METHOD AND PLANT FOR THE LOGISTICS OF PARTS

Description

[0001] The present invention relates to a method and a system for the logistics of parts, in particular for their processing, tracking and distribution in a system.

[0002] A generic process is known from the prior art in which a large number of parts, e.g., letters, parcels, or cartons, are transported, processed, sorted, and fed to the outbound goods area using conventional conveyor technology. The focus is often on the 'conveyor performance,' such as parts per hour. The individual part is not taken into account. WO 2013 / 126048 A1 describes a system for the automatic picking of fragile articles / products in a material handling system and includes a processor for storing a picking plan, including instructions executable by the processor for controlling the automatic picker to pick articles / products from the memory. D1 does not refer to an overhead conveyor with trolleys.EP 2 899 144 A1 describes a conveying device for the automated dispensing of individual products along the conveying direction, with an adapter identification unit with an adapter for receiving individual products, wherein each individual product is equipped with an individual goods transponder.

[0003] The object of the present invention is therefore to think about and then carry out the processes in the operation and the logistics from the part, i.e. from the object to be treated, by means of individualizing the parts.

[0004] The problem is solved by a method and a system with the features of the independent patent claims.

[0005] In the inventive method for the logistics of parts, in particular for their processing, tracking, and distribution within a system, each individual part is recorded as unique. Each part undergoes processes along an individual journey. The logistics of the individual part are triggered by the necessary processes. This journey is understood, for example, as the individual modification of the part while it is in the system. For instance, damaged or dirty used parts can undergo a step-by-step repair or cleaning, and the part can be improved or modified in this context. According to the invention, the system identifies which processes are necessary for the individual part and conveys the part accordingly to the appropriate stations to complete these processes. The logistics of the part thus depend on the individual condition of the part.Each part thus goes through an individual path in the plant as a unique item until it has completed a career, development, or change that makes it suitable for further action, such as storage or order picking.

[0006] According to the invention, necessary processes include, in particular, the recording and supplementation of properties of the individual part and, for order fulfillment, the picking of the individual part, possibly together with other parts. The part thus develops further in its individual development. The individual development path of the individual part is its change of state and the processes necessary for this.

[0007] Each individual part is attached to a trolley as a product carrier, which is equipped with a read and / or write element, in particular a barcode or transponder, thus making each individual part unique. The trolley or product carrier therefore serves to uniquely identify the goods.

[0008] In a database associated with the system, an open data record is created or generated for each read and / or write operation. This record is then linked to form an electronically writable, individual data record for each part. The data record uniquely identifies the product or part with regard to its present or missing properties. As soon as a property of the part changes, this is updated in the data record.

[0009] The individual part is checked for the presence of information, such as article number and / or article description, or examined for the presence of predetermined properties, such as the condition of the part, and any existing or determined properties are entered into the data record.

[0010] The individual part is supplemented with at least one property at at least one workstation, and this supplemented property is entered into the data record. Through this process, the part evolves, and the data record is continuously updated over time, ideally until the part is complete and ready for shipment.

[0011] The logistics for each individual part depend on its existing and / or missing properties and / or the necessary addition of those properties. Logistics are therefore tailored to each part, which is treated as a unique item.

[0012] It is advantageous if the individual part is fed into a specifically defined process chain, e.g., for returned parts, or if part characteristics such as color, shape, or size, right down to identifying the part (e.g., water bottle or 0.5-liter filled cola bottle), are determined manually or automatically at workstations, particularly by photographing parts, e.g., inside and / or outside the system. This creates a kind of inventory of the part, allowing for the identification of characteristics that need to be added or changed, and the determination of the individual part's required path.

[0013] It is advantageous if each individual part undergoes a quality inspection, especially before being accumulated and / or stored in the system. This allows the part's existing / missing properties to be recorded and entered into the data record.

[0014] It is advantageous if, after the property(ies) have been added at the workstations or after it has been determined that no further property needs to be added, the individual part is placed in a storage area, buffer, or warehouse. This allows the part to be retrieved for the next process as needed.

[0015] It is advantageous if the individual part, based on the presence or absence of certain properties, is sent to a warehouse from which the individual part is sold online or through retail channels.

[0016] It is advantageous if, in the case of a lack of less important or a small number of properties, the individual part is sent to a wholesale warehouse from which the individual part is sold to a wholesaler.

[0017] It is advantageous if the individual part lacks important or a large number of properties and is sent to a recycling warehouse, from which the individual part is sent to a recycling or other recovery process.

[0018] By evaluating the properties of the part, a determination can be made regarding its further usability.

[0019] It is advantageous if the individual parts are transported on carriers, particularly trolleys, equipped with a read and / or write element, especially a barcode or transponder, to which individual parts are attached, e.g., clipped or hung on hangers, or placed, e.g., in bags or pouches, wire baskets, or trays, and which have a product label or existing characteristics, whereby the carriers and the associated parts are treated as individual unique items. The parts and the carrier can thus be "married" in the database and the data record, making the part a unique item.

[0020] It is advantageous if the existing properties of each individual part are stored in a data repository by means of a code and can be assigned to the code of the individual product carrier as needed. The current properties of the part are then linked to the product carrier and can be easily tracked.

[0021] It is advantageous if each goods carrier, particularly by means of a scanner or RFID reader, can be identified and guided through the system to specific workstations. The scanner or RFID reader is preferably installed in a fixed location (at a specific point within the system) and can communicate with the database from there; in particular, it can a) communicate which product carrier has arrived at which scanner and b) e.g. in the variable data record of this product carrier obtain the destination address for the next destination to be addressed (e.g. customer requests delivery with a specific shipping provider or quality control determines that a button needs to be sewn on → destination: sewing workshop ... etc.)

[0022] It recognizes the properties of the part, or even just the individual part itself, using the barcode or the readable and writable RFID chip, and then clears the immediate path for the part and its carrier within the conveyor system. This creates a customized logistics plan for the part based on its individual characteristics. The scanner or RFID reader is therefore preferably located near a switch in the conveyor system and is able to switch the switch as needed. However, it can also be located elsewhere and, from a greater distance, switch one or more switches according to the part being moved and its carrier. The scanner or RFID reader can thus become a decision point. Communication takes place with the database or a variable data record for each trolley (and therefore with the associated part).

[0023] It is advantageous if information about the current properties of each individual part is recorded at the workstations, or if the task in the process chain is displayed at that workstation, and if, after processing the individual part, all information that is important or relevant for that part can be electronically saved in the data record. This allows the part to be processed individually at the workstation and its progress to be further developed. After processing, the data record is updated.

[0024] Depending on the current properties and location of each individual part, its further transport route is determined. This can be done, for example, by detection using a scanner and the corresponding instruction to a control system.

[0025] The further transport route of each individual part is determined according to the current workstation utilization. The part can then be routed to another workstation with available capacity, even if a different attribute of the part is added there. The part's journey can thus be developed individually and depending on the plant's utilization. Alternatively, the part can also be placed in a buffer storage area.

[0026] It is advantageous if the individual part is dynamically stored in the storage areas or storage zones and picked as soon as it makes sense.

[0027] It is advantageous if the individual parts are transported on carriers, especially hanging on trolleys, whereby the carriers are all marked as unique items by means of a read and / or write element, especially barcodes or RFID chips.

[0028] The individual parts could be, for example, returns or used textiles. It is advantageous if the parts are checked for their condition and suitability for further processing, and if their identification and condition are determined using the identified properties, and the necessary steps in the process chain are defined.

[0029] According to the invention, the presence of all buttons, the functionality of zippers, holes in the textile, and / or the general condition of the textile are defined as properties and entered into the individual data record. It is advantageous if the size and / or the general condition of the textile are also defined.

[0030] The described process is used for processing, tracking, and distributing parts / goods with the following characteristics: Each part is considered unique, yet also a 'mass phenomenon'. It is handled, controlled, and monitored in a process-oriented manner.

[0031] An example of an application of the invention is an automotive supplier tasked with supplying production for a passenger car assembly line from five manufacturers "just in time" and "just in sequence." Every 1.5 minutes, information for the next required vehicle is transmitted electronically. Parts are fed into production from a dynamic buffer containing over 30,000 parts and an additional 10,000 parts in a connected static warehouse with over 15,000 different item positions, so-called SKUs (stock keeping units). The time from this transmission until handover to one or more transfer points is only about 90 minutes.

[0032] According to the invention, the parts are individualized: On an airplane, the passenger's boarding pass plus ID card serve as the 'admission ticket'. The (manufacturer-variable) identification for each part is individualized via a database and the so-called 'marriage' with numbered, 'unique' trolleys, meaning each part becomes unique. The data records for the individual parts can be completely different; there may even be parts without an article number.

[0033] The basic idea is this: the processes within the company and the logistics are conceived from the perspective of the part, the object. The object requires specific treatment to complete its journey, that is, to become perfect, and accordingly, it follows an individual path within the system. The part is recognized, processed, and moved as a unique item.

[0034] The processes according to the invention are as follows: the goods flow, as in traffic engineering, for example. High volumes must be managed, disruptions / intersections must be controlled, and priority routes, main directions, and 'green waves' must be defined and designed. There are decision points. At these points, for example, scanners read a barcode or transponder on the trolley. They identify the goods and assign each item / trolley its destination or its further route.

[0035] The career path of each part can be different. They are all individuals, all unique pieces, yet they all serve the purpose of leaving the facility at the goods dispatch point with a destination address.

[0036] It is a data-based operating model: From goods receipt (loading the trolley) to goods dispatch, each item is accompanied, monitored, tracked, controlled as a unique item and even in case of deviations (errors) is brought back 'on track'.

[0037] One special feature is the data management: an open data set per part, which can be extended or modified almost arbitrarily.

[0038] The data management allows for an open data record per part to further characterize and describe the 'unique items' (e.g., item number: define part: item, color, size), supplemented by assessment, evaluation, condition: new, used; 1st / 2nd choice; production details of the part.

[0039] The data set contains, for example, three areas per part. a) Unique barcode trolley + unique barcode part / item b) IN Part-, product-, process-oriented fields Completion: Part ... from now on ... qualified for shipping c) OUT Shipping-oriented processes until leaving the facility, e.g. packing, weighing ... until loading the truck, etc.

[0040] The open data record for the part may contain fields for outgoing goods information: assignment of the part to an addressee / recipient: customer; supplier; special features before delivery: e.g. 'value added services'; export documents, etc.

[0041] The facility features in particular "holding buffer zones", i.e. workstations with upstream and downstream rest zones (waiting transport).

[0042] The system's control unit can also include a returns management function. This defines a process chain that can depend on the condition of the goods, e.g., 'OK' for sale, repackage, dry cleaning; part only for 'second-hand' or bulk goods, or recycling.

[0043] The invention focuses on 'customization' – individualization. The perspective changes over time: at the beginning, the part / product is the focus; at the end, the recipient and their wishes dominate the scene.

[0044] The invention can generally be described as event-driven logistics or / or as mass production with a lot size of 1.

[0045] The process management is implemented in such a way that, for example, scanners are present at decision points which can specify or confirm the next destination.

[0046] A system according to the invention serves to carry out the method described above. The system comprises a control unit, a database, and an overhead conveyor with a plurality of trolleys as carriers for holding parts. Furthermore, at least one workstation is provided where at least one property of a part is added. Each trolley is connected to a read and / or write element, and an open data record is created / generated for each read and / or write element, which is linked to an electronically writable, individual data record for each part. Each individual part is recorded as unique, with the control unit assigning processes to each individual part in the course of an individual workflow, and the logistics of the individual part being triggered by the necessary processes.

[0047] The workplace is equipped in such a way that the part can be supplemented with at least one additional feature.

[0048] It is advantageous if the existing, missing and / or added property(ies) are entered into the data record.

[0049] The process and the material features as described above can be present individually or in any combination.

[0050] Further advantages of the invention are described in the following exemplary embodiments. These show: Figure 1 an example of a flowchart of process management in a plant according to the invention, Figure 2 an assignment of properties of a part to a read / write element according to the data management system according to the invention, Figure 3 an example of a material flow, Figure 4 an example of a first-level layout and Figure 5 An example of a third-level layout.

[0051] As in Figure 1As shown, the process in the input area of ​​the system is specifically related to the individual part. Later, in the output area of ​​the system, the focus shifts more towards the order being placed. Of course, according to the invention, it is also possible for the entire system to operate on a part-specific basis.

[0052] The item, in this case a garment, enters the facility and is first registered in the Registration Area. A barcode is printed and attached to each item. The item is then photographed, and its various characteristics are recorded. This recording can be done manually, meaning a person inspects the item and enters the identified or missing characteristics into the database, linked to the item and its barcode. Alternatively, it can be done automatically, by analyzing the photograph of the item, recording its characteristics, and entering them into the database.

[0053] After the parts are scanned and registered, each one is arranged on its own trolley. Depending on the requirements, the part is then transported to various workstations for processing to complete any missing properties. These workstations are equipped differently, for example, with a photo station, or with automatic or manual tools for improving the part's properties, thus advancing its performance. The logistics for each part are managed in such a way that each individual part is recorded as unique, with each part following a specific process path. The logistics for each part are triggered by these individual processes. The specific tasks required for each part, as well as the available capacity of the workstations, determine its placement at each workstation.The logistics of each individual part depend on its existing and / or missing properties and / or the necessary addition of those properties. Each goods carrier is identified, particularly by means of a scanner, and can be guided and routed through the system to specific workstations.

[0054] In the facility according to Figure 1Once the part's properties have been improved as much as necessary or possible, it is moved to a holding buffer from which it can be distributed to further stations. In this case, the part is either conveyed to a static storage area, for example, if it is not expected to be needed for an extended period. Alternatively, it can be moved directly or via quality control to a buffer intended for online sales. Another alternative is to move the part via quality control to a holding buffer. Finally, when the part is to be picked, it enters a dynamic buffer and from there, depending on the order and the part's properties, to output points for recycling, wholesale sale, or packaging and retail sale.

[0055] In Figure 2Figure 1 illustrates a variant implementation of the data management system of the present invention. A data record is assigned to a specific trolley and part pair. Scanners use a barcode to identify the trolley and, consequently, the part. In a database associated with the system, an open data record is created / generated for each read and / or write operation. This record is then linked to form an electronically writable, individual data record for each part. Part information, including its properties and, if applicable, shipping data, is incorporated into the data record. These properties are added during the part's processing at the workstations. Thus, gaps in the data record, representing missing properties, are gradually filled. When a scanner queries the current properties, the system can determine the next step: moving the part to another workstation or a specific storage location to fill in the remaining gaps.This is therefore an event-driven logistics system.

[0056] The goods or parts are moved according to an individual logistics plan. With a large number of individual parts being moved individually, a highly efficient system concept emerges, capable of quickly capturing, storing, and shipping even individual parts with very specific properties.

[0057] In Figure 3 A material flow according to the invention is illustrated. Initially, the individual parts are handled on a part-by-part basis. Later, for shipping or order picking, processing is order-based. The order can consist of several parts or just one part with very specific properties. The parts are repeatedly placed in waiting buffers, dynamic buffers, or static or dynamic storage until they reach a further processing station or are shipped.

[0058] In Figure 4This is an example of a layout for one level of a system. The layout includes overhead conveyor tracks, switches, workstations, and buffers through which individual parts can pass to improve their performance. Additional levels, not shown, contain further storage and buffers for trolleys carrying parts currently waiting. The trolleys are continuously scanned and guided to their next position. At this next position, for example, a part's property is improved, the part is inspected, stored, or picked.

[0059] Figure 5 shows an upper level, for example a third level of the layout of the Figure 4In this level, the parts await retrieval, either randomly or sorted according to a predetermined storage strategy. They can be marked so that, for example, they are always filtered by priority based on the 'oldest part' (the part that has been in the filtering process the longest). Parts can be moved to this third level for temporary storage from either the first or second level. When the parts are needed for picking, they are either moved to the second level for further filtering or sorting, or to the first level for sorting, or directly to the packing station.

[0060] The present invention is not limited to the embodiments shown and described. Modifications within the scope of the claims are possible, as is a combination of the features, even if these are shown and described in different embodiments.

Claims

1. A method for controlling an installation and for logistics of parts, in particular for processing, tracking and distributing them in the installation, wherein - each individual part is detected as a single piece, - the individual part is connected / coupled to a trolley which is equipped with a reading and / or writing element, in particular a barcode or transponder, as a result of which the individual part becomes a single piece, - an open data set is created / generated for each reading and / or writing element in a database which is assigned to the installation, which open data set is linked to form an electronically writable, individual data set per part, and - the individual part is checked for the presence of information, such as, for example, article number and / or article description, or is examined for the presence of predetermined properties, and existing or determined properties are entered into the data set, characterized in that - the presence of all the buttons, the functional capability of zip fasteners, holes in the textile and / or the general state of the textile are defined as properties and are entered into the individual data set, - processes are assigned to each individual part by the controller in the course of an individual career path, and the logistics of the individual part are triggered by the necessary processes, - the individual career path of the individual part is the change in state thereof and the processes necessary for this are the detecting and supplementing of properties of the individual part and the commissioning, if appropriate with further parts, of the individual part, - the individual part is supplemented with at least one property at at least one workplace and this supplemented property is entered into the data set, - the logistics of the individual part are carried out as a function of its existing and / or missing properties and / or the required supplementing of its properties, and - the further transport path of the individual part is determined as a function of the current properties of the individual part and the location of the individual part and corresponding to a current loading capacity of the workplaces, and the part is then directed to a workplace in which free capacities are present.

2. The method according to the preceding claim, characterized in that the individual part is supplied to an individually determined process chain, for example for return parts, or in that properties of the parts, such as color, shape or size, up to the identification of the part, for example water bottle or 0.5 l filled Cola bottle, are determined manually or automatically at workstations, in particular by photographing parts, for example in and / or outside the installation.

3. The method according to one or more of the preceding claims, characterized in that the individual part is subjected to a quality check, in particular before jamming and / or storing in the installation.

4. The method according to one or more of the preceding claims, characterized in that the individual part, after supplementing the property(s) at the workplaces or after it has been determined that no further property is to be supplemented, is supplied to a jamming zone, a buffer or a store.

5. The method according to one or more of the preceding claims, characterized in that the individual part is stored dynamically in the jamming regions or the store zones and - as soon as appropriate - is commissioned.

6. The method according to one or more of the preceding claims, characterized in that the individual part, in the presence or absence of certain properties, is supplied to a store from which the individual part is sold online or via retail, and / or in that the individual part, in the absence of less important or a small number of properties, is supplied to a wholesale store from which the individual part is sold to a wholesale, and / or in that the individual part, in the absence of important or a large number of properties, is supplied to a recycling store from which the individual part is supplied to a recycling or other utilization process.

7. The method according to one or more of the preceding claims, characterized in that the individual parts are transported on goods carriers, in particular on trolleys, which are equipped with the reading and / or writing element, in particular a barcode or transponder, to which individual parts are fastened, for example clamped or suspended on brackets, or placed, for example in bags or sacs, grid baskets or trays, and which have a goods label or existing properties, wherein the goods carriers or the parts connected thereto are treated as individual single pieces.

8. The method according to one or more of the preceding claims, characterized in that the existing properties are stored in a data memory by means of a coding of the individual part and, if required, are assigned to the coding of the individual goods carrier.

9. The method according to one or more of the preceding claims, characterized in that each goods carrier, in particular by means of a scanner, can be identified and guided through the installation in a targeted manner to workstations and sluiced.

10. The method according to one or more of the preceding claims, characterized in that information about the current properties of the individual part is detected at the workstations or the task in the process chain is displayed at this workplace and, after the individual part has been processed, all information which is important or relevant for this part can be stored electronically in the data set.

11. The method according to one or more of the preceding claims, characterized in that the individual parts can be, for example, returns or used textiles, which are checked for their state or their further processing, and the identification and the state are determined by means of the determined properties and the necessary steps are predefined in the process chain.

12. An installation for carrying out the method according to one or more of the preceding claims, wherein the installation has a controlling means, a database and a suspended track with a multiplicity of trolleys as goods carriers for receiving parts and at least one workplace, at which at least one property of a part is supplemented, wherein - each trolley is connected to a reading and / or writing element and - an open data set is created / generated for each reading and / or writing element in the database which is assigned to the installation, which open data set is linked to form an electronically writable, individual data set per part, and - each individual part is detected as a single piece, characterized in that - the presence of all the buttons, the functional capability of zip fasteners, holes in the textile and / or the general state of the textile are defined as properties and are entered into the individual data set, - processes are assigned to each individual part by the controlling means in the course of an individual career path, and - the logistics of the individual part are triggered by the necessary processes, and - the workplace is equipped in such a way that the part can be supplemented with at least one property, - the controlling means of the installation brings about the logistics of the individual part as a function of its existing and / or missing properties and / or the required supplementing of its properties, and - the controlling means of the installation determines the further transport path of the individual part as a function of the current properties of the individual part and the location of the individual part and corresponding to a current loading capacity of the workplaces, and then directs the part to a workplace in which free capacities are present.

13. The installation according to the preceding claim, characterized in that the existing, the missing and / or the supplemented property / properties is / are entered into the data set.