Information processing device, information processing system, information processing method, and information processing program

Abstract

To provide a technology that enables warehouse operations to continue even if an error occurs in a picking robot. [Solution] An information processing device according to an embodiment includes a communication interface that receives picking result information including the error type of an error detected by a picking system including a picking robot and an inspection unit during operation of the picking system based on an order list, and a processor that predicts the number of inventory mismatches and the number of rejected products based on the error type.

Description

[Technical Field]

[0001] An embodiment of the present invention relates to an information processing device, an information processing system, an information processing method, and an information processing program. [Background technology]

[0002] In recent years, digital transformation (DX) has been progressing in logistics warehouses and other facilities. As a result, various robots are working together to automate tasks in logistics as well. For example, a picking robot can be used to pick products from containers in a product transport system at the upstream stage and supply them to a sorter system at the downstream stage, completely automating the warehouse's outbound work. However, if a picking robot fails to pick an item, a discrepancy will occur between the number of products recorded in the product transport system at the upstream stage and the actual number of products in the sorter system at the downstream stage, making it impossible to continue warehouse operations.

[0003] For example, Patent Document 1 discloses a technique for creating an allocation plan for a picking work unit including a picking robot based on picking success / failure estimation information. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2023-182175 Summary of the Invention [Problem to be solved by the invention]

[0005] Even when based on picking success / failure estimation information as disclosed in Patent Document 1, there is still a problem that discrepancies may occur between the number of products recorded in the upstream product transport system and the downstream sorter system and the actual number of products, making it impossible to continue warehouse operations.

[0006] The present invention has been made in light of the above circumstances, and aims to provide a technology that allows warehouse operations to continue even if an error occurs in a picking robot. [Means for solving the problem]

[0007] The information processing device according to the embodiment includes a communication interface that receives picking result information including an error type of an error detected by a picking system including a picking robot and an inspection unit during operation of the picking system based on an order list, and a processor that predicts the number of inventory mismatches and the number of rejected products based on the error type. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a conceptual diagram showing an example of the arrangement of devices in a warehouse system according to an embodiment. [Figure 2] FIG. 2 is a block diagram illustrating an example of the configuration of a WES according to an embodiment. [Figure 3] FIG. 3 is a block diagram showing an example of the configuration of a WCS according to an embodiment. [Figure 4] FIG. 4 is a block diagram illustrating an example of the configuration of a picking robot according to an embodiment. [Figure 5] FIG. 5 is a block diagram illustrating an example of the configuration of an inspection unit according to an embodiment. [Figure 6] FIG. 6 is a flowchart illustrating an example of the operation of the picking system according to an embodiment. [Figure 7] FIG. 7 is a diagram showing the operation of the picking robot, the notification to the product conveyance system, the operation of the sorter system, etc. for each error type according to one embodiment. [Figure 8] FIG. 8 is a diagram showing an example of picking result information transmitted from the picking robot WCS32 to the WES2. [Figure 9]FIG. 9 is a diagram showing an example of picking result information transmitted from the picking robot WCS32 to the WES2. [Figure 10] FIG. 10 is a diagram showing an example of a screen displayed on the operator's terminal according to an embodiment. [Figure 11] FIG. 11 is a flowchart showing an example of the operation of the WES according to an embodiment. [Figure 12] FIG. 12 is a flowchart showing an example of the operation of the WES2 according to an embodiment. [Figure 13] FIG. 13 is a flowchart showing an example of the operation of the WES2 according to an embodiment. [Figure 14] FIG. 14 is a diagram showing an example of a screen displayed on the operator's terminal according to an embodiment. [Figure 15] FIG. 15 is a diagram illustrating an example of an operation of an error recovery procedure by an attendant according to an embodiment. [Figure 16] FIG. 16 is a diagram illustrating an example of an operation of an error recovery procedure by an attendant according to an embodiment. [Figure 17] FIG. 17 is a diagram illustrating an example of an operation of an error recovery procedure by an attendant according to an embodiment. [Figure 18] FIG. 18 is a diagram illustrating an example of the operation of an error recovery procedure by an attendant according to an embodiment. [Figure 19] FIG. 19 is a flowchart illustrating an example of optimization processing by the WES according to an embodiment. [Figure 20] FIG. 20 is a flowchart illustrating an example of optimization processing by the WES according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, an information processing device, an information processing system, an information processing method, and an information processing program will be described in detail with reference to the drawings. In the following embodiments, parts with the same numbers perform the same operations, and redundant description will be omitted. For example, when there are multiple identical or similar elements, a common symbol may be used to describe each element without distinguishing between them, or a subnumber may be used in addition to the common symbol to describe each element with distinction between them.

[0010] In the following description, the term "A" or "B" means at least one of A or B, and the term "A," "B," or "C" means at least one of A, B, or C. Furthermore, the term "A" and "B" also means at least one of A and B, and the term "A," "B," and "C" means at least one of A, B, and C.

[0011] [Embodiment] (composition) FIG. 1 is a conceptual diagram showing an example of the arrangement of devices in a warehouse system according to an embodiment. As shown in Fig. 1, the warehouse system includes a warehouse management system (WMS: Warehouse Management System) 1, a warehouse execution system (WES: Warehouse Execution System) 2, a product transport system (WCS: Warehouse Control System) 31, a picking robot WCS 32, a sorter system WCS 33, a product transport system 4, a picking robot 51, an inspection unit 52, a product transport system linkage module 53, a sorter system linkage module 54, and a sorter system 6. In one embodiment, the picking robot 51, the inspection unit 52, the product transport system 53, and the sorter system linkage module 54 configure a picking system. The picking system includes at least the picking robot 51 and the inspection unit 52.

[0012] Here, when there is no need to distinguish between the product transport system WCS31, the picking robot WCS32, and the sorter system WCS33, they will be simply referred to as WCS3. In other words, WCS3 refers to at least one of the product transport system WCS31, the picking robot WCS32, and the sorter system WCS33.

[0013] The WMS1 can be configured with one or more general-purpose computers. The WMS1 includes a processor, memory, and interface. The processor is a central processing unit (CPU), a micro processing unit (MPU), a digital signal processor (DSP), or the like. The memory stores the processor's operating program, etc. The interface communicates with the WES2, etc. via a network.

[0014] WMS1 receives outbound orders such as order lists from an external device. WMS1 transmits the received outbound orders to WES2. WMS1 also receives work results, including outbound status, from WES2.

[0015] The WES2 can be configured with one or more general-purpose computers. The WES2 includes a processor, memory, and an interface. The processor is a CPU, MPU, DSP, or the like. The memory stores the processor's operating program, etc. The interface communicates with the WCS3, etc. via a network.

[0016] WES2 receives outbound orders and other order lists from WMS1. WMS1 sends the order lists to WCS3. WES2 also receives information from WCS3, such as the operation history and status of the equipment to which WCS3 is connected, and sends work results and other information created based on that information to WMS1.

[0017] The product transport system WCS31 is composed of one or more computers, i.e., a processor, memory, and an interface. The processor may be a CPU, MPU, DSP, or the like. For example, the product transport system WCS31 outputs product transport instructions to the product transport system 4 based on an order list and controls the product transport system 4.

[0018] An order list is a list of products stored on warehouse shelves or the like, and specifies one or more products. For example, an order list may include product information, ordering information, delivery information, etc. Furthermore, an order list may include a flag indicating first-time arrival, a flag indicating unregistered image or uncompatible recognition dictionary, and a product grasping success rate. Note that the flag indicating first-time arrival, the flag indicating unregistered image or uncompatible recognition dictionary, and the product grasping success rate may be information held as a product database by the product conveyance system WCS31 or the like.

[0019] Product information includes the number of products, product names, product IDs, whether picking was successful, etc. Order information includes the order date and time and the orderer, etc. Delivery information includes the delivery destination, delivery date and time, and the recipient, etc.

[0020] The picking robot WCS32 is composed of one or more computers, i.e., a processor, memory, and an interface. The processor may be a CPU, MPU, or DSP. The picking robot WCS32 acquires products and product information from the product conveyance system 4, which is a preceding device, and supplies the products and product information to the sorter system 6, which is a subsequent device. Here, the product information may be, for example, code information indicating the product represented by a one-dimensional or two-dimensional code.

[0021] The product transport system 4 is a system for transporting shelves or cases, etc., arranged in a warehouse to the picking system 5. For example, the product transport system 4 includes an automated guided vehicle (e.g., an AGV: Automated Guided Vehicle, an AMR: Autonomous Mobile Robot) that transports shelves or cases containing the necessary products to the picking system 5 according to an order list.

[0022] The picking robot 51 is a device for picking products. The picking robot 51 is composed of one or more computers, i.e., a processor, a memory, an interface, etc. The processor is a CPU, an MPU, a DSP, etc. For example, the picking robot 51 communicates with the picking robot WCS 32, the product transport system linkage module 53, etc. under the control of the processor. Based on a picking instruction received from the product transport system linkage module 53 (described later), the processor of the picking robot 51 controls the picking robot 51 to pick up a product from a transported shelf or case and move the product from the picking position to a destination position. Here, the destination position is, for example, a predetermined position where the inspection unit 52 is located. The picking instruction may simply be an instruction to start picking. In this case, based on a detection signal of a product or case arriving at the picking position of the picking robot 51, the processor of the picking robot 51 controls the picking robot 51 to pick up the product that has arrived at the picking position or the product contained in the case and move the product from the picking position to the destination position of the inspection unit 52. The picking robot 51 may be any general device that can pick up products and move the picked products to a predetermined position, and therefore a detailed description thereof will be omitted here.

[0023] For example, when the picking robot 51 moves a product to a predetermined position, it is difficult for the picking robot 51 to detect the following problems. (1) 0 items picked up (even though the picking robot 51 judges that it has picked up an item, it has not actually picked up an item) (2) Multiple product placement (3) Picking the wrong product (i.e., wrong product) (4) Damage to goods (damage to goods during picking) Therefore, the inspection unit 52 described below is used to detect these problems.

[0024] The inspection unit 52, which is a product inspection device, is composed of one or more computers, i.e., a processor, memory, and an interface. The processor is a CPU, MPU, DSP, or the like. The inspection unit 52 transports inspected products to the sorter system 6. The inspection unit 52 recognizes the products placed on the inspection unit 52 using a sensor or the like, thereby determining the condition of the products picked by the picking robot 51. The inspection unit 52 transmits the determined product condition to the picking robot WCS 32.

[0025] For example, the inspection unit 52 receives information about the product to be inspected from the picking robot WCS 32. Then, the inspection unit 52 determines whether or not there is a problem with the product picked by the picking robot 51. Details of the method for determining whether or not there is a problem will be described later.

[0026] The product conveyance system cooperation module 53 is composed of one or more computers, i.e., a processor, memory, interface, etc. The processor is a CPU, MPU, DSP, etc. The product conveyance system cooperation module 53 reads product conveyance information from the operator screen of the product conveyance system 4 and sends a picking request to the picking robot 51. The product conveyance information includes product information (code information), the number of items, the container number to be picked, etc.

[0027] The sorter system cooperation module 54 is composed of one or more computers, i.e., a processor, memory, an interface, etc. The processor is a CPU, MPU, DSP, etc. After products are provided to the sorter system 6 from the picking robot 51 and the inspection unit 52, the sorter system cooperation module 54 transmits product information to the sorter system 6.

[0028] The sorter system 6 is a sorting device that sorts products transported by the inspection unit 52 to sorting destinations called sorting surfaces. The sorter system 6 sends products that have passed through the picking system 5 to the sorting destinations (sorting destinations) in accordance with sorting instructions received from the WCS 3.

[0029] FIG. 2 is a block diagram showing an example of the configuration of the WES2 according to an embodiment. As shown in FIG. 2, the WCS 3 includes a processor 201, a ROM 202, a RAM 203, an auxiliary storage device 204, a communication interface 205, and the like.

[0030] The processor 201 is a CPU, MPU, DSP, or the like. The processor 201 operates based on a program stored in a ROM 202, or the like. The processor 201 acquires an order list and outputs the order list to the product transport system WCS31, the picking robot WCS32, and the sorter system 33. The processor 201 also acquires from the product transport system WCS31 the transport results of the products according to the order list and the transport status, including the operation history of each piece of equipment. The processor 201 acquires from the picking robot WCS32 the shipping status, including the picking record of the products according to the order list and the operation history of each piece of equipment. The processor 201 then acquires from the sorter system WCS33 the sorter status, including the sorter storage of the products according to the order list and the operation history of each piece of equipment.

[0031] The ROM 202 is a non-transitory computer-readable storage medium that stores the above-mentioned programs. The ROM 202 also stores data or various setting values ​​used by the processor 201 when performing various processes. For example, the ROM stores various information such as an order list, the number of inventory mismatches, and the number of rejects. The number of inventory mismatches and the number of rejects will be described in detail later.

[0032] The RAM 203 is a memory used for reading and writing data, and is used as a so-called work area for storing data that is temporarily used when the processor 201 performs various processes.

[0033] The auxiliary storage device 204 is a non-transitory computer-readable storage medium and may store the above programs. The auxiliary storage device 204 also stores data used by the processor 201 when performing various processes, data generated by the processes of the processor 201, various setting values, and the like.

[0034] The communication interface 205 is an interface for transmitting and receiving data to and from various devices. The communication interface 205 connects to WMS1, WCS3, etc. The communication interface 205 also acquires order lists and the like from WMS1. For example, the communication interface 205 supports LAN (local area network) connections, etc. The communication interface 205 may also be configured to include separate interfaces for transmitting and receiving data to and from various devices.

[0035] The product transport system WCS31, picking robot WCS32, and sorter system WCS33 may have the same configuration, and will therefore be described as the above-mentioned WCS3. FIG. 3 is a block diagram showing an example of the configuration of the WCS 3 according to an embodiment. As shown in FIG. 3, the WCS 3 includes a processor 201, a ROM 302, a RAM 303, an auxiliary storage device 304, a communication interface 305, and the like.

[0036] The processor 301 is a CPU, an MPU, a DSP, or the like. The processor 301 operates based on a program stored in a ROM 302, etc. The processor 301 acquires an order list and outputs a picking instruction generated based on the order list to the picking robot 51.

[0037] ROM 302 is a non-transitory computer-readable storage medium that stores the above-mentioned programs. ROM 302 also stores data and various setting values ​​used by processor 301 when performing various processes. For example, the ROM of product conveying system WCS31 stores inventory information. Here, inventory information includes the number of products and types of products held on each shelf or case of product conveying system 4.

[0038] The RAM 303 is a memory used for reading and writing data, and is used as a so-called work area for storing data that is temporarily used when the processor 301 performs various processes.

[0039] The auxiliary storage device 304 is a non-transitory computer-readable storage medium and may store the above programs. The auxiliary storage device 304 also stores data used by the processor 301 when performing various processes, data generated by the processes of the processor 301, various setting values, and the like.

[0040] The communication interface 305 is an interface for transmitting and receiving data to and from various devices. The communication interface 305 connects to WES2 and the like. The communication interface 305 also acquires order lists and the like from WES2. For example, the communication interface 305 supports LAN connections and the like. The communication interface 305 may also be configured to include separate interfaces for transmitting and receiving data to and from various devices.

[0041] FIG. 4 is a block diagram showing an example of the configuration of a picking robot 51 according to an embodiment. As shown in FIG. 4, the picking robot 51 includes a processor 511, a ROM 512, a RAM 513, an auxiliary storage device 514, a communication interface 515, a picking means 516, and the like.

[0042] The processor 511 is a CPU, an MPU, a DSP, or the like. The processor 511 operates based on a program stored in a ROM 512, or the like. The processor 511 receives a picking instruction. The processor 521 then controls the picking means 516, which will be described later, and causes the picking means 516 to pick the product. The processor 521 then moves the picked product to a predetermined position in the inspection unit 52, which will be described later. The processor 521 also generates picking result information including information about the picked product, and transmits it to the picking robot WCS32.

[0043] The ROM 512 is a non-transitory computer-readable storage medium that stores the above-mentioned programs. The ROM 512 also stores data and various setting values ​​used by the processor 511 when performing various processes.

[0044] The RAM 513 is a memory used for reading and writing data, and is used as a so-called work area for storing data that is temporarily used when the processor 511 performs various processes.

[0045] The auxiliary storage device 514 is a non-transitory computer-readable storage medium and may store the above programs. The auxiliary storage device 514 also stores data used by the processor 511 when performing various processes, data generated by the processes of the processor 511, various setting values, and the like.

[0046] The communication interface 515 is an interface for transmitting and receiving data to and from various devices. The communication interface 515 is connected to the picking robot WCS32 and the like. The communication interface 515 also acquires picking information and the like from the picking robot WCS32. For example, the communication interface 515 supports LAN connection and the like. The communication interface 515 may also be configured to include individual interfaces for transmitting and receiving data to and from various devices.

[0047] The picking means 516 is a device for picking products. The picking means 516 may be any general device that can pick products and move the picked products to a predetermined position under the control of the processor 511. Therefore, a detailed description thereof will be omitted here.

[0048] The sensor 517 is a device used to recognize products. The sensor 517 may be any sensor capable of recognizing products, such as a photoelectric sensor, a camera, a barcode reader, etc. Therefore, detailed description thereof will be omitted here.

[0049] FIG. 5 is a block diagram showing an example of the configuration of the inspection unit 52 according to an embodiment. As shown in FIG. 5, the inspection unit 52 includes a processor 521, a ROM 522, a RAM 523, an auxiliary storage device 524, a communication interface 525, a conveyor 526, a sensor 527, and the like.

[0050] The processor 521 is a CPU, an MPU, a DSP, or the like. The processor 521 operates based on a program stored in a ROM 522, or the like. When the processor 521 receives an inspection instruction, it inspects the products picked by the picking robot 51 to determine whether there is a problem with the products. Furthermore, if the processor 521 determines that a problem has occurred as a result of the inspection, it generates an inspection result and outputs the generated inspection result to the picking robot WCS32.

[0051] The ROM 522 is a non-transitory computer-readable storage medium that stores the above-mentioned programs. The ROM 522 also stores data and various setting values ​​used by the processor 521 when performing various processes.

[0052] The RAM 523 is a memory used for reading and writing data, and is used as a so-called work area for storing data that is temporarily used when the processor 521 performs various processes.

[0053] The auxiliary storage device 524 is a non-transitory computer-readable storage medium and may store the above-mentioned programs. The auxiliary storage device 524 also stores data used by the processor 521 when performing various processes, data generated by the processes of the processor 521, various setting values, and the like.

[0054] The communication interface 525 is an interface for transmitting and receiving data to and from various devices. The communication interface 525 is connected to the picking robot WCS32 and the like. The communication interface 525 also acquires inspection instructions and the like from the picking robot WCS32. For example, the communication interface 525 supports LAN connections and the like. The communication interface 525 may also be configured to include individual interfaces for transmitting and receiving data to and from various devices.

[0055] The conveyor 526 is where the picking robot 51 places the products, and inspection processing is performed on the products as they flow along the conveyor 526. If the inspection processing finds that there are no problems with the products, the conveyor 526 moves the products to the sorter system 6, which is a subsequent device.

[0056] The sensor 527 includes a weight sensor 5271, a proximity sensor 5272, a camera 5273, and the like.

[0057] Weight sensor 5271 is a sensor for measuring the weight of products traveling on conveyor 526. For example, the measured weight of the products is used to determine whether there is a problem with the products, such as zero products, multiple products, the wrong product, damaged products, or dropped products.

[0058] The proximity sensor 5272 is a sensor for determining whether or not products are flowing on the conveyor 526. The proximity sensor 5272 is used to determine whether or not a problem such as zero pick-up or a dropped product has occurred.

[0059] The camera 5273 photographs the conveyor 526 and acquires a photographed image. The camera 5273 may be a general camera 5273. The photographed image taken by the camera 5273 is used to determine whether or not there is a problem with the product, such as multiple items being picked up, product damage, or product dropping.

[0060] It should be noted that the inspection unit 52 does not necessarily have to include the proximity sensor 5272 and the camera 5273. The information acquired by these is information for further improving the accuracy of inspection by the inspection unit 52, and is not necessarily an essential component.

[0061] (operation) (Picking and inspection operations) First, the picking operation and the inspection operation according to the embodiment will be described. FIG. 6 is a flowchart showing an example of the operation of the picking system 5 according to an embodiment. This flowchart is realized by the processor 511 of the picking robot 51 and the processor 521 of the inspection unit 52 reading and executing programs stored in the ROM 512 and ROM 522, respectively.

[0062] First, the product conveyance system cooperation module 53 reads the product conveyance information from the operator screen of the product conveyance system 4 and transmits a picking request to the picking robot 51, thereby starting the operation of this flowchart.

[0063] In step ST101, the processor 511 of the picking robot 51 acquires a picking instruction. For example, the processor 511 acquires a picking instruction that indicates a product to be picked based on a picking request received from the product conveyance system cooperation module 53.

[0064] In step ST102, the processor 511 attempts to recognize the product specified in the picking instruction. The processor 511 attempts to recognize the product based on sensor information from the sensor 517. For example, the processor 511 attempts to recognize the product based on an image captured by the camera that is the sensor 517.

[0065] In step ST103, processor 511 determines whether or not the recognition of the product has been successful. If it is determined that the recognition of the product has been successful, the process proceeds to step ST104. On the other hand, if it is determined that the recognition of the product has been unsuccessful, the process proceeds to step ST115.

[0066] In step ST104, the processor 511 executes a gripping and motion plan. The processor 511 determines how to operate the picking means 516. That is, the processor 511 executes a motion plan for how to grip the recognized product and move the product to a predetermined location (on the inspection unit 52).

[0067] In step ST105, the processor 511 determines whether the plan was successful. The processor 511 determines whether a grasping and motion plan could be created. For example, if the orientation of the product prevents the picking means 516 from grasping the product, or if the position of the product prevents the picking means 516 from moving the product to a predetermined position even after grasping the product, the processor 511 determines that a grasping and motion plan cannot be created. In this case, the processing proceeds to step ST115. On the other hand, if the processor 511 determines that the product can be grasped and moved to a predetermined position, the processor 511 can create a grasping and motion plan. In this case, the processing proceeds to step ST106.

[0068] In step ST106, the processor 511 performs picking. The processor 511 controls the picking means 516 in accordance with the created gripping and motion plan, and performs picking of the product.

[0069] In step ST107, processor 511 determines whether the product has fallen. Processor 511 determines whether the product has fallen during picking. For example, processor 511 recognizes the product based on sensor information from sensor 517, and determines whether the product can be recognized in the gripping and motion plan. If the product cannot be recognized based on the sensor information, or if the product cannot be recognized in the gripping and motion plan, processor 511 determines that the product has fallen. In this case, the processing proceeds to step ST113. On the other hand, if the product can be recognized in the gripping and motion plan, processor 511 determines that the product has not fallen. In this case, the processing proceeds to step ST108. Note that, when the product is gripped by suction, the determination of whether the product has fallen may be made based on a change in suction pressure.

[0070] In step ST108, the processor 511 releases the product. The processor 511 controls the picking means 516 to move the product to a predetermined position, that is, onto the conveyor 526 of the inspection unit 52, and then release the product.

[0071] In step ST109, the processor 511 starts inspecting the products. For example, the processor 511 sends a release completion notification to the picking robot WCS32. After releasing the products, the processor 511 generates a release completion notification. Then, the processor 511 sends the release completion notification to the picking robot WCS32 via the communication interface 515. The release completion notification may include picking results including the product IDs of the picked products. When the processor 301 receives the release completion notification, it generates an inspection start notification, which is an inspection instruction. The inspection start notification includes information such as the IDs of the products to be inspected, the shape and weight of the products. Then, the processor 301 sends the inspection start notification to the inspection unit 52 via the communication interface 305. Upon receiving the inspection start notification, the processor 521 starts inspecting the products.

[0072] In step ST110, processor 521 determines whether the inspection is normal. For example, processor 521 operates conveyor 526 to move the product to a location where weight sensor 5271 can measure the weight of the product. Then, processor 521 starts weighing the product using weight sensor 5271. Processor 521 uses proximity sensor 5272 to determine whether products are flowing on conveyor 526. Alternatively, processor 521 uses images captured by camera 5273 to determine whether there is a problem with the product. Note that although all of these determinations may be performed, it is sufficient to perform at least one of them.

[0073] If these determinations indicate that there is no problem with the product, processor 521 determines that the inspection is normal. Then, the process proceeds to step ST111. On the other hand, if these determinations indicate that there is a problem with the product, such as multiple items being picked up, product damage, a dropped product, or the wrong product, processor 521 determines that there is an abnormality in the inspection. Then, the process proceeds to step ST112.

[0074] After the inspection of the products is completed, the processor 521 operates the conveyor 526 to move the products to the sorter system 6.

[0075] In step ST111, the processor 521 notifies the normal sorting. For example, the processor 521 indicates to the normal sorter system 6 that normal sorting may be performed. A normal sort is generated. Then, the processor 521 notifies the sorter system cooperation module 54 of the normal sorting via the communication interface 525 and the picking robot WCS 32. The processor of the sorter system cooperation module 54 will present the normal sorting to the sorter system 6. The processor of the sorter system 6 will sort the products based on this presentation. In addition, the processor 301 of the picking robot WCS 31 notifies the picking robot 51 that inspection by the inspection unit 52 has been completed.

[0076] In step ST112, the processor 521 notifies the sorter system cooperation module 54 of the reject sort. For example, the processor 521 generates a reject sort indicating that an abnormality has been found in the product as a result of inspection and that the product should be rejected. The processor 521 then notifies the sorter system cooperation module 54 of the reject sort via the communication interface 525 and the picking robot WCS32. The processor of the sorter system cooperation module 54 presents the reject sort, which includes two-dimensional code information for sorting the products into the reject chute, to the sorter system 6. The processor of the sorter system 6 controls the products to be sorted into the reject chute based on the presentation. In addition, the processor 301 of the picking robot WCS32, which has received the reject sort, notifies the picking robot 51 of the completion of inspection by the inspection unit 52.

[0077] Furthermore, processor 521 generates error information indicating what type of abnormality has occurred in the product (no product, two picked, unknown product), and transmits the error information to picking robot WCS 32. Note that this error information may be transmitted at the same time as the reject sort transmitted to picking robot WCS 32, or may be transmitted at a different time.

[0078] In step ST113, the processor 511 notifies the sorter system 6 of a reject sort. For example, the processor 511 generates a reject sort indicating that the product should be rejected because it has been determined that the product has fallen. In other words, the reject sort includes error information indicating that the product has fallen during movement. The processor 511 then notifies the sorter system cooperation module 54 of the reject sort via the communication interface 515 and the picking robot WCS32. The processor of the sorter system cooperation module presents the reject sort including two-dimensional code information for sorting the product into the reject chute to the sorter system 6. The processor of the sorter system 6 controls the sorter system 6 to sort the product into the reject chute based on the presentation.

[0079] In step ST114, the processor 511 determines whether picking is complete. It determines whether picking is complete based on the picking instruction. If it is determined that it is complete, the process proceeds to step ST115. On the other hand, if it is determined that it is not complete, the process returns to step ST102.

[0080] In step ST115, processor 511 or processor 521 sends a picking completion notification to picking robot WCS32. Processor 511 or processor 521 creates a picking completion notification and transmits the created picking completion notification to picking robot WCS32 via communication interface 515. Processor 301 of picking robot WCS32 sends the picking completion notification to product transport system 4 via product transport system WCS31. As a result, product transport system 4 transports the next shelf or case.

[0081] (WES2 and WCS3 behavior when an error occurs) Next, the operation of the WES2 when an error occurs during the picking operation or the inspection operation will be described. In the above picking and inspection operations, errors can be classified into three types: errors occurring before the picking operation begins, errors occurring during the picking operation, and errors occurring during inspection. For example, if an error occurs in step ST103 or step ST105, it can be assumed that the error occurred before the picking operation began. If an error occurs in step ST107, it can be assumed that the error occurred during the picking operation. Alternatively, if an error occurs in step ST110, it can be assumed that the error occurred during inspection.

[0082] If an error occurs before the start of the picking operation, the processor 511 of the picking robot 51 stops the picking operation and completes the processing of the container being processed. Furthermore, the processor 511 transmits a picking completion notification including error information indicating a recognition failure or a gripping and motion planning failure to the picking robot WCS32.

[0083] The processor 301 of the picking robot WCS32 notifies the product transport system 4 via the product transport system linkage module 53 that the planned number of picks has been picked, and sends a picking completion notification. This causes the product transport system 4 to transport the next shelf or case to the picking station where the picking robot 51 is located. Here, the processor 301 of the picking robot WCS32 notifies the product transport system WCS31 that the specified number of picks has been completed, even though no products have actually been picked. This results in an information-material mismatch, where the inventory information of the product transport system WCS31 (denoted here as A for simplicity) does not match the actual number of products on the shelf or in the case in the product transport system 4 (denoted here as B for simplicity), and an inventory inconsistency occurs.

[0084] If an error occurs during a picking operation, as described above, the processor of the sorter system cooperation module 54 presents a reject sort including two-dimensional code information for sorting the products into the reject chute to the sorter system 6, and causes the products to be sorted into the reject chute. In addition, the processor 511 stops picking the next product and sends a picking completion notification to the picking robot WCS32 including error information including that the product fell during movement.

[0085] If an inspection error occurs, as described above, the processor of the sorter system linkage module 54 presents a reject sort including two-dimensional code information for sorting the products into the reject chute to the sorter system 6, and causes the products to be sorted into the reject chute. In addition, the processor 521 transmits error information indicating what type of abnormality has occurred with the products (no product, two picked, unknown product) to the WES2 via the picking robot WCS32. Meanwhile, the processor 511 continues picking the next product.

[0086] As described above, the picking robot WCS32 can identify the type of error (recognition failure, grasping and motion planning failure, falling during movement, no product, picking two products, unknown product) in the picking system 5 based on the picking completion notification or error information.

[0087] FIG. 7 is a diagram showing the operation of the picking robot 51, the notification to the product conveyance system 4, the operation of the sorter system 6, etc. for each error type according to one embodiment.

[0088] For example, Figure 7 shows, for each error number, the error timing, error type, operation of the picking robot 51, notification to the product transport system 4, operation of the sorter system 6, the number of inventory mismatches in the warehouse system (BA), and the number of rejects by the sorter system 6 (denoted here as C for simplicity).

[0089] As shown in Figure 7, error number A indicates a recognition failure, which is an error that occurs before the picking operation begins. In this case, the action of the picking robot 51 when the error occurs is to stop picking and notify the product transport system 4 of picking completion. In this case, since the picking operation has not been performed, there will be a surplus of items that have not been picked.

[0090] Error number B indicates a failure in grasping and motion planning, which is an error that occurred before the picking operation began. In this case, the action of the picking robot 51 when the error occurs is to stop picking and notify the product transport system 4 of picking completion. In this case, since the picking operation has not been performed, there will be a surplus of items not yet picked.

[0091] Error number C indicates an error during picking, where the product has fallen during movement. In this case, the action of the picking robot 51 when the error occurs is to stop picking from that point onwards and notify the product transport system 4 of picking completion. The sorter system 6 also rejects the product. In this case, the number of unpicked products for which picking has not been performed becomes surplus. The number of rejected products (number of dropped products) also becomes 1.

[0092] Error numbers D to F respectively indicate inspection errors: no product, two picked, and unknown product. In these cases, the action of the picking robot 51 when the error occurs is to continue picking. Then, the action of the sorter system 6 is to reject the product. The number of rejected items is 1, 2, and 1, respectively. In addition, in the case of two picked, one extra item is picked, resulting in a shortage of one item.

[0093] Regardless of the type of error, the processor 301 of the picking robot WCS32 transmits picking result information, such as the error type, container number, product ID, and number of picked products, to the host system WES2. The processor 201 of WES2 then records this information.

[0094] 8 and 9 are diagrams showing an example of picking result information transmitted from the picking robot WCS32 to the WES2.

[0095] Figures 8(a) and 9(a) show the picking result information sent by the picking robot WCS32, and Figures 8(b) and 9(b) show the picking result information stored in WES2. Figure 8 shows an example in which all pickings were successful, while Figure 9 shows a case in which some pickings were unsuccessful.

[0096] As shown in Figure 8, if all picking is successful, no inventory mismatch occurs, so the number of inventory mismatches and the number of rejects are 0.

[0097] On the other hand, as shown in FIG. 9(a), if an error occurs in some of the picking attempts, the picking result information will include the number of failures, the type of failure (error type), and the number of unpicked items. The example in FIG. 9(a) shows that double picking occurred the first time and a recognition failure occurred the second time. Because of the recognition failure, subsequent pickings (from the fifth item onward) were not performed. Then, processor 201 of WES2 predicts the number of inventory mismatches and the number of rejects based on the picking result information. For example, processor 201 predicts the number of inventory mismatches as the sum of the number of unpicked items and the number of recognition failures minus the number of double picks (i.e., 5 + 1 - 1 = 5). Furthermore, processor 201 predicts the number of rejects as the number of double picks multiplied by 2 (i.e., 1 x 2 = 2).

[0098] The processor 201 then displays the predicted number of inventory mismatches and the number of rejects for each product ID and each container to the operator. For example, the processor 201 controls the display of this information on a terminal carried by the operator via the communication interface 205. This information can then be used as reference information for the operator when adjusting inventory in the product conveying system 4 or resupplying products in the reject chute of the sorter system 6.

[0099] FIG. 10 is a diagram showing an example of a screen displayed on the operator's terminal according to an embodiment. As shown in Figure 10, the time and product name information are displayed in addition to the information shown in Figures 8 and 9. Also, by displaying the number of inventory mismatches and the number of rejected items, the operator can determine when to adjust the inventory of the product conveying system 4 and when to go to collect the products in the reject chute.

[0100] Furthermore, processor 201 determines whether the number of inventory mismatches or the number of rejected items exceeds a predetermined number. If it is determined that the predetermined number has been exceeded, processor 201 controls the terminal carried by the operator to display a warning.

[0101] FIG. 11 is a flowchart showing an example of the operation of the WES2 according to an embodiment. This flowchart is implemented by the processor 201 of the WES2 reading and executing a program stored in the ROM 202.

[0102] First, the picking robot WCS32 starts the operation of this flowchart by transmitting picking result information.

[0103] In step ST201, the processor 201 receives picking result information. The picking result information includes at least the information shown in FIG. 8(a) or FIG. 9(a).

[0104] In step ST202, the processor 201 predicts the number of inventory mismatches and the number of rejects. As described above, the processor 201 predicts the number of inventory mismatches and the number of rejects based on the picking result information.

[0105] In step ST203, the processor 201 determines whether the predicted inventory mismatch number exceeds a predetermined threshold. If it is determined that it does not exceed the threshold, the process ends. On the other hand, if it is determined that it does exceed the threshold, the process proceeds to step ST205. Here, the predetermined threshold may be a value that can be arbitrarily set by the operator.

[0106] In step ST204, the processor 201 determines whether the predicted number of rejects exceeds a predetermined threshold. If it is determined that the predicted number of rejects does not exceed a predetermined threshold, the process ends. On the other hand, if it is determined that the predicted number of rejects exceeds the predetermined threshold, the process proceeds to step ST205. Here, the predetermined threshold may be a value that can be arbitrarily set by the operator.

[0107] In step ST203 and step ST204, the process may end only if neither of the determinations exceeds a predetermined threshold. If either of the thresholds is exceeded, the process proceeds to step ST205. In step ST203 and step ST204, processor 201 may process these processes simultaneously, or may perform one of the processes first.

[0108] In step ST205, the processor 201 controls to display a warning. The processor 201 controls to display information indicating that at least one of the predicted number of inventory mismatches or the predicted number of rejects has exceeded a predetermined threshold on the operator's terminal.

[0109] In addition, in one embodiment, when the number of inventory discrepancies for a specific product exceeds a predetermined number, the processor 201 can also display a warning to the operator (terminal) to prompt them to prioritize checking and correcting the inventory in the warehouse system for the specific product.

[0110] FIG. 12 is a flowchart showing an example of the operation of the WES2 according to an embodiment. This flowchart is implemented by the processor 201 of the WES2 reading and executing a program stored in the ROM 202.

[0111] First, the picking robot WCS32 starts the operation of this flowchart by transmitting picking result information.

[0112] In step ST301, the processor 201 receives picking result information. The picking result information includes at least the information shown in Fig. 8(a) or Fig. 9(a).

[0113] In step ST302, the processor 201 predicts the number of inventory mismatches for a specific product. As described above, the processor 201 predicts the number of inventory mismatches for the product based on the picking result information.

[0114] In step ST303, the processor 201 determines whether the predicted inventory mismatch number for a specific product exceeds a predetermined threshold. If it is determined that it does not exceed the threshold, the process ends. On the other hand, if it is determined that it does exceed the threshold, the process proceeds to step ST304. Here, the predetermined threshold may be a value that can be arbitrarily set by the operator.

[0115] In step ST304, the processor 201 controls to display information prompting the operator to check and correct the inventory of the specific product. Since the predicted number of inventory mismatches has exceeded a predetermined threshold, the processor 201 controls to display information prompting the operator to check and correct the inventory of the specific product on the operator's terminal.

[0116] Furthermore, when the total number of rejects exceeds a predetermined number, the processor 201 can also display a warning to prompt replacement of the reject chute or manual re-feeding by an attendant, as will be described later.

[0117] FIG. 13 is a flowchart showing an example of the operation of the WES2 according to an embodiment. This flowchart is implemented by the processor 201 of the WES2 reading and executing a program stored in the ROM 202.

[0118] First, the picking robot WCS32 starts the operation of this flowchart by transmitting picking result information.

[0119] In step ST401, the processor 201 receives picking result information. The picking result information includes at least the information shown in Fig. 8(a) or Fig. 9(a).

[0120] In step ST402, processor 201 predicts the total number of rejects. As described above, processor 201 predicts the number of rejects based on the picking result information. Then, processor 201 adds the predicted number of rejects to the total number of rejects predicted after checking the reject chute, thereby predicting the total number of rejects.

[0121] In step ST403, the processor 201 determines whether the total number of predicted rejects exceeds a predetermined threshold. If it is determined that the total number does not exceed the predetermined threshold, the process ends. On the other hand, if it is determined that the total number exceeds the predetermined threshold, the process proceeds to step ST404. Here, the predetermined threshold may be a value that can be arbitrarily set by the operator.

[0122] In step ST404, processor 201 controls to display information urging the operator to check and replace the reject chute. Because the total number of predicted rejects has exceeded a predetermined threshold, processor 201 controls to display information urging the operator to check and replace the reject chute on the operator's terminal.

[0123] FIG. 14 is a diagram showing an example of a screen displayed on the operator's terminal according to an embodiment. 14, when the number of oolong tea inventory discrepancies exceeds a predetermined threshold, processor 201 controls to display a warning on the operator's terminal to prompt the operator to check and correct the inventory. Similarly, when the total number of rejects exceeds a predetermined threshold, processor 201 controls to display a warning on the operator's terminal to prompt the operator to check the reject chute.

[0124] This allows the operator to realize that an inventory check of a particular product must be performed or that a check of the reject chute must be performed.

[0125] Next, an example of an error recovery procedure for continuing the shipping operations of the warehouse will be described. 15 to 18 are diagrams showing an example of the operation of an error recovery procedure by an attendant according to one embodiment. 15 to 18 are diagrams showing examples of top views of a product conveying system 4, a picking system 5, and a sorter system 6. Here, an example is shown in which an ACR (Autonomous Case-handling Robot) system is used as the product conveying system 4, and t-Sort is used as the sorter system 6. However, the equipment used as the product conveying system 4 and the sorter system 6 is not limited to ACR and t-Sort, and any system capable of operating as the product conveying system 4 and the sorter system 6 may be used. Also, as shown in FIGS. 15 to 18, an example is shown in which a container containing products is conveyed from the conveying system 4. This container may be any type that can be conveyed by the conveying system 4, such as a tote, tray, or cardboard box.

[0126] Referring to FIG. 15, the operator first checks (1) the number of items that are insufficient for sorting, (2) the number of items that entered the reject chute (reject number), (3) the number of items that fell in the vicinity, and (4) the number of items that are inconsistent with inventory. The operator checks the number of items that are insufficient for sorting due to rejects by the sorter system 6 and the number of items that entered the reject chute (reject number). The operator checks the number of items that fell near the picking system 5. The operator checks the number of items that are inconsistent with inventory in the container of the product conveyance system 4. For example, the operator compares the number of items in the container with the number of items in stock on the product conveyance system WCS31. For example, if (4-A) the number of items in the container is greater than the number of items in stock on the product conveyance system WCS31, i.e., the actual number of items is greater than the number of items in stock on the system, the operator checks that there is a surplus of items in the container. On the other hand, if (4-B) the number of items in the container is less than the number of items in stock on the product conveyance system WCS31, i.e., the actual number of items is less than the number of items in stock on the system, the operator checks that there is a shortage of items in the container.

[0127] The operator then inputs the number of rejects and the actual number of inventory mismatches (i.e., the number of excess or shortage items in each container) into WES 2. For example, the operator uses a terminal to input the confirmed, i.e., actual number of rejects (C)' and actual number of inventory mismatches (BA)' into WES 2.

[0128] 16, the operator then collects (2) the rejected products and (3) the peripherally dropped products from the sorter system 6. Then, the operator supplies the collected products to the sorter system 6 again.

[0129] Referring to FIG. 17, the operator then supplies the excess products confirmed in (4-A) to the sorter system 6. Furthermore, the operator confirms (1) the number of products insufficient to be sorted and (2) the number of products rejected. As a result of the operations up to this point, (1) the number of products insufficient to be sorted becomes 0, and (2) the number of products rejected becomes ≧0.

[0130] Finally, referring to Figure 18, (2) the rejected items are returned to the container as missing items identified in (4-B). The rejected items in (2) match those in (4-B). Therefore, (1) the number of items missing in sorting, (2) the number of rejected items, and (4) the number of items in inventory that are inconsistent are all set to 0.

[0131] These actions allow the operator to recover from the occurrence of an error.

[0132] The processor 201 of the WES2 then compares the actual number of rejects (C)' and the actual number of inventory mismatches (BA)' input by the operator with the predicted number of rejects (C) and the number of inventory mismatches (BA). The processor 201 then evaluates the error detection accuracy of the picking system 5. For example, the processor 201 calculates the difference between the actual number of rejects (C)' and the predicted number of rejects (C), and evaluates the error detection accuracy for the number of rejects based on this difference. Similarly, the processor 201 calculates the difference between the actual number of inventory mismatches (BA)' and the predicted number of inventory mismatches (BA), and evaluates the error detection accuracy for the number of inventory mismatches based on this difference. If the processor 201 determines that this difference exceeds a predetermined threshold, it determines that the error detection function may not be operating correctly. The processor 201 then controls the operator's terminal to display a warning indicating that the error detection function is not functioning properly.

[0133] In one embodiment, the picking robot system PS operates continuously, allowing it to continue working for one batch, several batches, or even overnight. Error recovery is then performed in the morning or after the operator arrives at work. On the other hand, as described with reference to FIGS. 11 to 14, if there are many predetermined errors, the operator is notified and prompted to perform error recovery.

[0134] (First optimization process by WES2) Next, an example of optimization processing of WES2 according to an embodiment will be described. The processor 201 can predict the actual inventory information (B)' by acquiring inventory information of the product conveyance system WCS31 and adding or subtracting the predicted inventory mismatch number (BA) based on the picking result information.

[0135] For example, the processor 201 of the WES2 optimizes warehouse operations using various information from each device. In this embodiment, the processor 201 performs optimization processing based on the estimated value (B)' of actual inventory information instead of the inventory information (B) stored in the product transport system WCS31. As an example of optimization processing in this case, when there are multiple product storage locations in the product transport system 4, the processor 201 allocates to each product transport system WCS31 an allocation that is predicted to result in the shortest shipping time based on information such as staffing and inventory quantity. This method is described in detail below.

[0136] FIG. 19 is a flowchart showing an example of optimization processing by WES2 according to an embodiment. This flowchart is implemented by the processor 201 of the WES2 reading and executing a program stored in the ROM 202.

[0137] First, the operation of this flowchart begins by WMS1 sending an outbound order to WES2.

[0138] In step ST501, the processor 201 receives the outbound order. The processor 201 receives the outbound order transmitted from the WMS1 via the communication interface 205.

[0139] In steps ST502, ST503, and ST504, the processor 201 acquires inventory information from the first product conveyance system WCS31, the second product conveyance system WCS31, and the third product conveyance system WCS31, respectively. The processor 201 periodically or as needed sends an inventory information acquisition request to each product conveyance system WCS31. The processor 301 of the product conveyance system WCS31 sends the inventory information in response to the request via the communication interface 305.

[0140] The inventory information acquired from the product conveyance system WCS31 in step ST502 and the sorter system WCS33 in step ST504 do not differ in the inventory quantity. Therefore, the process proceeds to step ST506. On the other hand, the inventory information acquired from the picking robot WCS32 in step ST503 may differ from the actual inventory quantity, as described above. Therefore, the process proceeds to step ST505.

[0141] In step ST505, the processor 201 estimates the actual inventory quantity based on the inventory information and the predicted mismatch number. The processor 201 estimates the actual inventory quantity based on the predicted mismatch number described with reference to FIG. 11 etc. and the inventory information acquired from the product conveyance system WCS31. The processor 201 estimates the actual inventory quantity by adding or subtracting the predicted mismatch number to the inventory information. For example, the estimated actual inventory value is the inventory information (A) of the product conveyance system WCS31 + the inventory mismatch number (BA). Since the inventory mismatch number (BA) is an estimate based on the picking result information, the estimate of the actual inventory quantity is the estimate of the actual product quantity (B) in the container.

[0142] In step ST506, processor 201 determines the optimal outbound order based on the estimated actual inventory quantity. Processor 201 determines the optimal order to be allocated to each product transport system WCS31 based on the estimated actual inventory quantity without using the inventory information stored in product transport system WCS31. Note that the method for determining the optimal order may be any commonly used method, and therefore a detailed description thereof will be omitted here.

[0143] In steps ST507, ST508, and ST509, the processor 201 transmits the determined outbound orders to the product transport system WCS31, the picking robot WCS32, and the sorter system WCS33 via the communication interface 205, respectively.

[0144] (Second optimization process by WES2) Next, another example of the optimization process of WES2 according to an embodiment will be described. For example, by using the estimated value (B)' of the actual inventory information instead of the inventory quantity (B), it is possible to hold an outbound order. For example, when an outbound order is received, the processor 301 of the product transport system WCS31 checks the inventory information (B) of the product included in the outbound order. If the inventory quantity (B) is insufficient for the outbound order quantity, the processor 301 controls the outbound order so as not to accept it. Conventionally, in this case, the processor 201 of the WES2 sends an outbound order acceptance error or the like to the WMA1.

[0145] In contrast, in one embodiment, an estimate (B)' of actual inventory information is used instead of the inventory quantity (B), and if the estimate (B)' of actual inventory information is sufficient for the order quantity, the processor 201 of WES2 does not send an error to WMS1. Then, after the operator checks and corrects the inventory, the processor 201 sends a shipping order again to the product conveyance system WCS31. This method is described in detail below.

[0146] FIG. 20 is a flowchart showing an example of optimization processing by WES2 according to an embodiment. This flowchart is implemented by the processor 201 of the WES2 reading and executing a program stored in the ROM 202.

[0147] First, the operation of this flowchart begins when WMS1 sends a shipping order to WES2. The following example shows an example in which there are three product transport systems WCS31 (first product transport system WCS31, second product transport system WCS31, and third product transport system WCS31). However, the number of product transport systems WCS31 is not limited to three, and the following process can of course be applied to cases in which there is one or more product transport systems WCS31.

[0148] In step ST601, the processor 201 receives the outbound order. The processor 201 receives the outbound order transmitted from the WMS1 via the communication interface 205.

[0149] In step ST602, the processor 201 transmits the outbound order. For example, the processor 201 acquires inventory information from each product transport system WCS31 and determines the allocation of the received outbound order based on the acquired inventory information. Then, the processor 201 transmits the outbound order to each product transport system WCS31 via the communication interface 205 based on the allocation.

[0150] In step ST603, the processor 201 determines whether the order acceptance is complete. The processor 201 determines whether an order acceptance for the outbound order has been received from each of the product transport systems WCS31. If it is determined that an order acceptance has been received from all of the product transport systems WCS31, the processing ends. On the other hand, if it is determined that an outbound order acceptance error has been received instead of an order acceptance from at least one of the product transport systems WCS31, the processing proceeds to step ST604.

[0151] In step ST604, the processor 201 acquires inventory information from each product transport system WCS 31. For example, the processor 201 transmits an inventory information acquisition request to each product transport system WCS 31. The processor 301 of the product transport system WCS 31 transmits the inventory information via the communication interface 305 in response to the request.

[0152] In step ST605, the processor 201 estimates the actual inventory quantity based on the inventory information and the predicted mismatch number. The processor 201 estimates the actual inventory quantity based on the predicted mismatch number described with reference to FIG. 11 etc. and the inventory information acquired from the product conveyance system WCS31. The processor 201 estimates the actual inventory quantity by adding or subtracting the predicted mismatch number to or from the inventory information.

[0153] In step ST606, the processor 201 determines whether the estimated actual stock quantity is greater than the outgoing order quantity. If there is a product whose estimated actual stock quantity is less than the outgoing order quantity, the process proceeds to step ST610. On the other hand, if the estimated actual stock quantity is greater than the outgoing order quantity, the process proceeds to step ST606.

[0154] In step ST607, the processor 201 waits for the inventory to be corrected. The processor 201 controls the display of a warning on the operator's terminal, as described with reference to FIGS. 11 to 13, etc. For example, the processor 201 controls the display of a warning on the operator's terminal to the effect that error recovery needs to be performed, as described with reference to FIGS. 15 to 18, to the operator. This causes the operator to perform error recovery. The processor 201 then waits while the operator is performing error recovery.

[0155] In step ST608, the processor 201 transmits the outbound order. After error recovery is performed, the processor 201 transmits the outbound order determined in step ST602 to each product conveyance system WCS31 via the communication interface 205.

[0156] In step ST609, the processor 201 determines whether the order acceptance is complete. The processor 201 determines whether an order acceptance for the outbound order has been received from each of the product transport systems WCS31. If it is determined that an order acceptance has been received from all of the product transport systems WCS31, the processing ends. On the other hand, if it is determined that an outbound order acceptance error has been received instead of an order acceptance from at least one of the product transport systems WCS31, the processing proceeds to step ST610.

[0157] In step ST610, the processor 201 transmits an outbound order acceptance error. The processor 201 transmits the outbound order acceptance error received in step ST609 from the product conveyance system WCS31 to the WMS1 via the communication interface 205. If the actual inventory quantity is smaller than the outbound order quantity, or if the actual inventory quantity is greater than the outbound order quantity and an outbound order acceptance error is received again even after error recovery has been performed, the processor 201 transmits the received outbound order acceptance error to the WMS1.

[0158] The above-described operation prevents WES2 from sending a shipping order reception error to WMS1 based on erroneous inventory information from product conveyance system WCS31.

[0159] (Effects of the embodiment) According to the embodiment described above, even if an error occurs in the picking system 5, the picking robot system PS can continue to operate. Furthermore, based on the error detection result in the picking system 5, the processor 201 can predict and present locations where recovery work by the operator is required. This reduces the amount of recovery work by the operator.

[0160] Furthermore, the number of inventory discrepancies is predicted, and the actual inventory quantity is predicted based on the inventory information stored in the product transport system WCS31 and the predicted number of inventory discrepancies.Since outbound orders can be accepted based on the predicted actual inventory quantity, rather than the inventory information, the operation of the entire warehouse system can be continued.

[0161] [Other embodiments] In the embodiment, an error detection method, an error recovery method, and an optimization processing method for an outbound order have been described, but the embodiment can also be applied to an inbound order, an inventory transfer operation, and the like.

[0162] The program according to this embodiment may be transferred in a state stored in an electronic device (computer) such as the WES2, the product transport system WCS31, the picking robot WCS32, the sorter system WCS33, the picking robot 51, or the inspection unit 52, or may be transferred without being stored in an electronic device. In the latter case, the program may be transferred via a network or in a state stored in a storage medium. The storage medium is a non-transitory, tangible medium. The storage medium is a medium (computer-readable medium) that can be read by the computers such as the WES2, the product transport system WCS31, the picking robot WCS32, the sorter system WCS33, the picking robot 51, or the inspection unit 52. The storage medium may be any medium capable of storing a program and being readable by a computer, such as an optical disk (e.g., a CD-ROM), a magnetic disk, or a semiconductor memory (e.g., a memory card), and its form is not important.

[0163] Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the scope of the invention and its equivalents as defined in the claims. [Explanation of symbols]

[0164] 1. WMS 2…WES 201...Processor 202...ROM 203...RAM 204...Auxiliary storage device 205...Communication interface PS: Picking robot system 3…WCS 31...Product conveying system WCS 32...Picking robot WCS 33...Sorter system WCS 301...Processor 302...ROM 303...RAM 304...Auxiliary storage device 305...Communication interface 4. Product transport system 5. Picking system 511...processor 512...ROM 513...RAM 514...Auxiliary storage device 515...Communication interface 516...Picking method 517...Sensor 51...Picking robot 52...Inspection unit 521...Processor 522...ROM 523...RAM 524...Auxiliary storage device 525...Communication interface 526...Conveyor 527...Sensor 5271...Weight sensor 5272...Proximity sensor 5273...Camera 6...Sorter system

Claims

1. a communication interface for receiving picking result information including an error type of an error detected by a picking system including a picking robot and an inspection unit during operation of the picking system based on the order list; a processor that predicts the number of inventory mismatches and the number of rejected products based on the error type; An information processing device comprising:

2. the error type includes a recognition failure indicating that the picking robot is unable to recognize the product, or a grasping and motion planning failure indicating that the picking robot has failed to grasp or plan its motion, When the error type is the recognition failure or the grasping and motion planning, the processor determines that there is a surplus of products by the amount of products that have not been picked by the picking robot. The information processing device according to claim 1 .

3. the error type includes a drop during movement indicating that the picking robot has dropped the product while moving it, When the error type is the drop during movement, the processor determines that there is a surplus of products corresponding to the products not picked by the picking robot, and increments the reject number by 1. The information processing device according to claim 1 .

4. The error type includes a "no product" indicating that the inspection unit could not detect the product, or a "missing product" indicating that the product is damaged or incorrect, The processor increments the reject count by 1 when the error type is the product not present or the product is unknown. The information processing device according to claim 1 .

5. The error type includes a double-item detection indicating that two products have been detected by the inspection unit, the processor increments the reject count by 2 when the error type is the double-cavity error; The information processing device according to claim 1 .

6. The processor controls to display the predicted number of inventory mismatches and the number of rejects. The information processing device according to claim 1 .

7. The processor determines whether at least one of the number of inventory discrepancies or the number of rejects exceeds a predetermined threshold, and when it determines that the threshold has been exceeded, controls to display a warning prompting the user to check and correct the inventory. The information processing device according to claim 1 .

8. The processor determines whether the number of inventory discrepancies for a specific product exceeds a predetermined threshold, and if it determines that the number of discrepancies exceeds the threshold, controls to display a warning prompting the user to check and correct the inventory of the specific product. The information processing device according to claim 1 .

9. The processor predicts the total number of rejects based on multiple pieces of picking result information, determines whether the total number of rejects exceeds a predetermined threshold, and, if it determines that the total number of rejects exceeds the threshold, controls to display a warning urging replacement of the reject chute. The information processing device according to claim 1 .

10. The communication interface further receives an actual number of inventory mismatches and an actual number of rejects due to the error recovery operation; the processor evaluates performance of an error detection function of the picking system based on the predicted number of inventory mismatches, the predicted number of rejects, the actual number of inventory mismatches, and the actual number of rejects. The information processing device according to claim 1 .

11. the communication interface further acquires inventory information from a product conveyance system connected to the information processing device; the processor estimates actual inventory information based on the predicted inventory discrepancy number and the inventory information, determines an order list to be assigned to the product transportation system based on the actual inventory information, and transmits the determined order list to the product transportation system; The information processing device according to claim 1 .

12. the communication interface further receives inventory information from a product transport system connected to the information processing device; the processor estimates an actual inventory quantity based on the predicted inventory discrepancy number and the inventory information, determines whether the estimated actual inventory quantity is greater than the quantity included in the order list, and if it determines that the estimated actual inventory quantity is greater, transmits the order list to the product transportation system; The information processing device according to claim 1 .

13. the communication interface receives the inventory information after receiving an order acceptance error indicating a shortage of inventory in response to the transmission of the order list; The information processing device according to claim 12.

14. an information processing device; a product conveyance system connected to the information processing device; a picking system including a picking robot and an inspection unit connected to the product conveying system; The picking system comprises: a communication interface for receiving an order list from the information processing device; a processor that detects an error during an operation based on the order list and transmits picking result information including an error type of the error to the information processing device; The information processing device comprises: a communication interface for receiving the picking result information; a processor that predicts the number of inventory mismatches and the number of rejected products based on the error type; An information processing system comprising:

15. the processor of the picking robot attempts to recognize the product based on the order list, and if the product cannot be recognized, controls the processor to transmit a picking completion notification to the product transport system and include a recognition failure indicating that the product could not be recognized as the error type in the picking result information. The information processing system according to claim 14.

16. When the processor of the picking robot determines that it has recognized the product, it grasps the product and carries out an action plan, and as a result of the implementation, it determines whether the grasping and action plan has been created, and when it determines that the grasping and action plan cannot be created, it transmits a picking completion notice to the product transport system and controls the picking result information to include a grasping and action plan failure, indicating that the grasping and action plan could not be created, as the error type.

16. The information processing system according to claim 15.

17. When the processor of the picking robot determines that the gripping and motion plan has been created, it picks the product based on the gripping and motion plan, moves the product to a predetermined location, determines whether the product has fallen during the movement, and when it determines that the product has fallen, transmits a reject sort to the downstream sorter system, and controls the picking result information to include "fall during movement" indicating that the product has fallen as the error type.

17. The information processing system according to claim 16.

18. An information processing method executed by a processor of an information processing device, receiving picking result information including an error type of an error detected by a picking system including a picking robot and an inspection unit during operation of the picking system based on the order list; predicting the number of inventory mismatches and the number of rejected products based on the error type; An information processing method comprising:

19. An information processing program comprising instructions to be executed by a processor of an information processing device, the instructions comprising: receiving picking result information including an error type of an error detected by a picking system including a picking robot and an inspection unit during operation of the picking system based on the order list; predicting the number of inventory mismatches and the number of rejected products based on the error type; An information processing program comprising:

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