Inventory management system and method
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-12-08
- Publication Date
- 2026-03-25
Smart Images
Figure 2026053386000001_ABST
Abstract
Description
Technical Field
[0001] [Claiming Priority] This application claims priority based on U.S. Provisional Patent Application No. 62 / 463,017, filed on February 24, 2017, entitled "INVENTORY MANAGEMENT SYSTEM AND METHOD", the entire disclosure of which is incorporated herein by reference.
Background Art
[0002] In traditional self-service store chains, the most cost-effective way to replenish store inventory is undoubtedly by "case", that is, supplying the store with the shipping cases of products received from the supply manufacturer. The alternative is to replenish by "each", that is, supplying the store in individual product units less than the quantity of a case, but this method is very costly, so in large stores such as supermarkets and hypermarkets, it is common to replenish with cases shipped in pallet shipments as the main unit.
[0003] In the traditional distribution model, retail stores receive pallets of cases at the distribution center ("DC"), but its essential role is to replenish the inventory within the store network by periodically shipping a specific set of cases of the products required (already "ordered") at each store to each store. In most DCs, these orders are processed using a manual case picking process where the cases of pallets are lined up in aisles and human operators move from one product pallet to another to transfer the number of single cases ordered from the store, and the selected cases are loaded onto the order pallet for shipping to the store. These systems are not secure in that stock shortages occur due to human intervention. Even systems with some degree of automation do not have an effective tracking system for tracking each item from the manufacturer to the customer.
Summary of the Invention
[0004] In summary, the disclosed technology relates to a system that features a fully automated supply chain in combination with tracking technology and a unified commerce engine (UCE). Such a system makes it possible to track the precise location of every product (or individual item) from the manufacturer's facility to the customer's bag. For example, the supply chain comprises an order processing system having a regional distribution center equipped with RDC robotic automation configured to pick up one or more incoming pallets; a single-item pallet having multiple cases of common goods, each case of goods containing a common single item; further RDC robotic automation configured to pick up and store the common cases of goods; further RDC robotic automation configured to provide one or more outgoing pallets in response to orders from the distribution center; and a market distribution center equipped with MDC robotic automation configured to receive one or more outgoing pallets, each containing multiple cases of mixed goods; further MDC robotic automation configured to pick up cases of mixed goods from one or more outgoing pallets; and further MDC robotic automation configured to pick up and store single items from each of the cases of mixed goods in the MDC storage system; and further MDC robotic automation configured to fill order totes in response to market orders. MDC Robotic Automation is further configured to process market orders using multiple common or different order totes and sub-totes that flexibly match the market's sales speed.
[0005] Another example suggests that a fully automated supply chain would enable a consignment model where manufacturers retain ownership of individual items until they reach the customer's bag. This contrasts with the current system where retailers retain ownership because they cannot guarantee the location and safety of individual items to the manufacturer.
[0006] In another example, a regional distribution center processes orders from multiple market distribution centers.
[0007] In another example, regional distribution centers and market distribution centers have integrated distribution centers.
[0008] Another example shows how market distribution centers can automate the decanting process (i.e., moving from cases to totes / subtotes of various sizes) and minimize the transportation costs of individual items shipped in less dense totes / subtotes than cases on pallets. For example, mixed cases may be shipped on pallets for long-distance transport (e.g., thousands of miles) from the manufacturer or regional distribution center to a market distribution center. At the market distribution center, the pallets are broken down into less dense totes and subtotes, which are then shipped to markets over shorter distances (e.g., tens of miles).
[0009] In another example, market distribution centers and automated supply chains generally enable the shipment of individual items to markets in totes / subtotes that match the market's sales speed. This allows markets to replenish quickly, utilize minimal inventory, and offer more products (SKUs) to customers in smaller stores. This solves a major problem for markets today: limiting their product range or expanding their stores. If they limit their product range, they lose customers. If they increase their product range, they have to make their stores larger to accommodate the individual items they receive at the case level. Using this technology, markets can increase their product range without expanding their stores.
[0010] Further examples suggest that as manufacturers optimize the size of their products to suit customers and the use of totes and sub-totes becomes common, they will likely optimize their packaging to efficiently fit inside the totes and sub-totes.
[0011] In another example, at least one non-transient memory containing at least one processor and computer program code is provided, and the at least one memory and computer program code is configured to use at least one processor to provide substantially continuous traceability of goods from the capture of approaching pallets to the delivery of market orders, and to automatically secure and / or track the goods.
[0012] In another example, a tote bag includes a common tote bag that also includes a sub-tote bag.
[0013] In another example, market orders are generated from the market in response to inventory levels, and market robotic automation is configured to receive market orders processed by multiple order totes with mixed single items, and market robotic automation is further configured to retrieve and store mixed single items from market storage, and market robotic automation is further configured to selectively retrieve single items from the market storage system and process an order from one of multiple customer orders for mixed single items in response to a customer order.
[0014] In another example, a market is a retail store.
[0015] In another example, a market is any suitable distribution center.
[0016] In another example, a mixed single item ordered by multiple customers includes the consolidation of orders for one or more frozen storage totes, chilled storage totes, or fresh food picking totes.
[0017] In another example, the unified commerce engine comprises at least one processor and at least one non-transient memory containing computer program code, and is configured to monitor the SKU rate of one or more markets to show the highest number of SKUs for one or more markets based on the inventory storage capacity of one or more markets, and to optimize the inventory levels of one or more markets.
[0018] In another example, the unified commerce engine comprises at least one processor and at least one non-transient memory containing computer program code, and is configured to monitor and optimize inventory levels and inventory speeds at one or more regional distribution centers, as well as replenishment at one or more market distribution centers and replenishment at one or more markets, at every stage of the entire supply chain process, from case-level capture at regional distribution centers through customer orders in the market.
[0019] In another example, the unified commerce engine comprises at least one processor and at least one non-transient memory containing computer program code, and is configured to secure individual items within an automated supply chain and fully track individual items within the automated supply chain from receiving pallets from manufacturers at regional distribution centers for sale to the customer, and the unified commerce engine is further configured to enable a consignment model in which manufacturers retain ownership of the goods at every stage of the entire supply chain process until the point of sale or delivery, and manufacturers can view their inventory in real time through the unified commerce engine.
[0020] In another example, the unified commerce engine comprises at least one processor and at least one non-transient memory containing computer program code. The unified commerce engine is configured to secure individual items within an automated supply chain and to fully track individual items within the automated supply chain, from receiving pallets from manufacturers at regional distribution centers to sales or delivery to customers. The unified commerce engine is further configured to show manufacturers data related to their products included in the retail supply chain, including location, inventory levels, inventory speed, sales levels, and other information related to products within the entire supply chain process or at any stage of the retail supply chain. The unified commerce engine is further configured to show data related to all products included in the retail supply chain, including location, inventory levels, inventory speed, sales levels, and other information related to products within the entire supply chain process or at any stage of the retail supply chain. The unified commerce engine is further configured to show separately data related to isolated products included in the retail supply chain, including location, inventory levels, inventory speed, sales levels, and other information related to products within the entire supply chain process or at any stage of the retail supply chain, with isolated products separated by relationships such as market-specific data and manufacturer-specific data. [Brief explanation of the drawing]
[0021] [Figure 1] This is an exemplary system for carrying out steps based on an aspect of this embodiment. [Figure 2] This is a process flow diagram. [Figure 2-1] This is a process flow diagram. [Figure 3] This is an exemplary system. [Figure 4] It is a market distribution center. [Figure 5] It is an automated distribution center for the market process. [Figure 6] It is an automated decant. [Figure 7] It is an automated decant. [Figure 8] A system for moving a sub tote. [Figure 9] A system for moving a tote. [Figure 10] A replenishment system. [Figure 11] A manual decanting system. [Figure 12] A system for moving a sub tote. [Figure 13] A system for moving a sub tote. [Figure 14] A single-item picking workstation. [Figure 15] A single-item picking workstation. [Figure 16] Indicates storage of completed orders. [Figure 17] Indicates integration of orders. [Figure 18] Indicates delivery of orders. [Figure 19] Indicates delivery of orders.
Best Mode for Carrying Out the Invention
[0022] Referring to FIG. 1, an exemplary system 10 for performing steps according to aspects of the present embodiment is shown. Although the present embodiment is described with reference to exemplary embodiments or embodiments shown in the drawings, it should be understood that it can be implemented in many alternative forms. Those skilled in the art will further understand different ways to vary the parameters of the disclosed embodiments while maintaining the spirit and scope of the present invention.
[0023] Embodiments of this disclosure include U.S. Patent No. 9,139,363, titled "Automated System for Transporting Payloads", U.S. Patent No. 9,598,239, titled "Automated System for Transporting Payloads", U.S. Patent Application No. 15 / 171,802, filed June 2, 2016, titled "Storage and Retrieval System", U.S. Patent Application No. 15 / 591,956, filed May 10, 2017, titled "Order Fulfillment System", U.S. Patent Application No. 15 / 816,832, filed November 17, 2017, titled "Order Fulfillment System", U.S. Patent Application No. 15 / 867,373, filed January 10, 2018, titled "System and Method of Robot Task Assignment and management", and "Inventory Management Apparatus and methods disclosed in U.S. Patent Application No. 15 / 826,045, filed November 29, 2017, entitled "System", U.S. Patent Application No. 15 / 884,677, filed January 31, 2018, entitled "Automated Proxy Picker System for Non-Fungible Goods", and U.S. Patent Application No. 15 / 884,938, filed January 31, 2018, entitled "Packing by Destination for Automated Fulfilled Goods" may be utilized.
[0024] According to embodiments of this disclosure, an automated retail supply chain enables reduced market inventory, traceability at the product level, and manufacturer consignment. Here, rapid replenishment of subtotes matched to the size of market velocity (single item sales rate) allows the market to reduce its on-hand inventory and to offer a higher number of SKUs in the same or smaller facility, as opposed to the market receiving single items at the case level or in disassembled packs that do not match their store velocity. Here, single items are secured within an automated supply chain with complete traceability from receiving pallets from manufacturers at regional distribution centers (RDCs) to selling them to customers in order bags. Such an automated supply chain enables a consignment model in which manufacturers can retain ownership of goods until the point of sale or delivery. Furthermore, manufacturers can view their inventory in real time through a unified commerce engine at every stage of the entire supply chain process. Manufacturers can access customer trends and data. As shown in Figure 1, the palletized goods cases 12 are received at one or more regional distribution centers (RDCs) 14, as further described below, the RDCs 14 supply the palletized goods cases 16 to market distribution centers (MDCs) 18, which decant and store similar individual items in sub-totes 24 of various sizes, and supply the totes containing mixed individual item sub-totes 20, 22 to the market 26. Alternatively, shipments are made to stores or markets in totes directly from distribution centers that do not have market distribution centers, or where the functions of regional distribution centers and market distribution centers can be combined. Market distribution centers not only enable sufficient scale to perform automated decanting, but also limit the cost of transporting totes and sub-totes to limited areas, such as metropolitan areas. More efficient shipments of individual items in densely packed pack cases on pallets can be maintained between regional distribution centers and market distribution centers.The market distribution center also provides the capacity to store a wide assortment of products that customers may order for delivery to the market in the next rapid replenishment delivery, which are not regularly stocked in the market.
[0025] Referring to Figure 2, a process flow diagram 50 is shown. At 52, the manufacturer ships one or more pallets containing individual cases to a Regional Distribution Center (RDC). At 54, pallet IDs are collected along with case data and stored in the Unified Commerce Engine (UCE). Pallet, case, and product IDs can be barcode labels, RFID tags, or equivalent tracking systems. At 56, the pallets are received using an automated storage and retrieval system (AS / RS), an AlphaBot palletbot. At 58, an order for case replenishment is received from the Market Distribution Center (MDC). At 60, pallets containing cases are automatically retrieved from storage. At 62, a robot picks layers of cases to create a "Rainbow Pallet" or individual cases to create a "Mixed Pallet". At 64, IDs for the Rainbow Pallet or Mixed Pallet are generated and stored in the UCE along with case data. At 66, the Rainbow Pallet or Mixed Pallet is received at the MDC. In step 68, the UCE calculates the distribution of individual items per subtote (subtote size) based on the individual item rate supplied to the market. In step 70, the case is automatically decanted to the subtote size and tote distribution in the MDC using the AlphaBot system. In step 72, the individual item data is stored in the UCE along with the associated original (parent) case and pallet ID, as well as the subtote ID and tote ID. In step 74, the tote containing the subtote is stored in the AlphaBot system, and its corresponding location is stored in the UCE. In step 76, an order for subtote (individual item) replenishment is received from the market. In step 78, the bot collects the product tote (P tote) containing the subtote and the empty order tote (O tote) to the picking workstation. In step 80, the subtote is automatically moved from the P tote to the O tote. In step 82, the locations of the subtote and individual items are stored in the UCE. In step 82, the relationship between all upstream original case and pallet data is saved.In decision 84, is the O tote full of P totes? If yes 86, proceed to 90. If no 88, proceed to 80. In 90, the bot indicates to the robot that it will transport the mixed SKU O totes to a rack and load the totes onto the rack, or to load them onto a pallet. In 92, a tote pallet ID is generated and stored in the UCE along with the tote, sub-tote, individual item, and original data. In decision 94, is the pallet full of O totes? If yes 96, proceed to 100. If no 98, proceed to 90. In 100, the rack or pallet of O totes is loaded onto a truck for shipment to the market. In 102, the rack or pallet of O totes is received at the market, and the totes are automatically transferred to the market alphabot system. In 104, the location of the sub-totes and individual items is stored in the UCE, where the relationship between all upstream original cases and pallet data is stored. In 106, the customer order is received, and a schedule is made for picking. In step 108, the Material Control System (MCS) calculates the order bag packing distribution and sequence. In step 110, the bot retrieves the P tote containing the sub-totes of the ordered individual items and the O tote containing the empty order bag to the picking workstation. In step 112, the individual items are transferred from the sub-totes in the P tote to the order bag in the O tote either by an automated method using machine vision tracking or by a manual method. In step 114, the location of the individual items in the order bag is stored in the UCE, where the relationships of all original data are stored. In step 116, is it determined that all individual items have been transferred to the order bag? If yes, proceed to step 122. If no, proceed to step 110. In step 122, is customer delivery scheduled? If yes, proceed to step 132. If no, proceed to step 128. In step 128, the order tote containing the order bag is stored in the AlphaBot system. In step 130, the location of the order, as well as all individual item and associated source data, are stored in the UCE. In step 132, at the time of delivery to the customer, the bot collects the O tote containing the order bag and transports it to the customer's cart or vehicle.In 134, the completion of the order (sale) is stored in the UCE, where all original location data and history are available to the manufacturer of the product. In 136, the retailer pays the manufacturer for the sold individual items after deducting the retail margin agreed upon by the retailer. In the method of this disclosure, the UCE calculates the distribution of individual items per subtote (size of subtote) based on the rate of distribution of individual items in the supplied market. Where the UCE may employ a shrinkage rate monitor or a shrinkage rate monitor of rate changes, the distribution of individual items, replenishment watermarks, and replenishment rates may be modified by the UCE as a function of the rate of a given SKU. Here, the inventory level of a given SKU in a given market or store may be maintained in an optimized watermark that is variable as a function of rate, or otherwise may be optimized to show the maximum number of SKUs based on storage area, etc.
[0026] In addition to manufacturers knowing the location of every single item from the moment it leaves their factory, they can access the UCE database to determine the speed of their product sales at all locations, customer purchasing trends, and data until it is delivered to the customer. Manufacturers can leverage near real-time UCE data to optimize their production schedules, shipping schedules, regional product offerings, and product attributes such as flavor, size, and bundle.
[0027] Referring to Figure 3, an exemplary system 150 is shown. As described, the unified commerce engine 152 can centrally manage and track inventory levels and distribution. System 150 may have an operating manual 154 that identifies systems, processes, and integrations. Mobile customers 156 may be provided with ambient AI, phone UI, tablet UI, and PC UI or other suitable UIs that interface with UCE 152 or other UIs, e.g., market UI or store UI. Phone UI, product reader, large screen UI, scale, checkout kiosk, related UIs, order staging and integration, a new SMART store MCS for manual picking managers, and the AlphaBot storage system may be provided. Analytics 160 may be further provided. Orders, customers, inventory, and products 162 may further interface with UCE 152. MDC 164, with the AlphaBot storage and retrieval system, DC MC, and new warehouse management system (WMS), may further interface with UCE 152. RDC166 and the retail enterprise system 168 can further interface with UCE152.
[0028] Referring to Figure 4, the market distribution center 200 is shown. Pallets 202 of cases are decanted into subtotes at the decanting station 204. Storage equipment 206 stores the totes with or without subtotes. Product totes are presented to pickers for processing orders at the product tote station 208. Order totes are loaded onto portable racks 210 for transport by truck, or for processing orders.
[0029] Referring to Figure 5, an automated market distribution center 250 for the market process is shown. This process is divided into three areas: receiving 252, order processing 254, and replenishment to stores 256. At 258, the supply truck arrives at the automated DC. At 260, the pallet ID is scanned. At 262, the pallet is transported from the supply truck to the automated decanting station. At 264, is the SKU known? If Yes 268, proceed to 272. If No 270, proceed to 274. At 272, the optimal subtote distribution is determined based on the MSRQ (Minimum Safe Replenishment Quantity). At 274, the SKU and case attributes are captured. At 276, a subtote is selected from the overlapping variable-size subtotes. At 278, the case is opened. At 280, all individual items are transferred from the case to the subtote. At 282, the empty case is disposed of. At 284, the subtote is placed in the product tote. In decision 286, is the product tote full? If yes, proceed to 292. If no, proceed to 264. In 292, place the (product tote) P tote into the storage structure. In 294, transport the P tote to the automated picking station. In 296, transfer the sub-tote from the P tote to the (order tote) O tote based on the SRQ (Safety Replenishment Quantity) of each store. In 298, return the P tote to the storage structure. In decision 300, is the O tote full? If yes, proceed to 306. If no, proceed to 294. In decision 306, is the order to be delivered immediately? If yes, proceed to 312. If no, proceed to 314. In 312, transport the O tote to the mobile storage rack. In 314, transport the O tote into the storage structure. In decision 316, is the storage rack full? If yes 318, proceed to 322. If no 320, proceed to 312. In 322, transport the mobile storage rack to the delivery truck. In 324, the delivery truck arrives at the automated store. In 326, the mobile rack is placed into the storage structure at the automated store.
[0030] Referring to Figure 6, an automated decanting station 350 in a market distribution center is shown. Referring to Figure 7, an automated decanting station 350 in a market distribution center is also shown. Pallets 352 with cases are first introduced into the decanting station. A first robotic arm 354 picks the cases and positions them using a box cutter 356, which removes the cardboard boxes and exposes the individual items 358. A second robotic arm 360 picks the individual items while a cardboard conveyor 362 processes the cardboard boxes from the box cutter. Variable-sized subtotes 364 are provided inside tote 366, which are loaded with the appropriate number of individual items and stored in a storage device 368 as product totes.
[0031] Referring to Figure 8, a system or station 400 is shown for moving sub-totes to consolidate orders in the market tote. Here, a mobile robot 402 moves the product tote and order tote 404 to robot 406, which picks sub-totes from the product tote and selectively places them in the market order tote.
[0032] Referring to Figure 9, a system 450 for moving totes to transfer lots from market DC to market is shown. Racks are shown, but instead of using racks, totes can be stacked directly onto pallets using tote bail arms. Storage device 452 stores product totes and order totes. Portable racks 456 can be loaded by mobile robots 454, and contain order totes for making market orders, for example, combinations of totes and sub-totes 458. Trucks 460, 462 are provided for transporting racks that can be loaded manually or by mobile robots 464.
[0033] Referring to Figure 10, a replenishment system or station 480 for replenishing from racks to a distribution center is shown. Although racks are shown, instead of using racks, totes can be stacked directly onto pallets using a tote bail arm. A track 482 can provide racks 484, 486, and a mobile robot 488 operating on a rail structure 490 can pick totes from the racks to replenish the storage structure 492.
[0034] Referring to Figure 11, another embodiment without market DC decanting is shown, which includes a manual decanting system or station 500 for receiving and manually decanting cases at the market. Here, the palletized cases 502 may be depalletized by operator 504, and individual items may be loaded from the depalletized cases into a sub-tote 506 by operator 508. The sub-tote may be loaded into a tote 512, and a mobile robot 510 may pick the tote 512 to be placed in a storage device 514.
[0035] Referring to Figure 12, a subtote transfer system or station 530 is shown for transferring subtotes automated for system defragmentation. In another embodiment, this system can be a manual system operated by an operator instead of a robot. A mobile robot 530 is supplied with totes 532 from transport and storage equipment 534. A robot 536 is provided to consolidate empty subtotes into totes for defragmentation of tote storage, thereby increasing the storage density within the system.
[0036] Referring to Figure 13, a system 570 is shown for moving one subtote to another, automated for system defragmentation within a storage structure 572. Here, a mobile robot 574 provides totes 576, 578, and 580 to a station having a Cartesian pick and placement robot 582 adapted to move subtotes 584 from tote to tote. Robot 862 has a gripper 586 that can be selectively actuated to pick or release subtotes and move them along the Z, X, and Y axes.
[0037] Referring to Figure 14, an automated single-item picking workstation 600 is shown. A mobile robot 602 is provided to be mobile on rails 604, 606 and on a vertical plane 608. Robot 614 selectively accesses tote 610 containing single items, which are transported and stored inside a deck or storage 612 and are selectively accessible by robot 602.
[0038] Referring to Figure 15, a manual single-item picking workstation 630 is shown. A mobile robot 632 is provided to be mobile on rails 634, 636 and on a vertical plane 638. An operator 644 selectively accesses a tote 640 containing a single item 648, which is transported and stored inside a transport deck or storage 642, and is selectively accessible by the robot 632. A UI 650 and a directional light beam 652 may be provided to direct the operator or picker 644.
[0039] Referring to Figure 16, the completed order storage system 660 is shown. The storage structure 662 provides a mobile robot 664, a transport deck 666 with or without a vertical surface 666, and a picking workstation 668.
[0040] Referring to Figure 17, order consolidation 700 is shown. The mobile robot consolidates totes 704 with fresh produce picked for delivery 710, chilled storage totes 706 such as ambient order totes and chilled order totes, and frozen storage totes 708 such as frozen order totes.
[0041] Referring to Figure 18, the delivery of an order by cart 742 is shown. Here, the mobile robot 744 selectively provides tote bags 746 from storage device 748 to cart 742.
[0042] Referring to Figure 19, the delivery of an order 770 by a mobile robot 772 is shown. Here, rails 774 from the storage structure are utilized by the robot 772, and totes 780 are delivered from storage to loading stations 776, 778 for pickup by, for example, a vehicle 782.
[0043] As used herein, the terms “comprise” and “comprising” are intended to be interpreted as inclusive, not exclusive. As used herein, the terms “exemplary,” “example,” and “illustrative” are intended to mean “serving as an example, instance, or illustration,” and should not be interpreted as indicating or not indicating a configuration that is preferable or advantageous to other configurations. As used herein, the terms “about” and “approximately” are intended to cover variations that may exist within the upper or lower limits of subjective or objective values, such as variations in characteristics, parameters, size, and dimensions. In one non-limiting example, the terms “about” and “approximately” mean within plus 10 percent or minus 10 percent. In one non-limiting example, the terms “about” and “approximately” mean sufficiently close to what a person skilled in the art in the relevant field would consider. As used herein, the term “substantially” refers to the complete or near-complete range or degree of an action, feature, characteristic, state, structure, commodity, or result, as understood by those skilled in the art. For example, a “substantially” circular object means that the object is either perfectly circular to the mathematically determinable limit, or nearly circular as recognized or understood by those skilled in the art. The exact degree of permissible deviation from absolute perfection may depend on the specific context. However, generally, proximity to completion results in the same overall outcome as absolute and overall completion would have been achieved or obtained. The use of “substantially” is equally applicable when used in a negative sense to refer to a complete or near-complete defect of an action, feature, characteristic, state, structure, commodity, or result, as understood by those skilled in the art.
[0044] Furthermore, the terms “robot” and “bot” are used interchangeably herein according to their conventional meanings, specifically a useful machine or device, i.e., a programmable, multifunctional device capable of moving materials, parts, tools, or special-purpose devices through various programmed actions for various tasks, assignments, instructions, etc., and / or a machine or device capable of performing a simple or complex set of actions and / or a machine or device capable of performing tasks that may or may not be human work in other ways and / or a machine or device that can perform tasks and interact with its environment without the assistance of human interaction and a machine or device that can operate automatically or be controlled by a computer.
[0045] Unless otherwise noted or defined herein, this disclosure and the drawings are described in relation to the conventional three-dimensional coordinate system of X, Y, and Z axes, where the X direction is generally left-right or east-west, the Y direction is generally in-out relative to the page plane of the document, and the Z direction is generally top-bottom or north-south on the page. As further explained herein, the terms “horizontal” and “vertical” are used in accordance with their conventional definitions as understood by those skilled in the art and as generally explained and developed below. For example, in the fields of physics, engineering, and construction, a direction considered vertical is usually along which a weight hangs in response to gravity. A horizontal direction is considered to be along a line or plane perpendicular or perpendicular to a vertical plane. Thus, moving horizontally is virtually equivalent to moving along the Earth, for example, forward, backward, left, right, etc., to traverse the Earth's surface, while moving vertically is virtually equivalent to moving upward (away from the ground) or downward (towards the ground, or into the ground). Integrating X, Y, and Z coordinate access with the terms vertical and horizontal, the Z-axis is vertical, the X and Y axes are horizontal, and the vertical Z-axis is perpendicular to them. To the extent that ambiguity arises from the inherent wording of the above explanation, such ambiguity is expected to be interpreted and clarified in accordance with the conventional interpretation of the terms horizontal and vertical.
[0046] Numerous modifications and alternative embodiments of the present invention will become apparent to those skilled in the art in view of the above description. Therefore, this specification should be construed as illustrative only and is intended to teach those skilled in the art the best model for carrying out the invention. Structural details may change without substantially departing from the spirit of the invention, and the exclusive use of all modifications within the appended claims is reserved. While embodiments within this specification have been described in a manner that allows for the writing of a clear and concise specification, it is intended and should be understood that embodiments can be combined or separated in various ways without departing from the invention. The present invention is intended to be limited only to the extent required by the appended claims and the rules of applicable law.
Claims
1. A fully automated and secure supply chain for end-to-end tracking of individual items, One or more distribution centers for receiving individual products from manufacturers and distributing said individual products to the market, Multiple robots in the one or more distribution centers for sorting individual items for shipment between the one or more distribution centers and the market, Multiple tracking sensors included in or associated with the multiple robots in order to capture identification information relating to the said individual item, A tracking system comprising a unified commerce engine for receiving and storing the identification information from the tracking sensor, the tracking system for tracking the location of individual items in each of the one or more distribution centers using the identification information, Equipped with, The aforementioned multiple robots, multiple tracking sensors, and tracking systems ensure complete traceability and individual product safety from delivery from the manufacturer to delivery to the market. A fully automated and secure supply chain.
2. The fully automated and secure supply chain according to claim 1, wherein the tracking system is configured to provide data to the manufacturer relating to the individual items included in the supply chain, and the data comprises at least one of the location, inventory level, inventory rate, and sales level at every stage of the entire supply chain.
3. The fully automated and secure supply chain according to claim 1, wherein individual orders from the market are stored in the tracking system.
4. The fully automated and secure supply chain according to claim 1, wherein the sale of individual items in the market is stored in the tracking system.
5. The fully automated and secure supply network according to claim 1, wherein the one or more distribution centers are equipped with decanting stations, and individual shipments are disassembled from cases into at least one of totes and subtotes.
6. The fully automated and secure supply network according to claim 5, wherein the plurality of robots include a decanting robot for disassembling individual cases into at least one of totes and subtotes.
7. The fully automated and secure supply chain according to claim 6, wherein the plurality of tracking sensors are part of or associated with the decanting robot for tracking and identifying individual items arriving at the one or more distribution centers.
8. The fully automated and secure supply network according to claim 1, wherein the one or more distribution centers comprise a regional distribution center and a market distribution center, and individual products are shipped from the market distribution center to the market.
9. The fully automated and secure supply chain according to claim 1, wherein individual items are shipped to the market in at least one of totes and sub-totes that match the sales speed of the market.
10. The fully automated and secure supply network according to claim 1, wherein the one or more distribution centers include a market distribution center.
11. A fully automated and secure supply chain according to claim 10, comprising: a first group of one or more robots configured to receive pallets containing cases of individual items at the market distribution center; a second group of one or more robots configured to take individual items out of the cases and store the individual items; and a third group of one or more robots configured to selectively retrieve stored individual items to process market orders.
12. The fully automated and secure supply chain according to claim 11, wherein a third group of one or more robots processes order totes using mixed single-item subtotes in response to market orders.
13. The fully automated and secure supply chain according to claim 11, wherein the market distribution center processes market orders using a plurality of common or different order totes that flexibly match the sales speed of the market.
14. The fully automated and secure supply chain according to claim 1, wherein the market comprises one of a retail store and a distribution center.
15. A fully automated and secure supply chain for end-to-end tracking of individual items, One or more distribution centers for receiving individual products from manufacturers and distributing said individual products to the market, A robot in multiple distribution centers, wherein the robots handle all sorting and transportation of individual items for shipment between the multiple distribution centers and between the distribution centers and the market, Multiple tracking sensors included in or associated with the multiple robots in order to capture identification information relating to the said individual item, A tracking system comprising a unified commerce engine for receiving and storing the identification information from the tracking sensors located in each of the aforementioned multiple distribution centers, Equipped with, The identification information is used by the aforementioned multiple robots, multiple tracking sensors, and the tracking system to ensure complete tracking of the location of individual items from the first distribution center among the multiple distribution centers to the last distribution center among the multiple distribution centers. The complete handling of individual items by the multiple robots and tracking by the tracking system at the multiple distribution centers ensure the complete safety of the individual items from receipt at the first distribution center to the final distribution center. A fully automated and secure supply chain.
16. The fully automated and secure supply chain according to claim 15, wherein the plurality of tracking sensors capture identification information relating to individual items by capturing data from pallets on which the individual cases are shipped.
17. The fully automated and secure supply chain according to claim 15, wherein the plurality of tracking sensors capture identification information relating to an individual item by capturing data from at least one of the containers and subtotes from which the individual item is shipped.
18. The fully automated and secure supply chain according to claim 15, wherein the plurality of tracking sensors capture identification information about an individual item by capturing data from the case in which the individual item is shipped.
19. A fully automated and secure supply network according to claim 15, wherein the first of the plurality of distribution centers has a decanting station for receiving a plurality of pallets, and the pallets are disassembled to form one or more pallets, each having a case of the same kind for a single item, and each having a case of a different kind for a single item.
20. The fully automated and secure supply chain according to claim 19, wherein an identifier is assigned to each of one or more pallets of the different types of individual cases, and one or more identifiers are tracked and stored by the tracking system.
21. The fully automated and secure supply network according to claim 19, wherein a second of the plurality of distribution centers has a decanting station for receiving one or more pallets of different types of individual items, and for disassembling the pallets to form one or more totes or sub-totes each containing an individual item.
22. The fully automated and secure supply chain according to claim 21, wherein an identifier is assigned to each of the tote or subtote, and the one or more identifiers of the tote or subtote are tracked and stored by the tracking system.
23. The fully automated and secure supply chain according to claim 21, wherein the assortment of individual items for the tote or sub-tote is set based on market demand.
24. The fully automated and secure supply chain according to claim 15, wherein the tracking system is accessible to the manufacturer so that the manufacturer can track the location of each individual item from its departure from the manufacturer to its sale to a customer in the market.
25. The fully automated and secure supply network according to claim 15, wherein the plurality of distribution centers include regional distribution centers and market centers.
26. A fully automated and secure supply chain according to claim 25, wherein individual items are transported from the manufacturer to the regional distribution center, from the regional distribution center to the market distribution center, and from the market distribution center to the market.
27. A fully automated and secure supply chain for end-to-end tracking of individual items, Multiple distribution centers for receiving individual products from manufacturers and distributing those individual products to the market, Multiple robots in the multiple distribution centers for sorting and transporting individual items for shipment between the multiple distribution centers and between the distribution centers and the market, Multiple tracking sensors included in or associated with the multiple robots in order to capture identification information relating to the said individual item, A tracking system comprising a unified commerce engine, wherein the unified commerce engine comprises at least one non-transient memory including at least one processor and computer program code, and the unified commerce engine is configured to ensure the individual item is secured at every stage of the automated and secure supply chain by fully tracking the individual item in the automated and secure supply chain from the receipt of the individual item from the manufacturer to the sale and delivery of the individual item in the market. A fully automated and secure supply network equipped with [features / equipment].
28. The fully automated secure supply chain according to claim 27, wherein the unified commerce engine is further configured to provide data to the manufacturer in relation to the individual items included in the automated secure supply chain.
29. The fully automated and secure supply chain according to claim 28, wherein the data is provided by the unified commerce engine, which includes the location, inventory level, inventory speed, and sales level of the individual items.
30. The fully automated secure supply chain according to claim 27, wherein the unified commerce engine is further configured to separately display data relating to specialized products included in the automated secure supply chain, the data comprising location, inventory levels, inventory speed and sales levels in the automated secure supply chain within the entire supply chain process and at every stage.
31. The fully automated and secure supply network according to claim 27, wherein the plurality of distribution centers include regional distribution centers and market centers.
32. A fully automated and secure supply chain according to claim 31, wherein individual items are transported from the manufacturer to the regional distribution center, from the regional distribution center to the market distribution center, and from the market distribution center to the market.