is easy to suppress the occurrence of work waiting in other work areas.

[0115] Preferably, in the carrier dividing operation, a required number of the articles of the target type in another work area other than the target work area are transferred to the carrier transported to the other work area.

[0116] According to this configuration, after the work in another work area other than the target work area is completed, it is possible to prevent the generation of odd-numbered carriers. Therefore, the capacity of the automatic warehouse can be easily compressed, and the work of centralizing the carriers is not required.

[0117] Preferably, the control system performs index calculation processing for calculating a duplicate risk index for all of the types, wherein the duplicate risk index indicates the possibility that the number of the object carriers is insufficient relative to the work area for performing the picking operation of the items of the object type.

[0118] The category whose duplication risk index is lower than a predetermined determination threshold is set as a duplication risk category,

[0119] The control system executes the batch generation process on the order information specifying the duplication risk type, and executes the total number of shipments increase process on the target carrier on which the articles of the duplication risk type are placed.

[0120] According to this configuration, it is possible to aggregate order information that specifies duplicate risk categories, and it is possible to set the number of work areas for picking operations for items of a category that has a smaller total number of items that can be shipped out relative to the number of orders, i.e., items of duplicate risk categories, to less than the total number of items that can be shipped out. In addition, even if it is not possible to set the number to less than the total number of items that can be shipped out, the total number of items that can be shipped out can be increased by executing the total number of items that can be shipped out increase processing. Therefore, in the work area for picking operations for items of duplicate risk categories, the possibility of operation waiting can be reduced.

[0121] Industrial Applicability

[0122] The technology of the present disclosure can be used in a picking system.

[0123] Description of Reference Numerals

[0124] 100: Picking system

[0125] 1: Automatic warehouse

[0126] 2: Operation area

[0127] 3: Control system

[0128] T: Conveying system

[0129] T1: First conveying path

[0130] T2: Second conveying path

[0131] 5: Carrier

[0132] W: Items

[0133] In: Order information

[0134] Nb: total number of items that can be shipped out

[0135] Nc: Number of target batch jobs

[0136] Nd: Repeat risk index

Claims

1. A picking system comprising: An automatic warehouse storing a plurality of carriers each carrying a plurality of articles; A plurality of work areas for performing picking operations, wherein the picking operations are to take out the items of the type and quantity specified in the order information from the carriers that have been shipped out of the automatic warehouse based on order information that specifies the type and quantity of the items required for each shipping destination; A conveying system for conveying the carrier between the automatic warehouse and the plurality of working areas; A control system controls the automatic warehouse and the conveying system, wherein: The control system is configured to execute batch generation processing, job allocation processing, and transport processing. The batch generation process aggregates a set number of the order information and treats the picking operations corresponding to the aggregated order information as a batch operation. The job allocation process allocates each of the plurality of batch jobs generated by the batch generation process to any one of the plurality of job areas. The transport process transports the carrier required for the batch work assigned by the work assignment process to each of the plurality of work areas, Each of the plurality of categories is set as an object category, the carrier carrying the articles of the object category is set as an object carrier, the total number of the object carriers that can be shipped out of the automatic warehouse is set as the total number of shipments that can be shipped out, and the number of batch operations that include the articles of the object category in the objects of the picking operation is set as the number of object batch operations, The control system, in the batch generation process, When the number of target batch jobs can be set to be less than the total number that can be shipped out, the order information is aggregated so that the number of target batch jobs is set to be less than the total number that can be shipped out, When the target batch job number cannot be set to be less than the total number that can be shipped, a total number that can be shipped increasing process is performed to increase the total number that can be shipped.

2. The picking system according to claim 1, wherein: In the batch generation process, if the control system cannot set the target batch job number to less than the total number that can be shipped, the total number that can be shipped is increased after the order information is aggregated so that the target batch job number is minimized.

3. The picking system according to claim 1 or 2, wherein: The processing for increasing the total number of items that can be shipped out includes a carrier splitting operation, wherein the carrier splitting operation is an operation of separating a plurality of the articles of the target type placed on one target carrier and placing them on a plurality of carriers. The object operation area is an operation area for the batch operation in which the objects of the picking operation include the items of the object type. In order to perform the carrier splitting operation in the object operation area, the control system controls the automatic warehouse and the conveying system to convey the object carrier and the carrier without the item to the object operation area.

4. The picking system according to claim 3, wherein: The conveying system includes, in addition to a first conveying path for conveying the carrier between the automatic warehouse and the plurality of work areas, a second conveying path for conveying the carrier between the plurality of work areas. After completing the carrier splitting operation in the object operation area, the control system controls the conveying system to use the second conveying path to convey at least one of the carriers carrying the items of the object type to the operation area other than the object operation area for the batch operation where the objects for the picking operation include the items of the object type.

5. The picking system according to claim 3, wherein: In the carrier separating operation, a required number of the articles of the target type in another work area other than the target work area are transferred to the carrier transported to the other work area.

6. The picking system according to claim 1 or 2, wherein: The control system performs index calculation processing for calculating a duplicate risk index for all the types, wherein the duplicate risk index indicates the possibility that the number of the object carriers is insufficient relative to the work area for the picking operation of the articles of the object type. The category whose duplication risk index is lower than a predetermined determination threshold is set as a duplication risk category, The control system executes the batch generation process with respect to the order information specifying the duplication risk type, and executes the total number of shipments increase process with respect to the target carrier carrying the articles of the duplication risk type.

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