Kitting procedure

Abstract

Method for kitting for assembling kits with components and parts that are required for the manufacture of a specific product or a specific assembly, wherein the components and parts are stored in single-variety storage containers (L) in a warehouse and are removed from storage for assembling the kit and transported to a goods-to-person station (11; 101; 101B) via stationary conveyors (17, 18, 19; 117, 118, 119), wherein all storage containers (L) with the components or parts contained in the kit are provided in a sequence at the goods-to-person station (11; 101; 101B) simultaneously by means of the conveyors (17, 18, 19; 117, 118, 119) in order to enable an operator (12; 102) to reload all components or parts of the kit into a kit container (K), characterized in that the Goods-to-man station (11; 101; 101B) a conveyor loop (16;116), in which the storage containers (L) are conveyed in a circle until kitting is completed, the conveyor loop (16) being arranged within the working area (13; 113) of the goods-to-person station (11; 101; 101B);

Description

The invention relates to a method and a system for cementing according to claim 1.Cementing refers to the assembly of components and parts needed to produce a particular product or assembly. The individual components are put together and distributed or delivered grouped together for this purpose. In this case, the later assembly sequence of the individual components is already taken into account during the assembly.In comparison to picking, a selected group of components is thus assembled which does not consist of a large article spectrum due to any customer order, but rather results especially from the product or the assembly to be produced. Each kit is thus predefined by the corresponding product or the assembly. Only the number of kits (e.g., depending on products or assembly to be replaced or repaired) is determined. There is usually no customer-specific composition of the kit.Thus, the later assembly process can be made more efficient and flexible. In addition, space savings are achieved in the installation area and the risk of confusion of components with a similar appearance is reduced.US 5 472 309 A describes an integrated storage system for storing and retrieving goods and for preparing the goods for their final disposal. The storage system includes numerous modular components that can be added to or removed from the system to meet a particular storage requirement. Inventory items stored in containers are stored on a rotary storage carousel. A plurality of workstations, each associated with temporary storage queues, are integrated into the carousel to facilitate high volume manipulations. Containers delivered from the warehouse carousel are placed in the temporary queue where they are stored until an operator is ready to work with the goods stored therein. The container is then delivered to a work area where the operator performs the desired task. The containers may then be delivered either to another suitable work station or back to the warehouse carousel.US 10 074 073 B2 describes a method for managing a warehouse system, which includes receiving a work request identifying a warehouse item and selecting a work station from a plurality of work stations at which the work request is to be fulfilled. The method also includes moving a storage bin that stores the identified storage item to the selected workspace and moving a storage bin that stores a storage item associated with the received work request to the selected workspace. The moving of the storage containers is carried out by means of mobile racks in which the storage containers are stored. The mobile racks are lifted, moved and deposited by intelligent robots. This type of movement requires a lot of free space for the robot to move and also sufficient space at the work station for the mobile racks.In contrast, the object of the present invention is to provide a method for cementing which is more space-saving and at the same time more efficient.This object is achieved by the method recited in claim 1. Advantageous embodiments are evident from the dependent claims and the description.According to the invention, it has been recognized that if all the individual storage containers with the components contained in a kit are provided in a sequenced manner at a goods-to-mann station simultaneously by means of conveyors, it is possible to increase the efficiency by the rapid provision of all the components via conveyors, since the conveyors can generally move storage containers faster than the robots via mobile racks and at the same time save space, since the conveyors only require installation space once, but different storage containers can be conveyed to and from the workplace or goods-to-mann station.In other words, all the components and parts required for the production of a particular product or assembly are made available simultaneously at the goods-to-man station in the anticipated order (sequence) for assembling the kit.Especially in the case of kits with few components and parts, all storage containers are then preferably also simultaneously in direct access (working area) for the weather (operator of the goods-to-mann station). This results in a particularly efficient and accelerated method. In other words, at the goods-to-man station, all storage containers with the components or parts contained in the kit are simultaneously in the access area of the operator. It is particularly preferred if three storage containers are presented to the weather simultaneously.In kits with many components and parts (e.g. 4-8), although all storage containers are also present simultaneously at the goods-to-mann station, they are presented only one after the other for reasons of working area space, so that the weather actually has access to only the practicable amount of storage containers. Since the sequence or sequence must be observed in any case during the cementing operation, the subsequent conveying (subsequent presentation) of the further storage containers is of no importance for the cementing operation per se. Thus, despite a compromise with respect to the amount of storage containers presented (or station size), an efficient possibility also of assembling larger kits results, since the storage containers are present at the goods-to-mann station and are always presented as required.According to the invention, the goods-to-mann station has a conveying loop in the working area, in which the storage containers are circulated until the completion of the cementing.In order to introduce supplies of storage containers sequenced, to enable subsequent orders for other kits etc., the conveyor loop (loop) at the goods-to-mann station can have a parallel buffer section.When kits are assembled with very many components and parts (e.g., >8-22), a space problem arises in the preservation of all storage containers at the goods-to-man station. In order to solve this, the conveying loop (loop) at the goods-to-man station can have an abbreviation (double loop). In other words, the conveying loop now has a transverse conveying section which connects the conveying loop sections (loop sides) in an abbreviated manner. This results in an approximately "8" configuration. The length of the conveying loop is thus increased without additional space requirements.Depending on the operating mode and storage container amounts, it can therefore be expedient if both filled storage containers and empty storage containers use the abbreviation.Accordingly, it is also expedient that completely filled kit containers are removed from the conveying loop as quickly as possible in order to create space. Therefore, these will always be transported away from the conveying loop as far as possible, in particular transported directly to a lift, which distributes the finished kits in the overall store.Alternatively, kit containers and storage containers that are completely filled at the goods-to-man station can be conveyed away via the same conveyor paths.At the goods-to-mann station, large or bulky components and parts and / or outer packaging can be provided on one (or more) pallet space. In other words, parts and components too large and / or heavy for the storage containers are provided on pallets separately. The same applies to outer packaging, for example. Cartoning Kit. These are usually placed as the first "part" in the kit container and subsequently all "other" genuine kit parts (or components) are put together therein. It is understood that, if necessary, a plurality of pallets with such parts and / or components and / or outer packaging or intermediate floors etc. can also be provided on pallets at the cementing location.It is expedient to exchange storage containers emptied by the cementing at the goods-to-man station in a targeted manner with filled storage containers, which is easily possible by the conveying technology used, since this enables the individual removal or exchange. For this purpose, a buffer section can be arranged, for example, parallel to the presentation arrangement for the storage containers, which buffer section permits individual control.The described cementing methods and the cementing workstations allow, on the one hand, a cementing on stock-called kit to stock-or a cementing on demand or just in time-called kit to order to be carried out in an efficient manner.The kits may also comprise special tools and / or special screws, etc., in addition to the components and parts required for the manufacture of a particular product or assembly.In particular, the method according to the invention is suitable for the external supply of workshops and repair or maintenance teams with replacement or repair kits. This relates in particular to the automobile and truck sector in which many prefabricated assemblies are used.Further details of the invention will become apparent from the following description of exemplary embodiments with reference to the drawing, in which FIG. 1 shows a schematic top view of a cementing workstation for carrying out a method in a first variant; FIG. 2 shows a schematic top view of a cementing workstation for carrying out the method according to the invention in a second variant; FIG. 3 shows a schematic top view of a cementing workstation for carrying out the method according to the invention in a third variant; FIG. 4 shows a schematic top view of the cementing workstation from FIG. 3 during the execution of the method according to the invention in a fourth variant; FIG. 5 shows a schematic top view of the slightly modified cementing workstation from FIG. 3 during the execution of the method according to the invention in a fifth variant; and FIG. 6 shows a schematic perspective view of an entire cementing area with slightly modified cementing workstations from FIG. 5 in cooperation with further conveying technology.FIG. 1 shows a schematic top view of a cementing workstation 1 for carrying out the method according to the invention in a first variant. This cementing workstation is designated as a whole with 1.In the working area 3 of the operator or the weather 2, up to three single-grade storage containers L 01, L 02, L 03 are simultaneously presented frontally on a row 6 in direct access. In addition, a kit container K to be filled is provided via corner in a target location 5, which is supplied with empty containers via a separate target or kit container supply 4.Behind the row 6 of storage containers 01, 02, 03 there is a buffer section 7 parallel thereto, which permits a targeted and individual supply and disposal of the locations of the row 6 when, for example, a storage container becomes empty during the cementing.For the delivery of storage containers, the buffer section 7 is connected to a corresponding conveyor 8 which purposely provides storage containers L of the same type from a storage means, not shown.For the discharge of both filled kit containers K or emptied storage containers L, the buffer section 7 is connected at the end facing the target location 5 to a corresponding conveyor 9, via which the target location 5 itself is also connected.At the work station 1, up to three source or storage containers L are thus simultaneously available for the worker or colders. Kits which are manufactured at this workstation 1 must therefore typically consist of up to three components or parts of the storage containers L. The worker 2 thus places the components or parts in the correct sequence 01, 02, 03... in the kit container K and then carries away the latter via the conveyor 9. The worker then starts with the next kit container.If the kit changes, the storage containers L also change.If during the cementing a storage container L becomes empty before completion of the cementing order (number of kits), the now empty storage container is transported into the storage (shuttle storage) not shown and replaced by a new full storage container. This is ready in good time on the buffer section 7 of the work station 1 and occupies the space in the row 6 of emptied and transported storage containers.If the kit needs to be manufactured only once, the manufacture of larger kits at this workstation 1 is also conceivable. In this case, the corresponding storage container L is transported away directly after the access, as it were emptied. It thus makes room for a possible further storage container L, for example L04 as a subsequent container.In addition, bulky components or parts as well as outer packages can be provided on a pallet P at the station.FIG. 2 shows a schematic top view of a cementing workstation for carrying out the method according to the invention in a second variant. This cementing workstation is designated as a whole as 11. In this variant, up to eight storage containers are available to the worker 12. However, only five are shown here.In the working area 13 (partial leg of the loop 16, see below) of the operator or the weather strip 12, a plurality of single-grade storage containers L are simultaneously presented frontally in direct access. The remaining storage containers L are located on a conveying loop or loop 16 arranged within the working region 13.In addition, a kit container K to be filled is provided via corner in a target location 15, which is supplied with empty containers via a separate target or kit container supply 14.For the delivery of storage containers L, the loop 16 is connected to a corresponding conveyor 18 which intentionally provides storage containers L of the same type from a storage means, not shown.For the discharge of both filled kit containers K or emptied storage containers L, the loop 16 is connected to a conveyor 19. Since the target location 5 itself is also connected to the loop 16, it can be disposed of accordingly.Parallel to the loop 16 between the connection of the conveyors 18, 19, a buffer section 17 is provided which, as before, is used to hold a targeted supply, without hindering the conveying flow on the loop or the conveying loop 16. Alternatively or additionally, containers may be buffered on the conveyor 18.The feeding conveyor 18 is supplied by a container lift 20 which is connected to or extends from a shuttle storage (not shown). Analogously, the discharging conveyor 19 opens out to a container lift 21, which is likewise connected to a shuttle store (not shown) or extends therefrom.If the lifts 20, 21 are located in shelves of a gate of the shuttle store, it is expedient if the spacing of the conveyors 18, 19 corresponds to the shelf spacing.At the work station 11, up to eight storage containers L are preferably available to the worker. Analogously to the smaller workplace 1, orders with up to eight components or parts can thus be produced from storage containers L or even larger ones with a single kit number to be produced.After the worker has removed the required number of components for the current kit from the corresponding storage container L and activated the container change, the storage container is changed, i.e. conveyed further in the loop 16. Thus, the worker can even concentrate completely on a storage container L during the cementing operation and the removal process is simplified again.Alternatively, the worker could also remove corresponding components or parts from a plurality of storage containers, for example three, and then transport them as a group.The container can also be changed in a time-controlled manner, i.e. after a predeterminable personal "processing time".The container itself is expediently changed in the "shadow" of the processing time. Thus, the worker can add the next component or part to the kit without waiting.Even in the case of kits with only two components, the storage container must continue to move after removal in one variant.Empty storage containers L are disposed of via the circulation of the conveying loop 16 and immediately replaced by the appropriate supply container. Finished kit containers K are also disposed of through the loop 16.After completion of the cementing task, all storage containers L are disposed of together with the (last) kit container and immediately replaced by the following task. At this time, this is already ready according to its sequence with storage containers L* on the buffer section 17 of the workstation 11.The work station 101 shown in FIGS. 3 to 5 is in principle a variant of the work station 11.Essential differences from the work station 11 are, besides the size of the conveyor loop 116, that it has a cross connection as short cut 122, and that the buffer section is formed as buffer section 117 of the feeding conveyor 118. In addition, it is also possible (cf. FIG. 5 ) to provide pallet spaces.The workstation 101 offers different operating modes in order to be able to efficiently display storage containers for a wide range of four up to 22 storage containers L in order to carry out appropriate cementing, which is explained below with reference to FIGS. 3-5.All operating modes connect the basic mode of operation of the workstation 101. As in the case of the workstation 11, storage containers L are supplied to the worker 102 via a circulating conveying loop 116. Thus, the container can remove the required components from the respective container L 0X in its working area 103 and add them to the respective kit K in the place 105. The supply and discharge is carried out analogously above.The difference in the operating modes for the workstation 101 now consists in reducing the duration of the revolutions if necessary in order to achieve sufficiently rapid access to the revolving storage containers L even in the case of a few storage containers L, or in providing sufficient conveying length for many storage containers L.In the case of cementing with a few storage containers L (as shown in FIG. 3 ), the storage containers L use a shorter circulation path, which is made possible by the use of the abbreviation 122. The loop or the conveying loop 116 is thus shortened in a targeted manner.Supply containers or storage containers L* of a possible next order are available in this configuration more buffer spaces. In the illustration, in addition to the currently revolving order with storage containers L 01... L 05 with a supply container L 01 nfor the storage container L 01, a further order with five containers L* and a further order L** are also depicted on the buffer section 117.The supply container L 01 nprecisionally waits directly at the revolving storage containers L before the abbreviation in order to replace the storage container L 01 becoming empty.In the operating mode (as shown in FIG. 4 ) with over eight and under 19 storage containers L, the storage containers L circle around the outer loop 116 of the workstation 101.The abbreviation 122, which is used for orders with few and very many components (cf. below) from storage containers L, is not used in this operating mode. Makeup containers stand on the buffer locations within the loop 116 on the feeder buffer section 117.In the case of cementing (cf. FIG. 5 ) with 19 to 22 components or parts of storage containers L, both the outer circulation of the loop 116 and the abbreviation 122 are used for the circulation of the storage containers L.In this operating mode, just as in the operating mode with 9 to 17 components of storage containers L, the buffer section 117 lying in the loop 116 is available for buffering the storage containers L.In this operating mode, storage containers L must be divided during the circulation and subsequently brought together again. In the merging, the sequence must (and will) be followed.In addition, the workstation 101B of FIG. 5 also comprises a provision of pallets P. As described above, the cementing workstations 1 and 101 and also 101B have, in addition to the above-described container connection, additionally a connection to a pallet conveyor 125 at the location P. The worker is therefore not only provided with the respective storage container L or kit container K, but also with a series of source pallets. Thus, bulky components or parts and outer packaging can be provided on one or more pallets P1... PX at the work station.FIG. 6 shows possibilities for utilizing an entire cementing area with slightly modified cementing workstations 101B from FIG. 5 in cooperation with further conveying technology.The four cementing workstations 101B shown are arranged approximately square--viewed from above--and each divide a pair of lifts 121, 122. These therefore serve as a feed for one work station and at the same time as a discharge for the respective other work station.At the same time, the respectively supplying lift 121, 122 for the workstations serves as a supply not only for storage containers L, but also for the supply 114 with empty kit containers K to be filled. Depending on the arrangement, two adjacent workstations can possibly share one supply 114 (see left workstations).In FIG. 6, the right half of the figure also shows the pallet conveying system 125 in the region P for the provision of a plurality of pallets P 1,... PX. The pallet conveying system 125 comprises, among other things, simple reversible pallet conveyors 126 at the locations P 3 and P 4 and also more complex infeed and outfeed conveying systems 127 at the locations P 1 and P 2.List of reference characters1, 11, 101, 101B Cementing workstation 2, 12, 112 Worker 3, 13, 113 Working area 5, 15, 115 Target location 16, 116 Loop or conveying loop 2, 12, 102 Kitter, Worker 20, 120 Container lift 21, 121 Container lift 4, 14, 114 Kit container supply 5, 15, 105 Target location 6 Row 7, 17, 117 Buffer section 8, 18, 118 Conveyor 9, 19, 119 Conveyor K Kit container L, L1... Lx, L*, L** Storage container P Pallet area P1... Px Locations 7, 17, 117 Buffer section 122 Abbreviation 125 Pallet conveyor 126 Pallet conveyor 127 Infeed and outfeed conveyor

Claims

A method of cementing for assembling kits comprising components and parts required for the production of a particular product or assembly, wherein the components and parts are stored in single-grade storage containers (L) in a store and are transferred and transported to a goods-to-man station (11; 101; 101B) via stationary conveyors (17, 18, 19; 117, 118, 119) for assembling the kit, wherein all storage containers (L) with the components or parts contained in the kit are provided sequenced at the goods-to-man station (11; 101; 101B) simultaneously by means of the conveyors (17, 18, 19; 117, 118, 119) for providing an operator (12; 102) for transferring all components or parts of the kit into a kit container (K), characterized in that the goods-to-mann station (11; 101; 101B) has a conveying loop (16; 116) in which the storage containers (L) are circulated until the completion of the cementing, wherein the conveying loop (16) is arranged within the working region (13; 113) of the goods-to-mann station (11; 101; 101B).Method according to claim 1, characterised in that large or bulky components and parts and / or outer packaging are provided on a pallet location (P) at the goods-to-man station (11; 101; 101B).Method according to claim 1 or 2, characterised in that storage containers (L) emptied by the cementing are changed in a targeted manner with filled storage containers at the goods-to-man station (11; 101; 101B).Method according to one of the preceding claims, characterized in that at the goods-to-man station (11; 101; 101B) all storage containers (L) with the components or parts contained in the kit are simultaneously in the access area (13; 113) of the operator.Method according to one of the preceding claims, characterized in that, at the goods-to-man station (11; 101; 101B), completely filled kit containers and storage containers are conveyed away via the same conveyor paths (17, 18, 19; 117, 118, 119).Method according to claim 1, characterised in that the conveying loop (13; 113) has a parallel buffer section (17; 117) at the goods-to-man station (11; 101; 101B).Method according to one of the preceding claims 1 or 6, characterized in that the conveying loop (13) has an abbreviation (122) at the goods-to-man station (11; 101; 101B).Method according to claim 7, characterised in that both filled storage containers and empty storage containers use the abbreviation (122).Method according to one of Claims 6 to 8, characterized in that completely filled kit containers (K) are always transported away directly from the conveying loop (13; 113), in particular are conveyed directly to a lift (21; 121).

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