Micro-fulfillment system for ultra fresh products
Patent Information
- Application Number
- EP2024732265
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-09-11
- Filing Date
- 2024-06-10
- Publication Date
- 2025-10-15
AI Technical Summary
Conventional micro fulfillment systems are limited in their product range due to spatial constraints, leading to challenges in handling fresh, ultrafric, or rare products, which results in a poor ecological footprint and inefficient order processing.
A picking system that includes a micro-fulfillment system with an automated storage system for standard products, a farm unit for producing special products, and conveyor technology to connect the farm unit with the workplace, enabling same-day processing of orders containing fresh or rare products without external transports.
This solution allows for the efficient and sustainable processing of customer orders, including fresh and rare products, within a short time frame, reducing energy consumption and CO2 emissions while enhancing customer satisfaction through immediate delivery.
Smart Images
Figure EP2024065903_20032025_PF_FP_ABST
Abstract
Description
Micro-fulfillment system for ultra-fresh products The present invention relates to a picking system, a picking installation, and a method for processing a picking order containing a special product. The invention is particularly used by retailers, preferably grocery retailers, operating online in an urban environment to implement a one-day delivery strategy. Today's customers have limited time and are willing to pay for convenience. Online, customers can search for products, especially basic (daily) necessities, on multiple sites and across multiple channels and find an attractive price within seconds. If providers don't put the customer first, a negative shopping experience—whether in-store or online—will likely cause customers to choose a competitor. Micro-fulfillment is already helping providers create a seamless shopping experience and overcome challenges such as urbanization, fast deliveries, and labor shortages. A "micro-fulfillment system" refers to an order fulfillment system with high storage density and high throughput that is designed to process orders within the shortest possible time (e.g. within one to two hours). This involves using proven storage and picking technology on a smaller scale in order to be closer to the consumer or customer in the smallest possible space, particularly in urban areas. Real estate is expensive in urban areas. This also makes it more expensive and difficult for retailers to be "close" to consumers than ever before. Since online orders have not generated profits in the past - and e-commerce continues to grow - most current fulfillment models are unsustainable. Consumers want immediate gratification, and they like to shop online. They want their goods delivered quickly and, if possible, free of charge, and expect a seamless shopping experience, regardless of the channel they use to buy.The labor shortage in logistics is currently a major challenge. The aging population, delayed population growth, and the declining number of people available for warehouse work make automation unavoidable. Companies are using automation not only to relieve their employees of non-value-added tasks, but also to empower skilled workers to make their operations more efficient, competitive, and profitable (source: www.dematic.com on "micro fulfillment"). Advantages of conventional micro-fulfillment systems are (source: www.dematic.com on “micro fulfillment”): Faster order processing: Automation enables orders to be fulfilled in less than one hour. Optimal use of space: Micro-fulfillment fits into the existing space and reduces footprint and costs. Scale for growth: Micro-fulfillment is flexible and allows you to easily expand the system to increase capacity and adapt order processing to business needs. Accurate picking: Software synchronizes equipment, processes, and inventory for fast and accurate delivery. Proximity to the consumer: By utilizing existing retail space in urban warehouses and distribution centers, goods can be stored close to the end customer A mini- and / or micro-fulfillment system is a miniaturized distribution center, i.e., a miniaturized automated storage and picking system, such as an automated small parts warehouse (ASW), a shuttle rack warehouse, or another compact storage system, e.g., a fully automated tote stacking warehouse. These miniaturized systems can be installed in the rear of a (stationary, existing) retail store. They are characterized by high storage density, high ceiling height, narrow aisles, and automated warehouse machines (e.g., shuttles). The problem with conventional micro-fulfillment systems is that these systems can only access a very limited product range in terms of the number of different products or product types, particularly due to the spatial limitations of the warehouse, so that there are only a few storage spaces on the shelves. Limiting the product range to a predetermined number of different product types is also problematic when, in order to process an order, a product transfer must be carried out between different micro-fulfillment systems because not all of the required products are available in the original micro-fulfillment system to process the order from "one (single) source," namely this one micro-fulfillment system. Transport between distant micro-fulfillment systems pollutes the environment, particularly with regard to CO2 emissions. In these cases, order processing is not sustainable. This problem is exacerbated when a product is not available in any of the micro-fulfillment systems located nearby and therefore has to be retrieved from a central warehouse located even further away. It is even worse when this product is not available in the central warehouse and therefore has to be ordered from the manufacturer. Furthermore, fresh and ultra-fresh products pose a problem, particularly in the food retail trade. Fresh and ultra-fresh products, such as fruit, vegetables, herbs, etc., are characterized by short or very short best-before dates and are therefore not included in the standard range of automated storage systems that work with storage containers. It is difficult, if not almost impossible, to store fruit and vegetables for extended periods in storage containers, which in turn are stored on a shelf. Although fresh fruit and vegetables are delivered daily, the fruit and vegetables are not added to the storage container storage system, i.e. inventoried, but consumed directly from the incoming goods load carrier. Due to the perishable nature of these products, only small quantities are usually ordered per micro-fulfillment system.These small inventory quantities are typically consumed on the same day, or at the latest the next day, to minimize the number of products discarded due to expiration. Micro-fulfillment system operators could reorder more of these products, but this would result in the negative ecological footprint described above. The same problem arises with products that are ordered or sold extremely rarely. Examples of rarely sold products in a grocery store include pencil sharpeners, scissors, and preserving jars. New production technologies also allow textiles and clothing to be completely customized and manufactured quickly. These rare and / or customized products are not part of the retailer's standard product range and must be laboriously sourced from another source (central warehouse or directly from the manufacturer), which costs time and money. DE 10 2016 100 133 A1 relates to a method for producing customized padding adapted to the shape of a piece of cargo to be transported. The padding can be produced using a 3D printer. US 2019 / 0 009 334 A1 concerns a system for additive manufacturing. Therefore, it is an object of the present invention to provide a picking system and a picking system with such a picking system, which result in a better ecological footprint and in particular enable the (automated) processing of customer orders containing fresh or extremely rare products on the same day of receipt of the order. This object is achieved by a picking system for processing a picking order which comprises a special product and which is in particular a corresponding retail picking order, wherein the picking system has: a fulfillment system, in particular a micro-fulfillment system (MFS), which has: an automated storage system with storage containers, which comprises an assortment (exclusively) of (pre-specified) standard products, which are preferably stored in the storage containers; a workstation for picking and packing the products of the picking order; an automated warehouse conveyor system which connects the storage system and the workstation;a controller that is communicatively connected to the warehouse system, the workstation, and the warehouse conveyor system, and that is configured to pick the picking order and prepare it for collection and / or delivery, in particular to pack it, within the same day on which the picking order is received by an operator of the picking system; at least one farm unit that is configured to produce the special product that is not stored in the storage containers and, as soon as it is produced, to issue the special product on demand based on the picking order; and another conveyor system that connects the farm unit and the workstation to transport the special product to the workstation after its production and issue in order to fully process the picking order without using products from outside the picking system. External picking system means that the corresponding product is not available within the respective picking system and must be obtained from another picking system, from a central warehouse and / or directly from the external manufacturer which entails a corresponding transport and time expenditure, which is undesirable. A key difference between conventional fulfillment systems (such as a central warehouse or distribution center) and micro-fulfillment systems (small order picking systems, particularly in urban environments) is the additional farm unit. The farm unit does not exist in the conventional approach, at least not in combination with micro-fulfillment systems. The farm unit opens up new possibilities and, in particular, contributes to expanding the product range and enhancing and accelerating order processing. The farm unit replaces the producer or manufacturer of specialty products. Logistical (relocation) transport i) between the producer or manufacturer and a central warehouse, ii) between the central warehouse and the fulfillment system, and iii) between the fulfillment systems themselves are eliminated. This results in less energy (fuel) consumption and less CO2 emissions. Fewer trucks travel between the individual, distantly located locations. The (end) customer receives fresh, ultra-fresh, and / or rare products within the shortest possible time, especially from a single source. Procurement and waiting times are eliminated. Customer satisfaction increases. One-day delivery strategies can be implemented even though the (picking order) contains products that, for example, have an (extremely) short shelf life and / or an (extremely) rare access frequency, and are therefore not part of the standard range that is stored in the (storage container) storage system. Preferably, the at least one farm unit comprises a vertical farm and / or a 3D printing farm and / or other product-individualizing production facilities. With a vertical farm, plants can be grown and harvested automatically, especially under otherwise unsuitable conditions (e.g., in the desert). This can be particularly advantageous in the food retail industry. A vertical farm is, in particular, a storage elevator system designed for the automated cultivation of plants. With the 3D printing farm, complex and hard-to-obtain products can be manufactured quickly and easily on-site. With new production technologies, e.g. weaving and / or sewing robots (product-customizing production equipment), textiles and clothing can be completely customized and produced quickly. Preferably, the at least one farm unit further comprises a farm control unit configured to cause excess production to be stored in the storage system; and / or to control production of the special product and to monitor a production status, particularly in the event of a mismatch between an order and harvest. The farm control unit enables automated production of plants and / or hard-to-obtain products, especially within a very short timeframe, making one-day delivery strategies easy to implement. Customers don't have to wait. They receive rare products immediately. Customer satisfaction increases. The plant operator doesn't have to worry about production because it is automated. The warehouse management system not only enables the coordination of the retrieval orders for standard products at the same time of availability at the workstation, but can also include the production time of special products in determining this time, so that the scheduled production of the special products and the scheduled retrieval of the standard products can be commissioned so that i) all order items or order lines of an order are available and can be packed at the time of availability at the workstation and ii) the customer can be informed of an exact earliest collection time. Preferably, the system further comprises a transfer station where the completed and packed picking order is made available for collection by the customer and which is connected to the workstation via the conveyor system. The transfer station enables the facility operator to offer "Click & Collect," increasing customer satisfaction. Preferably, the control system is set up to trigger a retrieval order in the warehouse system and a production order in the farm unit to process the picking order. Standard products come from the warehouse system. Specialty products are manufactured in the shortest possible time. Order processing times are shorter compared to the traditional approach. Customers can receive (ultra-)fresh products that have just been harvested. Customers can obtain hard-to-find products without having to wait. Preferably, the standard products are non-perishable and / or suitable for being stored in the warehouse system for a longer period of time (e.g. several days or weeks), and the special product i) is perishable, fresh or ultra-fresh, ii) is a product produced in a farm unit with an extremely low access frequency or iii) is an individual or a customizable product that has to be specially produced due to the picking order. The farm unit enables the plant operator to supply products that he would otherwise not be able to supply with the same freshness, in the same time, or at all. This advantage is particularly noticeable when the operator is a food retailer with a grocery product range. This means that the product range is a supermarket product range that essentially includes groceries. Preferably, the facility also includes a stationary retail store where customers can shop directly. This allows the operator to supply customers with products online and in-store, enabling an omnichannel strategy. In particular, the control system is also configured to generate in-store picking orders and issue them to store employees. In this way, the product range for online customers can be expanded even further, because products that are (only) available in the sales area and may not even be part of the warehouse system's product range can be used. This object is further achieved by a picking system comprising a picking system according to the invention positioned at a first location, and a further (micro-) fulfillment system positioned at a second location remote from the first location, such that product exchange between the system and the further system is only possible via means of transport (e.g., trucks), and wherein the first and second locations are preferably located within a single urban zone (city or district). Preferably, innovative and much faster systems that are completely independent of road traffic can also be used, such as drones or tunnel transport systems (e.g., Cargo sous terrain; see www.cst.ch). The object is further achieved by a method for processing a customer order comprising at least one special product and representing a picking order, preferably using a picking system according to the invention, comprising the steps of: Receiving the order by the system operator; Analyzing the order to determine whether at least one special product is included; If a special product is included, issuing a production order to the farm unit and initiating an automated production of the special product and preferably a harvest of the special product by the farm unit if it is is a plant-based food; delivery of the special product thus produced to the workplace, preferably using conveyor technology; packaging of the special product to hand it over directly to the customer or to a delivery service. It is understood that the features mentioned above and those to be explained below can be used not only in the respective combinations specified, but also in other combinations or on their own, without departing from the scope of the present disclosure. Exemplary embodiments of the disclosure are illustrated in the drawings and explained in more detail in the following description. Fig. 1 shows a block diagram of a picking system. Fig. 2 shows a perspective illustration of a picking system. Fig. 3 shows a schematic illustration of a picking system in an urban environment. Fig. 4 shows a functional and structural diagram of a picking system including components of a higher-level control system. Fig.5 shows a flowchart of a method for processing a picking order. The present invention is particularly applicable in the retail sector, preferably in the food retail sector. Retail can be roughly divided into two areas: i) grocery or general stores (such as "Flink" or "Gorillas") and ii) non-food retailers (such as "Amazon"). Food retailers can be further subdivided into: fast delivery services, which deliver to customers within one to two hours, preferably on the same day the order is placed; and slow delivery services, which deliver within the next day. The retailers mentioned above as examples (such as Flink, Gorillas, and Amazon) operate (exclusively) online with a one-day delivery strategy. This means that (end) customers place their orders online, and the retailers do not have any brick-and-mortar, local stores where customers can come and go to inspect and immediately pick up the desired products. Therefore, micro-fulfillment systems 14 (see Fig. 1) of the type mentioned above are used, which are located in close proximity (e.g., within a city). Express delivery services, in particular, use micro-fulfillment systems 14 for order processing. The present invention can be "Click & Collect" compatible. The Click & Collect function offers end customers the opportunity to initially research and purchase products online. However, the products are picked up by the customer themselves in a brick-and-mortar retail store or shop. This function is usually offered as a separate option on websites during the payment process; see Wikipedia on "Click and Collect." In contrast to "Click & Collect," with "Home Delivery" the ordered products can be sent directly to the customer (via a freight forwarder or parcel delivery service). In this case, the customer does not have to pick up the ordered products anywhere. The present invention can also be "home delivery" compatible. The present invention is "omnichannel" compatible. "Omnichannel" describes a model in which various sales channels (such as brick-and-mortar stores, commerce via social media, commerce via the Internet (e-commerce), commerce via landline telephone and mobile phones (apps), etc.) are optimally utilized to sell products. Market demands today are fast-moving. Customers are demanding and expect to be able to find the items they want anytime, anywhere. Most retailers therefore rely on an omnichannel strategy to keep up with these growing demands. To be successful in e-commerce, many retailers no longer sell their goods exclusively through their own online shop. Various sales channels such as Amazon or eBay marketplaces are used. The present invention meets these demands. Figure 1 shows a block diagram of a picking system 10. The picking system 10 comprises at least one picking system 12. In the following, the structure of a single picking system 12 will first be considered before the system 10 is examined in more detail. The statements regarding the picking system 12-1 in Figure 1 generally apply to any picking system 12. The system 10 and the system 12 are configured to process picking orders. The picking orders correspond to orders that customers place (online) with the operator of the system 10 and / or the system 12. These orders are characterized by one or more product types (order lines) and the associated quantity(s). An order can include several different products that differ in type. A distinction is made between standard products and special products. An order can include standard products and / or special products. The picking system 12 has a fulfillment system 14, which is particularly designed as a micro-fulfillment system (MFS). Furthermore, the picking system 12 has a farm unit 16 and a conveyor system 18. Optionally, the picking system 12 can also have an (automated) transfer station 20. The picking system 12 can be part of a stationary retail store (or retail outlet) 22. The fulfillment system 14 has an (automated) warehouse system 24, a (picker) workstation 26, a warehouse conveyor system 28 and an (MFS) control system 30. The storage system 24 may include a racking arrangement 32 comprising one or more racks 34 and at least one storage machine 36. The storage machine 36 may be implemented by one or more storage and retrieval machines, such as a (single-level) shuttle, arranged within a rack aisle defined between directly adjacent racks. The storage system 24 is operated with a plurality of storage containers (not shown) in which an assortment of predetermined standard products is stored. A standard product is understood below to be a product that has a minimum shelf life of several days and is preferably not spoiled. This applies in particular to the food retail sector. The standard products are particularly suitable for being stored in the storage containers of the storage system for a longer period of time (for example, several days and / or weeks). This also includes, for example, frozen products. The standard products are preferably stored in the storage containers according to type. The assortment is understood below to be the entirety of the products that are available to the fulfillment system 14 - through access to the storage system 24 - in order to process picking orders. It is understood that, in addition to the automated warehouse system 24, additional warehouses, such as a floor storage area for pallets, may be provided. Products from these warehouses are regularly picked manually and therefore do not represent standard products of the automated warehouse system 24. During picking, the products are removed from the storage containers according to the picking orders and placed in destination containers. When the filled destination containers are handed over to the end customer or shipped, the picked products no longer need to be reloaded or packed. In this case, the destination containers also represent the shipping containers. Alternatively, the destination containers can be transported to a packing workstation, where the picked products are reloaded into the shipping containers. In this case, there are several workstations 26, one for picking and another for packing. However, it is equally possible to perform the picking and packing activities at a single workstation 26. The automated warehouse conveyor system 28 can comprise continuous conveyors and / or discontinuous conveyors. The warehouse conveyor system 28 can be implemented by mobile robots and / or positively guided automated guided vehicles. The warehouse conveyor system 28 can comprise belt conveyors, roller conveyors, chain conveyors, overhead conveyors, and the like. Drones can also be used. The storage containers are transported to workstation 26 by the storage conveyor system 28 and then transported back to the racking arrangement 32. Workstation 26 can be operated manually, partially automated, or fully automated. The controller 30 can be communicatively connected to the warehouse system 24, in particular to exchange data required to process a picking order. This data can also include material flow data. The controller 30 can also be communicatively connected to the workstation 26 and the warehouse conveyor system 28. The controller 30 is further configured to pick (removal + delivery) the picking order within the same day (one-day delivery) on which the picking order is received by an operator of the picking system 12 and to prepare it (in particular to pack it) for collection and / or delivery. The farm unit 16 is configured to produce one or more special products (such as fresh food or 3D-printed products) that are (generally) not stored in the storage containers, in particular because they are not part of the standard assortment, and to issue the special product(s) as soon as they are produced, based on the picking order, on demand. Overproduction of special products can be temporarily stored in the storage system 24 and / or delivered to neighboring, remotely located other picking facilities (e.g., 12-2 in Fig. 1) for (immediate) consumption there. During this transitional period, the special products of the overproduction belong to the assortment but are nevertheless not standard products. This applies generally. The farm unit 16 can have a (separate) farm control unit (cf. farm control module 31 in Fig. 4) that can communicate with the MFS controller 30. The farm control unit is configured to cause the one or more special products contained in one of the picking orders to be produced as needed (in real time and immediately) and, if necessary, also harvested. The farm control unit can further be configured to store excess production in the storage system. Furthermore, it can Control production of the special product and monitor production status, especially in case of a delay between an order and harvest. The farm unit 16 can be a so-called vertical farm, as offered by the applicant under the product name "LogiFarm." This is an (automated) storage lift system based on the applicant's "Logimat" product and adapted for the cultivation and harvesting of green plants (e.g., vegetables and herbs) by providing appropriate air conditioning, irrigation, fertilization, etc. In the farm unit 16, for example, lettuce heads can be grown automatically. Each storage lift tray can contain lettuce heads at a different growth stage. Based on a corresponding picking order containing one or more lettuce heads, the farm control unit can receive a corresponding order from the M FS controller 30 to harvest a corresponding number of lettuce heads. The farm control unit selects a suitable one of the storage lift trays that is ready for harvesting and initiates the (automated) harvesting of the corresponding number of lettuce heads, which are then transported via the conveyor system 18 to the workstation 26 to complete the picking order. The MFS controller 30 can also be configured to trigger a retrieval order in the warehouse system 24 and a production order in the farm unit 16 to process the picking order. The retrieval order retrieves the storage containers from the warehouse system 24 to the workstation 26, which contain the standard products included in the picking order. The production order results in either a harvest of plants and / or the production of a special product or a component thereof. It may also be (economically) sensible to harvest the remaining lettuce heads from this tray (overproduction) and then feed them to the storage system 24 or another picking system (e.g. 12-2). The surplus lettuce heads can be placed in the storage bins, which leads to the surplus lettuce heads being returned to standard Products. As long as there are surplus lettuce heads in the storage system 24, no new lettuce heads will be produced by the farm unit 16 (as special products). Surplus lettuce heads that have been in the storage system 24 for too long (best before date exceeded) can be removed from the storage system 24, whereby the lettuce heads become special products again. If the picking system 12 includes a stationary retail store 22, the surplus production could also be offered for sale directly on the sales floor where customers shop as usual. In this case, the lettuce heads would continue to represent special products because they would not be stored in the storage system 24 and thus would not become standard products. If a sales area is available, so-called in-store picking can also be carried out, in which employees of the stationary retail store collect products and then either hand them over to a delivery service or make them available for “Click & Collect” pickup. Alternatively or additionally, the farm unit 16 can be configured, for example, as a farm of 3D printers (3D printing farm), with which a multitude of different products and / or product components (such as spare parts for products) can be printed live, on demand, and on-site. This particularly concerns the production of products with a low to extremely rare access frequency. Such products are typically referred to as C and / or D products. A products have the highest access frequency. A special product can also be a standard product that becomes a special product through individualization. If the system 12 is used, for example, in the environment of a shoe production including connected logistics, i.e. with a storage system 24 according to Fig. 1, shoes could be manufactured in a regular production unit and stored in the storage system 24 as standard products, in order to then be automatically picked. If, for example, a customer wishes to have his name printed on a standard shoe, this becomes a special product. In this case, the corresponding standard shoe is either produced normally or removed from the storage system 24 and then sent to a product-individualizing production facility (e.g. Laser engraving device) to apply the customer's name, thus turning the standard shoe into a special product. Generally, the farm unit 16 serves the purpose of producing specialty products that are not part of the product range of the automated storage system 24, in which the standard products are stored in storage containers. In other words, this means that all products stored in the storage containers of the storage system 24 are, by definition, standard products. It is also understood that the storage containers of the storage system 24 can be exchanged for other load carriers, such as trays, cartons, or (overhead conveyor) bags. However, the use of larger load carriers, such as pallets or mesh trolleys, in the storage system 24 is usually avoided. The further conveyor system 18 connects the farm unit 16 with the workstation 26 in terms of a material flow in order to transport the special products to the workstation after their production and issue in order to completely process the order without using products from outside the picking system. The transfer station 20 is connected to the workstation 26 via the conveyor system 18. The conveyor system 18 can be designed as a continuous conveyor (roller conveyor, chain conveyor, belt conveyor, overhead conveyor, etc.) or a discontinuous conveyor (mobile robots, forced-guided automated guided vehicles, drones, industrial trucks, etc.). The transfer station 20 is preferably fully automated. This means that both the receipt and release of the picked products can be automated. No employees are required. The transfer station 20 is configured to deliver completed orders to the delivery services or the customers. The transfer station 20 can be used to implement the aforementioned Click & Collect functionality. The transfer station 20 can be located remotely from the farm unit 16 and remotely from the storage system 24. The transfer station 20 can be configured to interact with the customer. This means that the customer can, for example, drive up to the transfer station 20 from outside. in order to then enter an individualized code that was previously assigned and sent to the customer for the purpose of handing over the completed order. Figure 2 shows a partially sectioned perspective view of a picking system 12. A stationary sales shop 22 and / or a transfer station 20 can be parts of the picking system 12. The transfer station 20 can be connected to the storage system 24 and the farm unit 16 via a conveyor system 18 with regard to a material flow. The workstations 26, of which four are provided as an example, can be coupled to the storage system 24 with regard to a material flow via the warehouse conveyor system 28. The farm unit 16 can be connected to the storage system 24 and the workstations 26 with regard to a material flow via the (other) conveyor system 18. It is understood that the transfer station 20 can also be located remotely, i.e., outside the picking system 12, e.g., in the city center, similar to an automated, self-sufficient parcel collection station. In this case, the transfer station 20 is connected to the system 12, e.g., via trucks, to implement the "Click & Collect" functionality. In the stationary retail store 22, customers can shop directly by placing the products they need, especially from the area of daily needs (such as groceries), in their shopping cart and paying at the checkout. Figure 3 shows a schematic perspective view of an urban catchment area in which six picking systems 12-1 to 12-6 are planned. The population density in the center can exceed 11,000 inhabitants / km 2 and can be extended to less than 1200 inhabitants / km 2It is understood that more or fewer order picking systems 12 can be provided. Figure 3 illustrates an example of the system 10 of Figure 1. The system 10 can (optionally) have a central warehouse 38 located well outside the urban area outlined by a dashed line 40. The order picking systems 12 are preferably all located within the Urban areas where real estate and land prices are high, so there is a need for miniaturization in the design of the picking systems 12. The system 10 may further include a higher-level controller 42, as indicated in Fig. 4. Fig. 4 shows a block diagram illustrating functional and structural components of the system 10. The functional components are shown in the upper part of the block diagram and essentially relate to control elements, which are preferably implemented as software modules, such as the higher-level controller 42 (see also Fig. 3). The control elements can be provided centrally or decentrally distributed. The control elements can be programs and algorithms that run on one or more data processing systems and are also stored there. The higher-level controller 42 may include one or more software modules: ERP 44, DOM 46, and / or WMS 48. The ERP module 44 represents an enterprise resource planning module that: supports the operator of the system 10 and / or the picking facility 12 in operating the business; and supports automation, financial planning, personnel planning, manufacturing, the supply chain, services, procurement, and the like. The DOM module 46 (DOM = Distributed Order Management) is order management software that uses logic-based order processing to orchestrate and optimize order fulfillment processes. The DOM module 46 is configured to minimize fulfillment lead times and maximize customer satisfaction, but at the lowest possible cost to the retailer, i.e., the operator of the system 10 and / or the facility 12.The DOM module 46 can streamline order management processes through automation, order routing, and omnichannel order fulfillment. The WMS module 48 (WMS = Warehouse Management System) can include a set of strategies and processes designed to organize the operations of a warehouse (e.g., Warehouse System 24) or a distribution center (e.g., Central Warehouse 40) and ensure that such a facility operates efficiently and can achieve its objectives. A key task of the control system, especially of DOM module 46, is the internal coordination of retrieval and production orders. The retrieval orders for storage containers with standard products and the production orders for special Products are coordinated in time so that all products of an order or customer order arrive at the workplace at the same time and in the shortest possible time, preferably in a sequence that is suitable for packaging. Further modules, such as a Dock Yard Management Module (DYMS module) or a Transportation Management Module (TMS module), both of which are not shown in Fig. 4, may be part of the higher-level controller 42. Fig. 4 further shows the farm control module 31, which is executed by the farm control unit to coordinate the cultivation and harvesting of, for example, fresh food and herbs. The MFS controller 30 can be operated with a warehouse control system module 33 for the warehouse system 24, which can also include a robot control module to coordinate discontinuous conveyors of the conveyor system 18. The system 12 can also be provided with a goods receipt 50, where incoming goods products (i.e. standard products) are received, and / or with a goods issue 52, where completed picked and packed orders are handed over to delivery services. Fig. 5 shows a flowchart for processing a customer's (online) order containing at least one special product (picking order). A system 12 as shown in Fig. 1 is used. In a first step, the order or picking order is received by the system operator (S10) and then analyzed (S12) to determine whether the order contains at least one special product (query S14). These steps can be performed by the controller 30. If a special product is included (S14: YES), a production order for the special product(s) is issued to the farm unit 16 by the controller 30 (step S16). The controller 30 (and / or the module 31) initiates the automated Production of the special product and, if necessary, its harvesting if it is a plant-based food (step S18). The special product thus produced is then sent to workstation 26 (step S20), preferably via conveyor system 18, which can in turn be initiated by controller 30 and / or module 31. The products are then picked and packed (step S22) to be handed over directly to the customer or to a delivery service (not shown). If the order (also) includes one or more standard products (No in query S14), these standard products are retrieved using the warehouse conveyor system 28 (S26) and brought to workstation 26 (S20), where they are then picked (withdrawal + delivery) and, if necessary, packed (S22). There, the standard products are combined with the special products, if included in the order, according to the picking order, in particular at the scheduled delivery time.
[0001] List of reference symbols 10 Order picking system 12 Order picking system 5 14 (Micro)Fulfillment System (MFS) 16 Farm Unit 18 Conveyor technology 20 Transfer station 22 Retail shop, stationary 10 24 storage system 26 workplaces 28 Warehouse conveyor technology 30 (MFS) control 31 Farm tax module 15 32 Shelf arrangement 33 Warehouse control module 34 shelves 36 storage machine(s) 38 Central warehouse / distribution center 20 40 City area / urban space 42 Control, superior 44 ERP module 46 DOM module 48 WMS module 25 50 Goods receipt (WE) 52 Goods issue (WA)
Claims
Patent claims 1. A picking system (12) for processing a picking order comprising a special product and, in particular, a corresponding retail picking order, the picking system (12) comprising: a fulfillment system, in particular a micro-fulfillment system (MFS), (14), comprising: an automated storage system (24) with storage containers, which comprises an assortment exclusively of standard products stored in the storage containers; a workstation (26) for picking and packing the products of the picking order; an automated warehouse conveyor system (28) which connects the storage system (24) and the workstation (26) to one another;a controller (30) that is communicatively connected to the storage system (24), the workstation (26), and the warehouse conveyor system (28), and that is configured to pick the picking order and prepare it for collection and / or delivery, in particular to pack it, within the same day on which the picking order is received by an operator of the picking system (12); at least one farm unit (16) that is configured to produce the special product that is not stored in the storage containers and, as soon as it is produced, to dispense the special product on demand based on the picking order; and another conveyor system (18) that connects the farm unit (16) and the workstation (26) to bring the special product, after its production and dispensing, from the farm unit (16) to the workstation (26) in order to completely process the picking order without using products from outside the picking system.
2. Order picking system according to claim 1, wherein the at least one farm unit (16) comprises a vertical farm and / or a 3D printing farm.
3. The picking system according to claim 1 or 2, wherein the at least one farm unit (16) further comprises a farm control unit configured to cause excess production to be stored in the storage system (24); and / or to control production of the special product and monitor a production status, particularly in the event of a mismatch between ordering and harvesting.
4. Order picking system (12) according to one of claims 1 to 3, which further comprises a transfer station (20) where the fully picked and packed order is made available for collection by the customer and which is connected to the workstation (26) via the conveyor system (18).
5. Order picking system (12) according to one of claims 1 to 4, wherein the controller (30) is configured to trigger a retrieval order in the storage system (24) and a production order in the farm unit (16) for processing the order picking order.
6. Order picking system (12) according to one of claims 1 to 5, wherein the standard products are non-perishable and / or suitable for being stored in the storage system (24) for a longer period of time, and the special product is i) perishable, fresh or ultra-fresh, ii) a 3D-printed product with an extremely low access frequency, or iii) a product manufactured in a farm unit with an extremely low access frequency, or iii) an individual or a product to be customized, which is to be specially manufactured because of the order picking order.
7. Order-picking system (12) according to one of claims 1 to 6, wherein the assortment is an assortment of a supermarket which essentially comprises food.
8. Order picking system (12) according to one of claims 1 to 7, which further comprises a stationary sales shop (22) where customers can shop directly.
9. Order picking system (12) according to claim 8, wherein the controller (30) is further configured to generate in-store picking orders and to issue them to employees of the retail store (22).
10. Order-picking system (12) according to one of claims 1 to 9, wherein the storage system (24) comprises a rack arrangement (32) and at least one storage machine (36), which is preferably operated in an aisle of the rack arrangement (32) or is formed by another compact storage system, and wherein the standard products (purely typed) are accommodated in storage containers which are stored in one or more shelves (34) of the rack arrangement (32) or in container stacks.
11. Order picking system (10) with an order picking system (12-1) according to one of claims 1 to 10, which is positioned at a first location, and a further (micro) fulfillment system (14) which is positioned at a second location which is arranged remotely from the first location, so that a product exchange between the system (12) and the further system (14) is only possible via means of transport, and wherein the first and second locations are preferably located within a single urban zone (city or district).
12. A method for processing a customer order comprising at least one special product and representing a picking order, preferably using a picking system (12) according to one of the preceding claims, comprising the steps: Receiving (S10) the order by the plant operator; Analyzing the order (S12) to determine whether at least one special product is included (S14); if a special product is included, issuing (S16) a production order to the farm unit (16) and initiating automated production of the special product and preferably a harvest of the special product by the farm unit (16) if it is a plant food (S18); Delivering (S20) the special product thus produced to the workstation (26), preferably using the conveyor system (18); and packing the special product (S22) in order to hand it over to the customer directly or to a delivery service.
13. The method of claim 12, further comprising: Delivery of one or more standard products to the workplace (26), provided that the order also includes the one or more standard products; and Packing one or more standard products together with the special product.