Automated Retail Supply Chain and Inventory Control Systems

Abstract

To provide a system and a method for supplying one or two or more commodities to a real store position.SOLUTION: In a distribution center (DC) capable of receiving a commodity, the commodity can be decanted to one or two or more sub-totes from a shipping container, and the one or two or more sub-totes are stored in one or two or more product totes (P totes), and the sub-totes are moved from the one or more product totes to one or two or more order totes (O totes) on the basis of a speed of the movement of a plurality of commodities at a real store position.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] (Priority) This application claims priority to U.S. Provisional Patent Application No. 62 / 427,652, entitled "Automated Retail Supply Chain and Inventory Control System," filed November 29, 2016, the entirety of which is incorporated herein by reference.

[0002] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application is related to and shares all common subject matter with co-pending U.S. Provisional Patent Application No. 62 / 423,614, entitled "Automated Service Retail System and Method," filed November 17, 2016, the entire disclosure of which is incorporated herein by reference.

[0003] (Technical field) SUMMARY OF THE INVENTION The exemplary and non-limiting embodiments described herein relate generally to automated retail supply chain inventory systems, and more particularly to inventory control systems used in supply chains according to exemplary embodiments. [Background technology]

[0004] In traditional self-service store chains, the most cost-effective way to replenish store inventory is by the "case," i.e., by supplying the store with shipping cases of product received from a supplier. An alternative is to replenish by the "each" (or "eaches"), i.e., by supplying the store with individual product units in quantities less than a case, but this method is very expensive, so generally, the standard shipping unit for replenishment in large stores such as supermarkets and hypermarkets is the case shipped on a pallet shipment.

[0005] In the traditional logistics model, retailers receive pallets of cases at a distribution center (“DC”), whose essential role is to replenish inventory for a network of stores by periodically shipping cases of the specific set of products needed (ordered) for each store. In most DCs, these orders are fulfilled using a manual case-picking process, in which pallets of cases are arranged in aisles and human operators move from one product pallet to the next, removing the number of cases ordered by the store from each and placing the selected cases on the order pallet to be shipped to the store. In some DCs, automated case-picking systems are used, the most advanced of which utilize mobile robots such as those described in U.S. Pat. No. 8,425,173. However, whether the order fulfillment process is manual or automated, the only order unit available to stores for almost all products is the case. This means that whenever a store needs to replenish inventory of a given product (represented by a stock-keeping unit or "SKU"), regardless of the sales rate that the product typically experiences in the store, it will receive at least the quantity of each of that SKU contained in a standard shipping case supplied by the manufacturer. The term "SKU" is used herein to refer to a single product or item (a.k.a., each). However, as will be understood by those skilled in the art, the present invention is not limited to only items with SKUs. SKU is only used herein in connection with exemplary embodiments selected for clarity of explanation. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Patent No. 8,425,173 Summary of the Invention [Problem to be solved by the invention]

[0007] While operationally efficient, case-level replenishment forces retailers to carry significantly more inventory in stores than would be necessary if the only consideration for replenishment were to avoid stockouts. The minimum replenishment quantity required to prevent stockouts depends on the speed and reliability of replenishment deliveries from the DC and can be defined as the minimum safe replenishment quantity ("MSRQ"), measured in average days of supply. While the "each" number in the MSRQ is SKU-specific, the number of days of supply used to calculate the MSRQ will typically be the same for all SKUs. For example, if a DC guarantees a one-day delivery service level to a given store, the MSRQ for that store could be only four average days of supply across all SKUs. Thus, a SKU that sells an average of five units per day would have an MSRQ of 20 each, while a SKU that sells only one unit per day would have an MSRQ of 4 each.

[0008] With the exception of a few "high velocity" products, a typical shipping case for a product may contain three weeks' worth or more of that SKU's sales volume. In other words, a store needs to allocate shelf space for that product three to five times the minimum quantity deemed necessary purely to avoid stockouts (e.g., each product's MSRQ). Thus, if a store can reduce replenishment volumes across all SKUs by one-third, the retailer can either downsize the store by two-thirds for the same assortment of products or triple the number of products offered. [Means for solving the problem]

[0009] A system and method for supplying one or more products to physical store locations is provided, the method including receiving one or more products from one or more suppliers at a distribution center (DC), the distribution center (DC) including a DC storage structure having a plurality of rack modules separated by aisles and having a plurality of storage levels, the DC storage structure storing a plurality of totes comprising empty totes, product totes, or a combination thereof, at least one DC mobile robot placing totes in the DC storage structure, retrieving totes from the DC storage structure, and transporting the totes through the storage structure, a picker placing one or more products into the empty totes or the product totes at a workstation, and a picker transferring the one or more products from the empty totes to the product totes at a workstation. When an empty tote is placed in the tote, the empty tote is designated as a product tote and one or more items are designated as each; when one or more items are placed in the product tote, the one or more items are designated as each; one of the at least one DC mobile robot transports the product tote to a DC storage structure and places the product tote in the DC storage structure for storage; one of the at least one DC mobile robot retrieves the product tote from the DC storage structure and transports the product tote to a shipping dock for shipping to a physical store; the physical store comprises a building having an automated fulfillment section, a shipping section including an inspection section, and a delivery section; and the physical store receives the product tote at the receiving section.

[0010] In one aspect, the physical store further comprises a store storage structure comprising a plurality of rack modules separated by aisles and having a plurality of storage levels, the store storage structure storing a plurality of totes that are empty in the case of empty storage totes, containing each in the case of storage totes, containing orders in the case of order totes, or a combination thereof, and the physical store further comprises at least one store mobile robot that moves horizontally and vertically across the store storage structure, transfers totes to the store storage structure, removes totes from the DC storage structure, and transports totes.

[0011] In another aspect, an automated order fulfillment system at a physical store picks one or more interchangeable items from each product tote and consolidates the one or more interchangeable items into one or more order totes for delivery to customers within the physical store.

[0012] In another aspect, the method further includes one or more sub-totes sized, dimensioned, and configured to fit within the empty tote and / or product tote, wherein the plurality of empty totes and / or product totes are sized, dimensioned, and configured to fit onto a standard pallet.

[0013] In another embodiment, the standard pallet comprises one or more of a North American pallet, a European pallet, an Australian pallet, or an Asian pallet.

[0014] In another embodiment, the one or more sub-totes comprise one or more of a 1 / 4 sub-tote, a 1 / 2 sub-tote, and / or a 3 / 4 sub-tote.

[0015] In another aspect, the step of the picker at the workstation placing one or more items into an empty tote or a product tote further includes placing the one or more items into one or more sub-totes.

[0016] In another embodiment, if one or more items are placed in an empty tote, the one or more items are placed in one or more sub-totes within the empty tote, and if one or more items are placed in a product tote, the one or more items are placed in one or more sub-totes within the product tote.

[0017] In another embodiment, each product contained within a single product tote has a different stock keeping unit (SKU).

[0018] In another embodiment, each item contained within a single sub-tote has the same SKU.

[0019] In another embodiment, each product contained within a single product tote has a different SKU.

[0020] In another embodiment, each item contained on a single pallet has a different SKU.

[0021] In another aspect, receiving one or more items at the DC from one or more suppliers further includes de-trashing the shipping cases from the suppliers at a decanting workstation in the DC.

[0022] In another aspect, receiving one or more items at the DC from one or more suppliers further includes at least one mobile robot transferring shipping cases from a shipping dock to a decanting workstation.

[0023] In another aspect, the method may further include tracking the quantity and location of each contained within each of the product totes in real time according to SKU, and instructing one of the pickers to allocate a predetermined quantity of each to the product totes.

[0024] In another aspect, the predetermined quantity of each is determined based on inventory requirements at the associated automated store.

[0025] In another embodiment, inventory requirements are based on automated real-time inventory counts based on SKUs at associated automated stores.

[0026] In another embodiment, inventory requirements are based on human orders from associated automated stores.

[0027] In another embodiment, inventory requirements are based on sales history at the associated automated store.

[0028] In another embodiment, the picker is a human.

[0029] In another embodiment, the picker is a mobile robot.

[0030] According to another aspect, a method is provided, wherein a DC storage structure comprises a plurality of rack modules separated by aisles and has a plurality of storage levels, the DC storage structure stores a plurality of totes comprising empty totes, product totes, or a combination thereof, at least one DC mobile robot places the totes in the DC storage structure, removes the totes from the DC storage structure, and transports the totes throughout the storage structure, the DC receives replenishment requests from a physical store for each desired quantity that is less than a quantity conventionally required to fill each pallet, the method including tasking the at least one DC mobile robot with retrieving one or more sub-totes from the DC storage structure containing each desired quantity, the at least one DC mobile robot retrieving the one or more sub-totes and placing them into one or more product totes for delivery to the physical store.

[0031] According to another aspect, the method further includes at least one DC mobile robot picking up and transporting one or more product totes to a shipping dock for transport to a physical store.

[0032] According to another aspect, one or more product totes contained within a single product tote each have a different stock keeping unit (SKU).

[0033] According to another embodiment, one or more sub-totes each contained within a single sub-tote have the same SKU.

[0034] According to another aspect, the method further includes the physical store receiving one or more product totes at a receiving section.

[0035] According to another aspect, a physical store comprises a building having an automated fulfillment section, a shipping section including an inspection section, and a distribution section.

[0036] According to another aspect, the method further includes the physical store receiving the product tote at a receiving section.

[0037] According to another aspect, an automated order fulfillment system at a physical store picks one or more interchangeable items from each product tote and consolidates the one or more interchangeable items into one or more order totes for delivery to customers within the physical store.

[0038] According to another aspect, multiple physical stores can be in network communication with the DC and each replenishment can be based on real-time requests from the multiple physical stores, and the multiple physical stores utilize standardized sized sub-totes and totes.

[0039] According to another aspect, the method is fully automated without human interaction.

[0040] These and other features of embodiments of the present disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0041] [Figure 1] 1 shows a schematic diagram of an automated distribution center in accordance with an exemplary embodiment of the present invention. [Figure 2] 1 is a flow diagram illustrating the flow of products through a retailer's supply chain under an embodiment of the present disclosure. [Figure 3A] Shown is an automated decanting workstation in a distribution center. [Figure 3B] Shown is an automated decanting workstation in a distribution center. [Figure 4] Shown is an automated sub-tote picking workstation in a distribution center. [Figure 5A] Detail of the distribution center's I / O interface is shown, including the portable racks that hold replenishment P-totes for transport to automated stores. [Figure 5B]Detail of the distribution center's I / O interface is shown, including the portable racks that hold replenishment P-totes for transport to automated stores. [Figure 6A] Detail of a semi-automatic or manual decanting workstation. [Figure 6B] Detail of a semi-automatic or manual decanting workstation. DETAILED DESCRIPTION OF THE INVENTION

[0042] 1-6B illustrate exemplary embodiments of methods and systems according to the present invention. While the present invention will be described with reference to one or more exemplary embodiments shown in the figures, it should be understood that the present invention can be embodied in many alternative forms. Moreover, those skilled in the art will recognize various ways to modify the parameters of the disclosed embodiments, such as the size, shape, or type of elements or objects, in a manner that remains consistent with the spirit and scope of the present invention.

[0043] Compared to self-service stores, automated retail stores, such as those taught in U.S. Provisional Patent Application No. 62 / 423,614, filed November 17, 2016, entitled "Automated Service Retail System and Method," (hereby incorporated by reference in its entirety), enable dramatic improvements in both the space and labor efficiency of retail store construction and management by replacing self-service packaged goods markets with a robotic each-pick system, such as that taught in "Intake and Retrieval System." A key element of the each-pick system is a "tote / subtote" storage structure that allows a primary storage container (tote) to be subdivided into multiple compartments, each containing a different product, using secondary containers (subtotes). The primary reason for this structure is that, rather than the popular alternative of dividing partitions, totes and subtotes are designed to be manipulated by robots, and each can be transferred between totes simply by transferring the subtote that contains it.

[0044] This capability also allows for the complete automation of the method of replenishing retail store networks, particularly automated retail store networks, a significant improvement over the traditional method of replenishing stores with shipping cases of products received from manufacturers.

[0045] While traditional storage facilities based on case-level inventory storage experience long replenishment times or cycles due to relatively high inventory and other inefficiencies, embodiments of the present invention enable less inventory, allowing for more frequent and granular replenishment. Reduced inventory levels, as described herein, improve inventory accuracy. Exemplary embodiments reduce inventory and associated storage space requirements by utilizing the tote / subtote storage architecture of an automated each-picking system used in automated stores to modify the process for fulfilling store replenishment orders at a DC. According to exemplary embodiments of the present invention, the DC is an automated DC. In the methods and systems of the present invention, product cases arriving on pallets from one or more suppliers or vendors are first opened, and each case is transferred to a subtote at one or more decanting workstations. This process, referred to as "decanting," is preferably performed immediately upon receipt of the case at the DC. While not required for the disclosed embodiments, it would be advantageous to automate this decanting process so that a robot, rather than a human, transfers the goods from the case to the subtote. As will be appreciated by those skilled in the art, the present invention is adapted to perform automated, semi-automated, or human decanting.

[0046] Once the decanting process is complete, the sub-totes filled during the decanting process are loaded into "product totes." These product totes may typically be single-product or single-SKU totes, since multiple cases of the same item or SKU will typically be decanted consecutively (after arriving on the same pallet). In other words, all of the items in a tote may be the same SKU, but will typically be distributed across multiple sub-totes within the tote.

[0047] A feature of the exemplary embodiment is that each of a given SKU can be decanted into multiple sizes of sub-totes so that it is not limited to a single size sub-tote. Thus, the replenishment amount of each SKU can vary from store to store based on the calculated MSRQ for that SKU in each store. A further feature of the exemplary embodiment is that a sub-tote may contain any quantity of each, including less than the quantity shipped in a case, down to a single each per sub-tote.

[0048] According to an exemplary embodiment of the present invention, once filled with product, the totes are transferred by a mobile robot from the decanting workstation and placed into a DC storage structure, where inventory is available to fulfill replenishment orders from remote stores. The order fulfillment process for these orders is nearly identical to the each-picking process performed in stores to fulfill customer orders, as described in U.S. Provisional Patent Application No. 62 / 423,614, incorporated herein. Specifically, the mobile robot retrieves the product tote (P tote) from the storage structure and brings the order tote (O tote) to the workstation, where each is transferred from the P tote to the O tote. The difference is that in this exemplary embodiment, the transfer is performed directly by the mobile robot handling the sub-tote containing each, rather than by a human or robotic picker handling each. As one skilled in the art will appreciate, this process could similarly be performed by a human picker without departing from the scope of the present invention.

[0049] Fulfilled O totes, each containing multiple SKUs typically housed in multiple single-SKU sub-totes, are shipped from the DC to the automated store network that the DC supports. At each store, the delivered O totes are received as P totes and introduced into the automated each-pick system operating within the store, where the delivered O totes are held in stock ready to be allocated each to fulfill customer orders, as described in U.S. Provisional Patent Application No. 62 / 423,614, incorporated herein by reference.

[0050] The automated retail supply chain of an exemplary embodiment of the present invention includes an automated DC and a network of automated retail stores supplied with replenishment inventory from the DC. Figure 1 illustrates the automated DC in schematic form, the details of which are described in more detail below.

[0051] Figure 2 illustrates the flow of product through an automated retail supply chain, according to an exemplary embodiment. Product flow begins with the arrival at an automated DC of pallets containing cases shipped by one or more suppliers. Typically, the pallets are single-product or single-SKU pallets, i.e., all cases of a product are of the same SKU. As one skilled in the art will appreciate, some pallets may be "rainbow" pallets with multiple single-SKU layers, but this minor complexity in the process will be ignored for purposes of this disclosure. Upon arrival, an operator must verify that the SKU is known—that is, the product's identity and other attributes are already captured in the system—and that the actual product received matches the registered SKU attributes. This step is substantially similar or identical to what occurs in manual or automated case-picking DCs supporting self-service stores; however, after SKU verification, the currently disclosed embodiment leaves such stores. The second step in the flow is to immediately send the received cases to a decanting workstation, where they are transferred to sub-totes, which are themselves placed within totes.

[0052] This flowchart shows, for example, where a truck or other suitable transport vehicle can arrive at a distribution center with each item in a case on a pallet. The pallet can be scanned to verify the case information. A determination is made as to which type of workstation the pallet should be directed to, and the pallet is directed to the appropriate decanting workstation. For example, the decanting workstation can be one of a manual decanting workstation, an automatic decanting workstation, or a semi-automatic decanting workstation. A first robot transfers the case from the pallet to a box opener, where the box is automatically opened / cut, and the first robot disposes of the top end of the case. A second robot selects a sub-tote of the appropriate corresponding size and places the sub-tote into the tote (e.g., product tote). The second robot then places each item from the opened case into the sub-tote, and if the tote is full of filled sub-totes, a mobile robot stores the completed (or partially completed) tote in a storage rack system. The selection of sub-tote sizes and / or size mix can be a function of the product velocity requirements of a given store to which they are being served. For example, the size mix of sub-totes can be presented as a function of the different stores to which they are being served based on the product velocity requirements of those stores. Each of these steps is represented in the flow of Figure 2 as shown in the receiving line above.

[0053] When an order for a product is received or a demand for a product is created from a given store, the order fulfillment process illustrated in FIG. 2 begins. Order fulfillment begins with a mobile robot directing an empty (or partially empty) order tote to be transferred to a picking workstation. Subsequently (or in parallel, or otherwise), another mobile robot brings a product tote with a sub-tote to the picking workstation, where the picking robot transfers the entire sub-tote to the order tote to fulfill the order. As will be appreciated by those skilled in the art, sub-totes can be intermixed based on the desired amount of inventory needed for a given store. According to an exemplary embodiment of the present invention, a determination is made regarding when an order is needed and / or when an order tote will be shipped, whether to move the order tote to a portable rack if the order tote is needed immediately, or whether to move the order tote to short-term / long-term storage if the order tote is needed in the future. When a given portable rack is full or at an appropriate level to fulfill one or more orders, it can be submitted to a given truck or transport for transportation to a networked store. According to an exemplary embodiment of the present invention, order totes or racks may be moved to storage or trucks or transports based on a determination as to whether a truck or transport is currently available. The flow charts illustrate possible sequences described herein, and alternative combinations may be made within the flow charts. Here, product tote, order tote, and other scheduling and dispatch decisions may be made based on order and sub-tote size and order timing and when orders need to be fulfilled and optimized.

[0054] 3A and 3B show detailed views of a decanting workstation. As shown in FIG. 3A, a mobile pallet robot transfers pallets with product cases to the decanting workstation. Upon exiting the truck, a barcode scanner, radio frequency identification (RFID) reader, or other identification technology is utilized to identify each case and each contained product. The destination decanting workstation can be selected based on the case and / or each, and the decanting workstation is best configured to operate as described with respect to FIG. 2.

[0055] According to an exemplary embodiment of the present invention, a first articulated arm robot uses a camera mounted on a distal link to identify the location of a case placed on a pallet, the first robot adjusts its variable-width gripper to the size of the previously identified case, and uses the camera to grasp the case, lift it off the pallet, and place it on a first conveyor.

[0056] The case is conveyed to a box cutter that uses a blade on a rotating head to cut along the bottom perimeter of the case. The box cutter uses the case's identifying indicia in conjunction with a camera to guide the rotating head around the perimeter of the case. Alternatively, the box cutter can use a fixed blade that cuts the bottom of the box as the box is conveyed through the box cutter in two orthogonal directions.

[0057] Once the case is cut along its bottom perimeter, it is transferred onto a second carousel, where the top and sides of the case are lifted upward by a first articulated arm robot. The first robot then discards the top and sides of the case onto a third cardboard conveyor, shown directly below the second conveyor. The cardboard is then transported by the third conveyor to a location where it can be collected for reuse.

[0058] The second articulated arm robot uses a variable-width end effector to pick a sub-tote from a stack of variable-sized sub-totes and place the selected sub-tote into the tote. The size of the selected sub-tote corresponds to the identification of each item to be transferred and the desired quantity of each item to be stored in the sub-tote. For example, the quantity of each item placed in the sub-tote is calculated based on the inventory rules and speed of each specific item at the retail store served by the automated DC. Sub-totes of different sizes and configurations can be placed within the tote to maximize storage density and decanting efficiency. The identification symbol (e.g., alphanumeric or bar code) is read and stored by a camera mounted on the second robot.

[0059] Once the sub-tote is placed in the tote, the second robot adjusts its variable pitch vacuum cup gripper to the item being picked. The second robot uses a camera mounted on the distal link to position the gripper and transfers the item from the opened case to the sub-tote. As will be appreciated by those skilled in the art, the second robot can alternatively use picking grippers other than vacuum (e.g., mechanical, conformal, etc.). The second robot can also be configured to automatically change gripper type based on the item being transferred.

[0060] After all of the pieces have been removed from the open case, a second conveyor carries the bottom of the case and drops it off its end onto a third cardboard transfer conveyor.

[0061] A key feature of the exemplary embodiment of the present invention is that each of a given SKU can be loaded into different sized sub-totes at the decanting workstation, allowing the replenishment quantity for each SKU to vary from store to store. According to the exemplary embodiment of the present invention, a standard replenishment quantity ("SRQ") can be calculated for each SKU at each store based on the MSRQ for that SKU / store. As an example, if a 1 / 8 sub-tote can hold 4 units of each of a given SKU ("XYZ"), a 1 / 4 sub-tote can hold 8 units of each of that SKU, and a 1 / 2 sub-tote can hold 16 units of each of that SKU. Furthermore, in this example, the MSRQ for all stores supported by a given DC is 5 average days of replenishment across all SKUs. Then, in this example, the SRQ for SKU XYZ would be 1 / 8 sub-tote containing 4 units of each for all stores with sales volume of only 5.6 units of XYZ each per week (4 / (5 / 7) = 5.6). For all stores with sales volume between 5.7 and 11.2 units of each per average week, the SRQ would be a 1 / 4 subtote containing 8 units of each, and for stores with sales volume between 11.3 and 22.4 units of XYZ each per average week, the SRQ would use a 1 / 2 subtote SRQ when ordering SKU XYZ from the DC. Note that the SRQ can also be a combination of multiple subtotes. For example, if a store's sales volume is between 22.5 and 28.0 units of SKU XYZ each per average week, the SRQ would be a combination of a 1 / 2 subtote containing 16 units of each and a 1 / 8 subtote containing 4 units of each.

[0062] According to an exemplary embodiment of the present invention, the distribution of subtote sizes into which all of a given SKU's are loaded at a decanting workstation should generally match the distribution of subtote sizes generated by summing all of the SRQs for that SKU across all stores supported by the DC. For example, if there are 100 stores supported by a DC and a case of SKU XYZ is being decanted, and the sum of all of the subtote sizes in those stores' SRQs for SKU XYZ is 40 1 / 8 subtotes, 60 1 / 4 subtotes, and 10 1 / 2 subtotes, then 36% of the subtotes into which each is loaded should be 1 / 8 subtotes (40 / 110=0.36), 55% should be 1 / 4 subtotes (60 / 110=0.55), and 9% should be 1 / 2 subtotes (10 / 110=0.09).

[0063] The next step in logistics according to an exemplary embodiment is to place the tote loaded with filled sub-totes into a storage structure, which is performed by one or more mobile robots. In particular, once a tote is filled with sub-totes containing each, the filled tote is retrieved by the mobile robot and placed into a storage structure or rack, as described in U.S. Patent Application Serial No. 15 / 171,802, filed June 2, 2016, entitled "Storage Intake and Retrieval System," the disclosure of which is incorporated herein by reference in its entirety. These totes may be product totes used in the order fulfillment process.

[0064] The next step in logistics is the order fulfillment process where replenishment subtotes are transferred from the product tote to the order tote, and this process is also performed fully robotically.

[0065] The mobile robot delivers the sub-tote (product tote) containing each to the picking workstation, as shown in Figure 4. The mobile robot also delivers the empty tote (order tote) to the picking workstation. A third articulated arm robot is used to move the order sub-tote containing each to the empty order tote. Once the order tote is filled with the sub-tote containing each, the mobile robot can store the tote in a storage structure or transfer it directly to the temporarily attached portable storage rack shown in Figures 5A and 5B.

[0066] The next step in logistics according to this disclosed embodiment is to ship the filled replenishment totes from the DC to the stores.

[0067] 5A shows a portable storage rack temporarily attached to a storage structure, a portable storage rack being transported to a truck, and a portable storage rack located in a truck destined for a retail store. A mobile robot is shown transferring a loaded tote to the portable rack temporarily attached to the storage rack.

[0068] The portable storage racks are transported using a mobile rack robot configured to move the portable storage racks. Specifically, the mobile rack robot itself is positioned below the portable storage rack, slightly lifts the portable storage rack, and uses computer navigation to move the portable storage rack to its destination. The mobile rack robot can fit into the space below the portable storage rack between its support legs at its narrow end or between support legs along its length. Alternatively, the mobile rack robot can be controlled by a human operator.

[0069] Alternatively, the portable storage rack can be transported manually on attached wheels or using a human-guided wheeled lift.

[0070] The open side of the portable storage rack, where the mobile robot can load a tote, has a latch that secures the tote from sliding out of its storage position when not attached to the storage structure. Additionally, the top of the trailer can have a beam along the length of the trailer that helps guide the portable storage rack into the trailer and prevents the portable storage rack from tipping over during transport.

[0071] 5B shows a rail structure over which the mobile robot travels when placing or picking totes from the portable storage rack. Alignment features, such as alignment pins or kinematic couplings, can be placed on the bottom of the rail structure to precisely position the portable storage rack on the rail structure and storage structure.

[0072] The rail structures and storage structures at the retail store contain the same alignment features so that the portable storage racks can be quickly and accurately aligned with the rail structures to transfer the totes to the storage structures. After the arriving full totes are transferred to the store's storage structures, the empty totes with their empty sub-totes can be transferred onto the portable storage racks for transfer back to the automated DC.

[0073] In scenarios where there is not enough space available to transport totes and sub-totes on portable storage racks back to the automated DC, stores can nest sub-totes and totes by using automated picking workstations normally used to pick each, or by transferring sub-totes between totes to increase storage density, i.e., de-fragmenting stored sub-totes. Nested totes and sub-totes can then be placed on trucks for delivery back to the automated DC.

[0074] Upon arrival at the retail store, the portable storage rack is removed from the truck and attached to the store's storage structure, where the mobile robot transfers the tote with the sub-totes containing each tote to the storage structure of each automated picking system operating within the store.

[0075] The remaining steps in the product flow according to the disclosed embodiments include fulfilling customer orders at each picking workstation and transporting the entire order to the customer, as described in U.S. Patent Application No. 15 / 171,802, filed June 2, 2016, entitled "Inbound / Outbound System," the entire disclosure of which is incorporated herein by reference.

[0076] Although the decanting workstations, picking workstations, storage racks, and portable racks are all illustrated and described as singular for simplicity, an automated distribution center is expected to accommodate multiples of each interacting with each other.

[0077] Figures 6A and 6B show a manual decanting workstation. Essentially, anywhere an articulated robot is installed, a human can be placed, alone or in combination, and a pallet and rack mobile robot can replace a human-pulled "pallet jack." The most difficult robot to replace a human would be a mobile robot, especially due to speed and volume constraints.

[0078] As used herein, the terms "robot" and "bot" are used interchangeably herein in accordance with their conventional meanings, and specifically refer to a useful machine or device, i.e., a programmable multi-function device that can move materials, parts, tools, or specialized devices through various programmed movements to perform various tasks, assignments, instructions, etc.; and / or a machine or device that can perform a series of simple or complex actions; and / or a machine or device that can perform tasks that may or may not be human work; and / or a machine or device that is a programmable mechanical device that can perform tasks and interact with its environment without the aid of human interaction; and a machine or device that can operate automatically or is controlled by a computer.

[0079] Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only, and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. Details of construction may vary substantially without departing from the spirit of the invention, and the exclusive use of all modifications is reserved. Within this specification, embodiments have been described in a manner that allows a clear and concise specification to be written, but it is contemplated and will be understood that the embodiments can be combined or separated in various ways without departing from the invention. It is intended that the present invention will be limited only to the extent required by applicable law.

Claims

1. 1. An order fulfillment system including a distribution center for supplying merchandise to physical stores, The order fulfillment system a decanting station for receiving merchandise from an upstream supplier of the merchandise to a distribution center, the decanting station receiving a plurality of sub-totes of different sizes, two or more of the plurality of sub-totes configured to fit within a product container, one sub-tote of the plurality of sub-totes selected for packaging with a same stock keeping unit (SKU) of merchandise, the size of the sub-tote selected based on inventory requirements of the same SKU of merchandise at a physical store location; a picking workstation configured to transfer merchandise from a product container to an order container, the merchandise being picked and placed in the order container based on an order for the merchandise at a physical store location, the sub-totes containing merchandise of the same SKU, the sub-totes being transferred as a whole from the product container to the order container at the picking workstation, the product container containing the sub-totes and transferring them from the decanting station to the picking workstation; a delivery section that loads order containers from the distribution center onto delivery vehicles, the delivery section loading order containers containing sub-totes with goods of the same SKU onto delivery vehicles for shipment to brick-and-mortar store locations; Order fulfillment system.

2. 10. The order fulfillment system of claim 1, further comprising a storage section configured to store product containers containing sub-totes having goods of the same SKU after the goods have been loaded into the product containers and before the product containers are transported to the picking workstations.

3. 10. The order fulfillment system of claim 1, further comprising a decanting robot that automatically decant items in the decanting station.

4. 2. The order fulfillment system according to claim 1, further comprising a decanting robot at said decanting station for automatically loading products of the same SKU into a sub-tote.

5. 10. The order fulfillment system of claim 1, wherein the items are manually decanted at the decanting station.

6. 10. The order processing system of claim 1, further comprising a picking robot configured to automatically grasp sub-totes of different sizes and transfer the sub-totes having items of the same SKU as a whole from the product container to the order container.

7. 10. The order fulfillment system of claim 1, wherein the sub-totes are manually transferred as a whole from the product container to the order container.

8. 10. The order fulfillment system of claim 1, further comprising a plurality of mobile robots configured to transfer the product containers from the decanting station, configured to transfer the product containers to a picking workstation, and configured to transfer empty product containers away from the picking workstation.

9. 9. The order fulfillment system of claim 8, wherein the plurality of mobile robots are configured to transport the order containers to the picking workstation, to transport the order containers from the picking workstation, and to transport the order containers to the delivery section.

10. 10. The order fulfillment system of claim 1, wherein merchandise is received from a manufacturer of merchandise at the decanting station.

11. a decanting station for receiving merchandise from an upstream supplier of the merchandise to a distribution center, the decanting station receiving a plurality of sub-totes of different sizes, two or more of the plurality of sub-totes configured to fit within a product container, one sub-tote of the plurality of sub-totes selected for packaging with a same stock keeping unit (SKU) of merchandise, the size of the sub-tote selected based on inventory requirements of the same SKU of merchandise at a physical store location; a picking workstation configured to transfer merchandise from a product container to an order container, the merchandise being picked and placed in the order container based on an order for the merchandise at the physical store location; a picking robot configured to automatically grasp sub-totes of different sizes and transfer the sub-totes having items of the same SKU as a whole from the product container to the order container; Order fulfillment system.

12. 12. The order fulfillment system of claim 11, further comprising a shipping section for transporting order containers from a distribution center, the shipping section transporting order containers containing sub-totes having goods of the same SKU from the distribution center for shipment to a brick-and-mortar store location.

13. 12. The order fulfillment system of claim 11, further comprising a storage section configured to store product containers containing sub-totes having goods of the same SKU after the goods have been loaded into the product containers and before the product containers are transported to the picking workstations.

14. 12. The order fulfillment system of claim 11, further comprising one or more decanting robots for automatically decanting items in the decanting station and automatically loading items of the same SKU into sub-totes at the decanting station.

15. 12. The order processing system of claim 11, further comprising a plurality of mobile robots configured to transfer product containers and order containers to and from the picking workstations.

16. 12. The order fulfillment system of claim 11, further comprising a plurality of mobile robots configured to transfer the plurality of sub-totes to the decanting station.

17. 1. An order fulfillment system including a distribution center for supplying merchandise to physical stores, The order fulfillment system a decanting station for receiving merchandise from an upstream supplier of the merchandise to a distribution center, the decanting station receiving a plurality of sub-totes of different sizes, two or more of the plurality of sub-totes configured to fit within a product container, merchandise of the same stock keeping unit (SKU) being placed in the plurality of sub-totes of different sizes, and each sub-tote of the plurality of sub-totes being directed to a different one of a plurality of physical store locations; a picking workstation configured to transfer merchandise from a product container to an order container, the merchandise being picked and placed in the order container based on orders for the merchandise at a plurality of physical store locations, each sub-tote having the same SKU of merchandise, the sub-totes collectively being transferred from the product container to the order container at the picking workstation, the product container receiving the sub-totes and transferring them from the decanting station to the picking workstation; Order fulfillment system.

18. 20. The order fulfillment system of claim 17, further comprising a picking robot configured to automatically grasp each sub-tote of the plurality of different sized sub-totes and transfer each sub-tote of the plurality of different sized sub-totes as a whole to a different order container.

19. 20. The order processing system of claim 17, wherein each sub-tote of the plurality of different sized sub-totes is manually transferred to a different order container as a whole.

20. 20. The order processing system of claim 17, further comprising a mobile robot configured to transfer product containers to the decanting station, configured to transfer product containers to the picking workstation, and configured to transfer order containers to the picking workstation.

21. 1. An order fulfillment system including a distribution center for supplying merchandise to physical stores, a decanting station for receiving multiple types of merchandise into a distribution center, the decanting station configured to transfer one type of merchandise into multiple sub-totes configured to fit within one or more product containers; a picking workstation configured to transfer one or more of the plurality of sub-totes from one or more product containers to one or more order containers, wherein one or more of the plurality of sub-totes are selected based on inventory requirements of a type of item at a brick-and-mortar location; a delivery section that transfers the one or more order containers to a shipping vehicle for shipment to the brick-and-mortar location. Order fulfillment system.

22. 22. The order fulfillment system of claim 21, wherein the plurality of sub-totes includes sub-totes of different sizes.

23. 23. The order fulfillment system of claim 22, wherein a combination of two or more sub-totes of different sizes corresponds to inventory requirements of one type of item at a brick-and-mortar location.

24. 22. The order processing system of claim 21, further comprising a storage section configured to store the one or more product containers after the one or more items of the one type have been loaded into the one or more product containers and before the one or more product containers are transferred to the picking workstation.

25. 22. The order fulfillment system of claim 21, further comprising a decanting robot for automatically loading said one type of product into said plurality of sub-totes at said decanting station.

26. 22. The order fulfillment system of claim 21, wherein the one type of item is manually decanted at the decanting station.

27. 22. The order processing system of claim 21, further comprising a picking robot configured to automatically grasp sub-totes of different sizes and transfer one or more of a plurality of sub-totes collectively having one type of item from the one or more product containers to one or more order containers.

28. 22. The order processing system of claim 21, wherein the sub-totes are manually transferred as a whole from the product container to the order container.

29. 22. The order processing system of claim 21, further comprising a plurality of mobile robots configured to transfer product containers from the decanting station, configured to transfer product containers to the picking workstations, and configured to transfer empty product containers away from the picking workstations.

30. 30. The order fulfillment system of claim 29, wherein the plurality of mobile robots are further configured to transport order containers to the picking workstation, to transport order containers from the picking workstation, and to transport order containers to the delivery section.

31. 1. A method of order fulfillment for a distribution center for supplying merchandise to physical stores, comprising: receiving a plurality of types of products at a decanting station to a distribution center; transferring one type of product into multiple sub-totes at a decanting station and placing the multiple sub-totes into one or more product containers; transferring, at a picking workstation, one or more of the plurality of sub-containers from the one or more product containers to one or more order containers, selecting one or more of the plurality of sub-containers based on inventory requirements for a type of item at the physical store; and in a delivery section, transferring the one or more order containers to a delivery vehicle for shipment to a brick-and-mortar store location. method.

32. 32. The method of claim 31 , wherein the plurality of sub-containers comprises sub-containers of different sizes.

33. 33. The method of claim 32, wherein a combination of two or more sub-totes of different sizes corresponds to inventory requirements for one type of item at a brick-and-mortar store location.

34. 32. The method of claim 31 , further comprising storing one or more product containers in a storage section after the one or more items are loaded into the one or more product containers and before the one or more product containers are transferred to a picking workstation.

35. 32. The method of claim 31, further comprising the step of automatically loading multiple sub-totes of one type of product at the decanting station by a decanting robot.

36. 32. The method of claim 31, further comprising manually decanting one type of product at a decanting station.

37. 32. The method of claim 31, further comprising the step of automatically grasping sub-totes of different sizes with a picking robot and transferring one or more of a plurality of sub-totes that collectively contain one type of product from the one or more product containers to the one or more order containers.

38. 32. The method of claim 31, further comprising manually transferring the sub-tote as a whole from the product container to the order container.

39. 32. The method of claim 31, further comprising the steps of: transferring, by a plurality of mobile robots, the product containers from the decanting station; transferring the product containers to a picking workstation; and transferring the empty product containers away from the picking workstation.

40. 40. The method of claim 39, further comprising the steps of: transferring, by the plurality of mobile robots, order containers to a picking workstation; transferring the order containers from the picking workstation; and transferring the order containers to a delivery section.

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