Tobacco storage and distribution integrated precision collaborative inventory preparation method and system

Abstract

This invention relates to the field of inventory preparation methods, specifically a precise and collaborative inventory preparation method and system integrating tobacco storage and sorting. It is executed collaboratively by a warehouse management system, an automated warehouse monitoring system, and a spare parts warehouse monitoring system. The method includes: performing a first inventory preparation operation during periods without orders, automatically allocating tobacco warehouse space and requesting a fixed quantity for the next sales cycle, thus pre-establishing inventory; and performing a second inventory preparation operation during the sorting process, dynamically selecting product specifications based on the planned sales volume for the next cycle, calculating precise order quantities, and generating outbound tasks with return or precise task markers from the warehouse management system. For return tasks, it guides the automatic return of small cartons; for precise tasks, it stores remaining cigarettes in a multi-level shuttle automated warehouse. This invention achieves full-process coverage from advance inventory preparation without orders to precise inventory preparation with orders, effectively improving operational continuity, reducing manual intervention and material waste, and forming an intelligent, closed-loop collaborative inventory preparation solution.

Description

Technical Field

[0001] This invention relates to the field of inventory preparation methods, specifically a precise and coordinated inventory preparation method and system that integrates tobacco storage and sorting. Background Technology

[0002] In tobacco commercial logistics centers, the integrated storage and sorting system is a key link in realizing automated cigarette warehousing and sorting, and its operational efficiency directly determines the speed and cost of order fulfillment. Traditional integrated storage and sorting systems typically rely on two strategies for replenishment: order-driven replenishment or planned replenishment based on fixed cycles and quantities. However, both of these models have significant shortcomings in dealing with the unique business fluctuations in the tobacco industry, which are measured in sales cycles. Specifically: 1. Poor operational continuity and startup delays: During the intervals between two adjacent sales cycles, i.e., the time window when the current cycle's orders are sorted and the next cycle's order data has not yet been generated, the system is in a "waiting" state due to the lack of clear order instructions, and cannot prepare goods for the next cycle in advance. This causes the sorting line to be unable to start immediately at the beginning of the new cycle, and it must wait for the goods to be prepared before it can start operating, resulting in a waste of valuable operating time and restricting the improvement of overall logistics efficiency.

[0003] 2. Low inventory accuracy, resulting in a large amount of waste: In the process of inventory preparation based on orders or fixed strategies, in order to meet sorting needs, the method of replenishing with full pallets is often adopted. However, sorting tasks usually do not require full pallets of cigarettes, resulting in some cigarettes remaining on the pallets after each replenishment. This not only occupies valuable automated warehouse space that could be used to store full pallets, but also requires additional complex logistics processing procedures such as outbound, unpalletizing, and return of the remaining stock, increasing equipment energy consumption, operation time, and manual intervention costs.

[0004] 3. Unscientific inventory turnover and lack of forward-looking adjustments: The existing system lacks a proactive response mechanism for changes in future demand. Even if the sales plan for the next sales cycle is obtained, the system cannot intelligently compare the planned sales volume with the current real-time sorting consumption. As a result, it cannot identify in advance which product specifications are about to see a decrease or zero in demand, and cannot initiate differentiated and precise replenishment strategies for these product specifications, leading to inventory backlog and waste.

[0005] In existing technologies, such as the flexible cigarette sorting method and system disclosed in CN112061664A, flexible replenishment technology based on order forecasting is disclosed. However, its core is still driven by orders or predicted orders, and it fails to solve the problem of advance operation in the time window without orders. For example, the intelligent warehouse return system and intelligent automated warehouse disclosed in CN219791323U focus on the intelligent return of surplus materials (small inventory), but its focus is on the handling of surplus materials after they are generated. It is a remedial solution after the fact and fails to be combined with accurate order calculation, so it cannot reduce the generation of surplus materials from the source of ordering.

[0006] Therefore, there is an urgent need in this field for a method and system that can achieve intelligent advance stock preparation and can perform accurate demand calculation and collaborative operations based on future sales plans and real-time sorting status. Summary of the Invention

[0007] To address the shortcomings of existing technologies, the purpose of this invention is to provide a precise collaborative inventory preparation method and system for tobacco storage and sorting that enables intelligent advance inventory preparation and allows for accurate demand calculation and collaborative operations based on future sales plans and real-time sorting status.

[0008] The technical solution adopted by this invention to solve its technical problem is: A precise and collaborative inventory preparation method integrating tobacco storage and distribution, the method is executed collaboratively by a warehouse management system, an automated warehouse monitoring system, and a spare parts warehouse monitoring system, and includes the following operations performed sequentially according to the business cycle: The first inventory preparation operation is performed after the sorting work of the current sales cycle is completed and before the order data for the next sales cycle is generated. This operation is used to pre-establish inventory for the next sales cycle and includes the following steps: S101: After the current sales cycle ends and before the order data for the next sales cycle is generated, the spare parts warehouse monitoring system distributes cigarette storage compartments in the spare parts warehouse for the specified cigarette specifications. S102: The spare parts warehouse monitoring system sends a requisition request to the warehouse management system according to a fixed quantity preset for each tobacco warehouse; S103: The warehouse management system responds to the requisition request, generates an outbound task to drive the automated warehouse outbound, and replenishes the cigarette packs into the assigned cigarette warehouse after unpacking. The second inventory replenishment operation is performed during the sorting process of the next sales cycle. It is used for dynamic and accurate replenishment based on the sales plan and includes the following steps: S201: Before sorting begins, the spare parts warehouse monitoring system obtains the planned sales volume for the next sales cycle; S202: During the sorting process, the spare parts warehouse monitoring system executes the following sub-steps: S2021: Product Specification Screening: Compare the planned sales volume for the next sales cycle with the current sorting tasks to determine the product specifications that need to be precisely stocked. S2022: Order Quantity Calculation: Based on the remaining sorting quantity of the flue corresponding to the product specifications that require precise stocking and the current inventory, the precise order quantity is dynamically calculated. S2023: Order Request Initiation: Sends a precise order request with accurate order quantity to the warehouse management system; S203: The warehouse management system responds to precise requisition requests and generates outbound tasks with task tags; S204: Perform the unpacking operation according to the outbound task, and perform the corresponding warehousing or return operation on the unpacked cigarettes and remaining materials.

[0009] As a preferred embodiment, a further technical solution of the present invention is: Preferably, in step S101, the distribution of cigarettes of a specified grade to the cigarette storage compartment in the parts warehouse includes manual or automatic distribution. Manual allocation involves the operator manually associating and binding the specified cigarette specifications with a specific cigarette compartment in the spare parts warehouse through the human-machine interface of the spare parts warehouse monitoring system. Automatic allocation is performed by the spare parts warehouse monitoring system, which executes the following automatic calculation and allocation process: S1011, Data Acquisition: Obtain the planned sales volume of each cigarette specification for the next sales cycle from the associated superior management system; S1012, Calculate the percentage: Based on the planned sales volume, calculate the percentage of each product specification's sales volume in the total planned sales volume; S1013, Calculate the number of warehouses: Multiply the sales percentage of each product specification by the total number of available empty cigarette warehouses in the spare parts warehouse to obtain the theoretical number of cigarette warehouses that each product specification should be allocated. S1014, Execute Allocation: Based on the calculated number of tobacco bins to be allocated to each product specification, the system automatically allocates the corresponding number of specific tobacco bins to each product specification.

[0010] Preferably, the product specification screening in step S2021 specifically involves identifying product specifications that will not be sorted in the next sales cycle, or whose planned sales volume in the next sales cycle is less than the current sorting task volume, as product specifications that require precise stocking.

[0011] Preferably, in step S2022, the precise order quantity is dynamically calculated through the following steps: Parameter acquisition: Obtain the remaining sorting task quantity and real-time inventory quantity of the product specifications that need to be precisely prepared in the spare parts warehouse of the corresponding flue. Basic calculation: Calculate the difference between the remaining sorting task quantity and the real-time inventory quantity; Decision and Output: If the difference is greater than zero, the difference will be output as the precise order quantity; if the difference is less than or equal to zero, the precise order quantity will be output as zero, which indicates that the current inventory of the cigarette warehouse corresponding to the spare parts warehouse can meet or exceed the remaining sorting demand, and no replenishment is required.

[0012] Preferably, in step S203, the task marker includes a return-to-database marker and a precision marker; When the system is not configured with a multi-level shuttle automated warehouse, the warehouse management system generates outbound tasks with a return-to-warehouse marker. When the system is configured with a multi-level shuttle automated warehouse, the warehouse management system generates outbound tasks with precise markings.

[0013] Preferably, when the outbound task has a return-to-warehouse marker, step S204 specifically includes: S2041: The automated warehouse monitoring system controls the transport of the corresponding pallet to the designated manual unpacking port and sends guidance information including product specifications and the number of items to be unpacked to the display terminal of that workstation; S2042: Manual disassembly is performed according to the instructions. The disassembled cigarette packs are scanned and then controlled by the spare parts warehouse monitoring system to be stored in the spare parts warehouse cigarette storage. S2043: The pallet containing the remaining cigarettes after unpacking is called the zero pallet, which is guided by the PLC control system to the full pallet entry port of the automated warehouse. S2044: The automated warehouse monitoring system requests and executes a return-to-warehouse task for the zero disk, and re-stores the zero disk into the automated warehouse.

[0014] Preferably, when the outbound task has a precise tag, step S204 specifically includes: S204a: The spare parts warehouse monitoring system assigns disassembly ports to outbound tasks to perform full disassembly operations; S204b: After the removed cigarette packs are scanned, the spare parts warehouse monitoring system controls the corresponding number of cigarette packs to be stored in the spare parts warehouse cigarette warehouse according to the accurate demand quantity; S204c: The remaining cigarettes after the entire tray is disassembled are transferred to a multi-level shuttle automated warehouse. S204d: The remaining cigarette items are stored in the warehouse by a shuttle monitoring system that is connected to the multi-level shuttle automated warehouse.

[0015] Preferably, the precise order request issued in step S2023 carries precise preparation product specifications, corresponding flue number, precise order quantity, and preparation task type identifier. The warehouse management system generates a unique corresponding outbound task based on the information in the precise order request.

[0016] The present invention also discloses a precise collaborative inventory preparation system for tobacco storage and sorting, to implement a precise collaborative inventory preparation method for tobacco storage and sorting, including a warehouse management system, an automated warehouse monitoring system and a spare parts warehouse monitoring system that are interconnected. The warehouse management system is used to respond to order requests and precise order requests, generate outbound and return tasks, and manage the outbound and return processes of automated warehouses. The automated warehouse monitoring system is used to receive outbound instructions from the warehouse management system, drive the automated warehouse to complete the outbound of whole pallets of cigarettes, control the physical flow of pallets, and execute the return of individual pallets to the warehouse. The spare parts warehouse monitoring system is used to allocate spare parts warehouses and tobacco storage areas for cigarette product specifications, initiate order requests and precise order requests, screen precise spare parts specifications and dynamically calculate precise order quantities, and coordinate and manage the entire stock preparation process.

[0017] Preferably, it also includes a multi-level shuttle automated warehouse and a shuttle monitoring system; The shuttle monitoring system is communicatively connected to the spare parts warehouse monitoring system and the multi-level shuttle automated warehouse, and is used to control the storage operation of the remaining spare parts transmitted to the multi-level shuttle automated warehouse.

[0018] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art: This system achieves a complete upgrade of the tobacco storage and distribution process, moving from passive response to proactive prediction. It breaks through the limitations of traditional order-driven inventory preparation, enabling intelligent allocation of tobacco warehouses and pre-establishment of inventory during the no-order window through the first inventory preparation operation. This eliminates operational delays caused by alternating sales cycles and significantly improves the continuity of logistics operations. Furthermore, by combining the planned sales volume of the next sales cycle with real-time sorting and inventory data, it dynamically selects and precisely prepares inventory specifications and accurately calculates the required quantity, avoiding material waste caused by over-stocking from the source. At the same time, the tobacco warehouse allocation is adaptable to manual or automatic modes, which can flexibly adapt to different business adjustment needs and make the allocation of warehousing resources more scientific.

[0019] Furthermore, this invention relies on the collaborative closed-loop operation of multiple systems such as warehouse management, automated warehouse monitoring, and spare parts warehouse monitoring to achieve intelligent control of the entire inventory preparation process. It also features two differentiated waste material handling schemes based on system configuration: return marking and precise marking. Small pallets can be automatically returned to the automated warehouse, while remaining cigarette packs can be precisely stored in a multi-level shuttle automated warehouse. This solves the problem of traditional waste materials occupying entire pallet spaces and improves inventory turnover efficiency. In addition, precise order requests carry comprehensive information and generate unique outbound tasks, allowing for precise traceability and refined control of inventory preparation operations. Overall, this forms a new intelligent, efficient, and closed-loop collaborative inventory preparation model adapted to the characteristics of the tobacco industry's sales cycle, effectively reducing manual intervention and lowering equipment energy consumption and operating costs. Attached Figure Description

[0020] Figure 1 This is a flowchart of the first inventory preparation operation in an embodiment of the present invention; Figure 2 This is a flowchart of the second stock preparation operation in an embodiment of the present invention; Figure 3 This is a diagram of the precise and collaborative inventory preparation system integrating tobacco storage and distribution in an embodiment of the present invention. Detailed Implementation

[0021] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0022] like Figures 1 to 3 As shown in this embodiment, a precise and collaborative inventory preparation method for integrated tobacco storage and distribution is provided. The method is executed collaboratively by a warehouse management system, an automated warehouse monitoring system, and a spare parts warehouse monitoring system, and includes the following operations performed sequentially according to the business cycle: System Architecture and Integration: A 5.0 dual-color LED strip screen is installed at the manual tray unpacking port of the tobacco logistics center to display the specifications and quantities of the products to be unpacked. The server, host computer, scanner, network equipment, and PLC (programmable logic controller) are all existing equipment.

[0023] The realization of this invention relies on information collaboration and data interaction between a Warehouse Management System (WMS), a Warehouse Control System (WCS), a Spare Parts Warehouse Monitoring System, a Shuttle Monitoring System, and a PLC Control System. This is achieved by developing a precise requisition interface in the WMS, expanding the return-to-warehouse task control and application interface in the WCS, and expanding the precise requisition calculation and instruction issuance functions in the Spare Parts Warehouse Monitoring System. The PLC Control System then executes the underlying device drivers. Each system works collaboratively. The WMS receives requisition requests through interfaces and is responsible for task generation and resource scheduling. Each device monitoring system (WCS, shuttle monitoring system, etc.) drives the devices to execute tasks through instruction interfaces. The Spare Parts Warehouse Monitoring System, as the intelligent hub, is responsible for calculating demand, allocating resources, and sending instructions and receiving feedback through data communication interfaces with the WMS, WCS, PLC, and various indicator terminals (such as LED strips) to achieve full-process control.

[0024] The first inventory preparation operation is performed after the sorting work of the current sales cycle is completed and before the order data for the next sales cycle is generated. This operation is used to pre-establish inventory for the next sales cycle and includes the following steps: S101: After the current sales cycle ends and before the order data for the next sales cycle is generated, the spare parts warehouse monitoring system distributes cigarette storage bins in the spare parts warehouse for specified cigarette specifications. Distributing cigarette storage bins in the spare parts warehouse for specified cigarette specifications can be done manually or automatically. Manual distribution involves the operator manually associating and binding the specified cigarette specifications with specific cigarette storage bins in the spare parts warehouse through the human-machine interface of the spare parts warehouse monitoring system. The operator binds the cigarette specifications that need to be prepared in advance to specific cigarette storage bins in the spare parts warehouse interface. Automatic distribution involves the spare parts warehouse monitoring system executing the following automatic calculation and allocation process: S1011, Data Acquisition: Obtain the planned sales volume of each cigarette product specification for the next sales cycle from the associated superior management system (such as the superior intelligent logistics platform).

[0025] S1012, Calculate the percentage: Based on the planned sales volume, calculate the percentage of each product specification's sales volume in the total planned sales volume.

[0026] S1013, Calculate the number of storage compartments: Multiply the sales percentage of each product specification by the total number of available empty tobacco storage compartments in the spare parts warehouse to obtain the theoretical number of tobacco storage compartments that each product specification should be allocated.

[0027] S1014, Execute Allocation: Based on the calculated number of cigarette storage bins to be allocated for each specification, the system automatically allocates the corresponding number of specific cigarette storage bins for each specification. The system automatically allocates spare parts warehouse cigarette storage bins for each specification until all spare parts warehouse cigarette storage bins are allocated. Excess specifications can be allocated to the spare parts warehouse mixed storage or multi-level shuttle automated storage and retrieval system.

[0028] S102: The spare parts warehouse monitoring system sends a request for goods to the warehouse management system according to a fixed quantity preset for each smoke compartment (e.g., 30 pieces per smoke duct); S103: The warehouse management system responds to the requisition request, generates an outbound task to drive the automated warehouse outbound, and replenishes the cigarette packs into the assigned cigarette warehouse after unpacking (e.g., by using a robotic arm).

[0029] The second inventory replenishment operation is performed during the sorting process of the next sales cycle. It is used for dynamic and accurate replenishment based on the sales plan and includes the following steps: S201: Before sorting begins, the spare parts warehouse monitoring system obtains the planned sales volume for the next sales cycle from the upper management system.

[0030] S202: During the sorting process, the spare parts warehouse monitoring system executes the following sub-steps: S2021: Product Specification Screening: Compare the planned sales volume for the next sales cycle with the current picking task to determine the product specifications that require precise stocking. Specifically, product specification screening involves identifying specifications that will not be picked in the next sales cycle, or whose planned sales volume for the next sales cycle is less than the current picking task volume, as products requiring precise stocking. This process can automatically identify specifications with large sales fluctuations, for example, automatically (or manually) setting specifications that will not be picked in the next sales cycle or whose sales volume decreases from large to small as "precise stocking" specifications.

[0031] S2022: Order Quantity Calculation: Based on the remaining sorting quantity of the flue corresponding to the product specifications that require precise stocking and the current inventory, the accurate order quantity is dynamically calculated.

[0032] In S2022, the precise order quantity is dynamically calculated through the following steps: Parameter acquisition: Obtain the remaining sorting task quantity and real-time inventory quantity of the product specifications that need precise ordering in the spare parts warehouse bound to their corresponding flue; Basic calculation: Calculate the difference between the remaining sorting task quantity and the real-time inventory quantity; Decision and output: If the difference is greater than zero, the difference is output as the precise order quantity; if the difference is less than or equal to zero, the precise order quantity is output as zero, which indicates that the current inventory of the corresponding spare parts warehouse can meet or exceed the remaining sorting demand, and no replenishment is required.

[0033] The calculation principle can be set to zero inventory after sorting, meaning the calculated precise order quantity equals the minimum quantity required to fulfill the remaining sorting tasks. For orders exceeding 30 pieces, a full pallet can be dispatched (e.g., 30 pieces / pallet); otherwise, orders will be placed based on the actual quantity.

[0034] S2023: Order Request Initiation: Sends a precise order request with accurate order quantity to the warehouse management system; the precise order request carries accurate preparation product specifications, corresponding flue number, precise order quantity and preparation task type identifier. The warehouse management system generates a unique corresponding outbound task based on the information in the precise order request.

[0035] S203: The warehouse management system responds to precise order requests and generates outbound tasks with task tags; task tags include return tags and precise tags: when the system is not configured with a multi-level shuttle automated warehouse, the warehouse management system generates outbound tasks with return tags; when the system is configured with a multi-level shuttle automated warehouse, the warehouse management system generates outbound tasks with precise tags.

[0036] S204: Perform the unpacking operation according to the outbound task, and perform the corresponding warehousing or return operation on the unpacked cigarettes and remaining materials.

[0037] When an outbound task has a return-to-warehouse flag: S2041: The automated warehouse monitoring system (stacking crane control system) transports the corresponding pallet to the designated manual unpacking station and sends guidance information (including product name and number of pieces to be unpacked) to the display terminal at that workstation, such as an LED screen, providing operators with clear visual guidance on product specifications and quantities. S2042: Manual dismantling is performed according to the instructions. After the dismantled cigarette packs are scanned by the cigarette pack barcode reader, they are controlled by the spare parts warehouse monitoring system to be stored in the spare parts warehouse cigarette storage. This process is called accurate dismantling and storage.

[0038] S2043: The pallet containing the remaining cigarettes after unpacking is called the zero pallet, and it is guided by the PLC control system to the full pallet entry point of the automated warehouse. Specifically, the WCS instructs the PLC to send it to the modified "full pallet entry point".

[0039] S2044: The automated warehouse monitoring system requests and executes a return-to-warehouse task for zero-pallets, storing the zero-pallets back into the automated warehouse. Specifically, after the pallet arrives, the PLC triggers a signal, the WCS requests a return-to-warehouse task from the WMS, and finally the WCS controls the stacker crane to store the zero-pallet back into the automated warehouse.

[0040] When the outbound task has precise markings: S204a: The spare parts warehouse monitoring system assigns dismantling ports to outbound tasks (automatically assigned based on the task execution status of each dismantling port; either robotic or manual ports are acceptable) to perform full dismantling operations, i.e., full dismantling without returning the parts to the warehouse.

[0041] S204b: After being scanned, the removed cigarette packs are controlled by the spare parts warehouse monitoring system to enter the corresponding number of cigarette packs into the spare parts warehouse cigarette storage according to the precise order quantity, thus achieving accurate warehousing.

[0042] S204c: The remaining parts after the complete disassembly are transferred to the multi-level shuttle warehouse; specifically, the spare parts warehouse monitoring system instructs the PLC to send them to the multi-level shuttle warehouse entrance.

[0043] S204d: The shuttle monitoring system, which is communicatively connected to the multi-level shuttle automated warehouse, controls the storage of the remaining cigarette packs. Specifically, after the remaining cigarette packs are scanned and identified by the multi-level shuttle barcode reader, the multi-level shuttle monitoring system performs the storage in the multi-level shuttle warehouse.

[0044] This invention also discloses a precise collaborative inventory preparation system integrating tobacco storage and sorting, to execute a precise collaborative inventory preparation method integrating tobacco storage and sorting. It includes a warehouse management system, an automated warehouse monitoring system, and a spare parts warehouse monitoring system that are interconnected. The warehouse management system responds to requisition requests and precise requisition requests, generates outbound and return tasks, and manages the outbound and return processes of the automated warehouse. The WMS adapter adds a precise requisition interface, precise outbound task generation, and return task generation functions to respond to part-level requisitions and manage the return process of small pallets. The WCS receives outbound instructions from the warehouse management system, drives the automated warehouse to complete the outbound of entire pallets of cigarettes, controls the physical flow of pallets, and executes small pallet return operations. The WCS adapter adds functions for specifying the return pallet route, controlling outbound tasks (making way for return), and applying for and executing return tasks to control the physical flow of pallets. The spare parts warehouse monitoring system is used to allocate spare parts warehouses and tobacco storage areas for cigarette product specifications, initiate order requests and precise order requests, screen precise spare parts specifications and dynamically calculate precise order quantities, and coordinate and manage the entire stock preparation process.

[0045] It also includes a multi-level shuttle automated warehouse and a shuttle monitoring system, used to receive remaining cigarettes after the spare parts warehouse monitoring system has accurately prepared the goods and to perform multi-level shuttle warehouse storage. The shuttle monitoring system is communicatively connected to the spare parts warehouse monitoring system and the multi-level shuttle automated warehouse, and is used to control the storage operation of the remaining cigarettes transmitted to the multi-level shuttle automated warehouse.

[0046] In addition, the system includes execution and instruction terminals, such as LED strip screens installed at the manual dismantling port, and cigarette barcode readers for identifying cigarette cartons. The entire system receives and executes instructions from various monitoring systems through an upgraded PLC control system, thereby achieving collaborative operation.

[0047] In summary, the tobacco storage and sorting integrated precision collaborative inventory preparation method and system disclosed in this invention constructs a data-driven, intelligent collaborative operational closed loop by expanding and integrating the functions and interfaces of existing systems such as WMS, WCS, spare parts warehouse monitoring system, shuttle car monitoring system, and PLC control system. This method creatively divides the inventory preparation process into two stages: advance inventory preparation without orders and precise inventory preparation with orders, with the spare parts warehouse monitoring system acting as the intelligent central hub for unified scheduling. By utilizing the orderless time window during the alternating sales cycle to execute the first inventory preparation operation, the waiting delay of sorting initiation is effectively eliminated, ensuring the continuity of logistics operations. During the sorting process, based on the sales plan for the next cycle and real-time sorting consumption, product specifications are dynamically screened and the required quantity is accurately calculated, achieving on-demand replenishment. This significantly reduces the amount of leftover cigarettes (small pallets or surplus materials) generated from full pallet shipments, lowering material handling costs and warehouse space occupancy.

[0048] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A precise and coordinated tobacco storage and distribution method, characterized in that: The method is executed collaboratively by the warehouse management system, automated warehouse monitoring system, and spare parts warehouse monitoring system, and includes the following operations performed sequentially according to the business cycle: The first inventory preparation operation is performed after the sorting work of the current sales cycle is completed and before the order data for the next sales cycle is generated. This operation is used to pre-establish inventory for the next sales cycle and includes the following steps: S101: After the current sales cycle ends and before the order data for the next sales cycle is generated, the spare parts warehouse monitoring system distributes cigarette storage compartments in the spare parts warehouse for the specified cigarette specifications. S102: The spare parts warehouse monitoring system sends a requisition request to the warehouse management system according to a fixed quantity preset for each tobacco warehouse; S103: The warehouse management system responds to the requisition request, generates an outbound task to drive the automated warehouse outbound, and replenishes the cigarette packs into the assigned cigarette warehouse after unpacking. The second inventory replenishment operation is performed during the sorting process of the next sales cycle. It is used for dynamic and accurate replenishment based on the sales plan and includes the following steps: S201: Before sorting begins, the spare parts warehouse monitoring system obtains the planned sales volume for the next sales cycle; S202: During the sorting process, the spare parts warehouse monitoring system executes the following sub-steps: S2021: Product Specification Screening: Compare the planned sales volume for the next sales cycle with the current sorting tasks to determine the product specifications that need to be precisely stocked. S2022: Order Quantity Calculation: Based on the remaining sorting quantity of the flue corresponding to the product specifications that require precise stocking and the current inventory, the precise order quantity is dynamically calculated. S2023: Order Request Initiation: Sends a precise order request with accurate order quantity to the warehouse management system; S203: The warehouse management system responds to precise requisition requests and generates outbound tasks with task tags; S204: Perform the unpacking operation according to the outbound task, and perform the corresponding warehousing or return operation on the unpacked cigarettes and remaining materials.

2. The precise and coordinated tobacco storage and distribution method according to claim 1, characterized in that: In step S101, the cigarette compartments in the parts warehouse for distributing cigarettes of a specified specification include manual or automatic distribution. Manual allocation involves the operator manually associating and binding the specified cigarette specifications with a specific cigarette compartment in the spare parts warehouse through the human-machine interface of the spare parts warehouse monitoring system. Automatic allocation is performed by the spare parts warehouse monitoring system, which executes the following automatic calculation and allocation process: S1011, Data Acquisition: Obtain the planned sales volume of each cigarette product specification for the next sales cycle from the associated superior management system; S1012, Calculate the percentage: Based on the planned sales volume, calculate the percentage of each product specification's sales volume in the total planned sales volume; S1013, Calculate the number of warehouses: Multiply the sales percentage of each product specification by the total number of available empty cigarette warehouses in the spare parts warehouse to obtain the theoretical number of cigarette warehouses that each product specification should be allocated. S1014, Execute Allocation: Based on the calculated number of tobacco bins to be allocated to each product specification, the system automatically allocates the corresponding number of specific tobacco bins to each product specification.

3. The precise and coordinated tobacco storage and distribution method according to claim 1, characterized in that: In step S2021, the product specification screening specifically involves identifying product specifications that will not be sorted in the next sales cycle, or whose planned sales volume in the next sales cycle is less than the current sorting task volume, as product specifications that require precise stocking.

4. The precise and coordinated tobacco storage and distribution method according to claim 1, characterized in that: Step S2022 specifically involves dynamically calculating the precise order quantity through the following steps: Parameter acquisition: Obtain the remaining sorting task quantity and real-time inventory quantity of the product specifications that need to be precisely prepared in the spare parts warehouse of the corresponding flue. Basic calculation: Calculate the difference between the remaining sorting task quantity and the real-time inventory quantity; Decision and Output: If the difference is greater than zero, the difference will be output as the precise order quantity; if the difference is less than or equal to zero, the precise order quantity will be output as zero, which indicates that the current inventory of the cigarette warehouse corresponding to the spare parts warehouse can meet or exceed the remaining sorting demand, and no replenishment is required.

5. The precise and coordinated tobacco storage and distribution method according to claim 1, characterized in that: In step S203, the task marker includes a return-to-database marker and a precision marker; When the system is not configured with a multi-level shuttle automated warehouse, the warehouse management system generates outbound tasks with a return-to-warehouse marker. When the system is configured with a multi-level shuttle automated warehouse, the warehouse management system generates outbound tasks with precise markings.

6. The precise and coordinated tobacco storage and distribution method according to claim 5, characterized in that: When the outbound task has a return-to-warehouse marker, step S204 specifically includes: S2041: The automated warehouse monitoring system controls the transport of the corresponding pallet to the designated manual unpacking port and sends guidance information including product specifications and the number of items to be unpacked to the display terminal of that workstation; S2042: Manual disassembly is performed according to the instructions. The disassembled cigarette packs are scanned and then controlled by the spare parts warehouse monitoring system to be stored in the spare parts warehouse cigarette storage. S2043: The pallet containing the remaining cigarettes after unpacking is called the zero pallet, which is guided by the PLC control system to the full pallet entry port of the automated warehouse. S2044: The automated warehouse monitoring system requests and executes a return-to-warehouse task for the zero disk, and re-stores the zero disk into the automated warehouse.

7. The precise and coordinated tobacco storage and distribution method according to claim 5, characterized in that: When the outbound task has a precise tag, step S204 specifically includes: S204a: The spare parts warehouse monitoring system assigns disassembly ports to outbound tasks to perform full disassembly operations; S204b: After the removed cigarette packs are scanned, the spare parts warehouse monitoring system controls the corresponding number of cigarette packs to be stored in the spare parts warehouse cigarette warehouse according to the accurate demand quantity; S204c: The remaining cigarettes after the entire tray is disassembled are transferred to a multi-level shuttle automated warehouse. S204d: The remaining cigarette items are stored in the warehouse by a shuttle monitoring system that is connected to the multi-level shuttle automated warehouse.

8. The precise and coordinated tobacco storage and distribution method according to claim 1, characterized in that: The precise order request issued in step S2023 carries precise preparation product specifications, corresponding flue number, precise order quantity, and preparation task type identifier. The warehouse management system generates a unique corresponding outbound task based on the information in the precise order request.

9. A precise collaborative inventory preparation system integrating tobacco storage and sorting, for executing the precise collaborative inventory preparation method integrating tobacco storage and sorting as described in any one of claims 1 to 8, characterized in that, This includes interconnected warehouse management systems, automated warehouse monitoring systems, and spare parts warehouse monitoring systems; The warehouse management system is used to respond to order requests and precise order requests, generate outbound and return tasks, and manage the outbound and return processes of automated warehouses. The automated warehouse monitoring system is used to receive outbound instructions from the warehouse management system, drive the automated warehouse to complete the outbound of whole pallets of cigarettes, control the physical flow of pallets, and execute the return of individual pallets to the warehouse. The spare parts warehouse monitoring system is used to allocate spare parts warehouses and tobacco storage areas for cigarette product specifications, initiate order requests and precise order requests, screen precise spare parts specifications and dynamically calculate precise order quantities, and coordinate and manage the entire stock preparation process.

10. The integrated tobacco storage and sorting precision collaborative stock preparation system according to claim 9, characterized in that: It also includes a multi-level shuttle automated warehouse and a shuttle monitoring system; The shuttle monitoring system is communicatively connected to the spare parts warehouse monitoring system and the multi-level shuttle automated warehouse, and is used to control the storage operation of the remaining spare parts transmitted to the multi-level shuttle automated warehouse.

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