Picking System

Abstract

To provide a picking system that can improve efficiency of a picking work.SOLUTION: A control system assigns a type value Va to types of objects to be handled and ranks the types, sets a type value Va of each type of the object to be handled so that the type value Va of each type becomes a value larger than the sum of type values Va of all types ranked lower than the type, and calculates a value of the sum of type values Va of all types included in each order information In as a similarity index Ex of each order information In. In batch generation processing, the control system aggregates a plurality of order information In to be processed within a unit period in order of the similarity index Ex.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a picking system including an automated warehouse that stores a plurality of mounting bodies, each with a plurality of items placed on it; a plurality of work areas in which picking work is carried out to remove items of the type and number specified by order information from the mounting bodies released from the automated warehouse, based on order information that specifies the type and number of items required for each shipping destination; a conveyance system that transports the mounting bodies between the automated warehouse and the plurality of work areas; and a control system that controls the automated warehouse and the conveyance system. [Background technology]

[0002] In a picking system used in a logistics center or the like, a carrier carrying items of a type specified in order information is transported from an automated warehouse to a work area. Then, in the work area, a picking operation is performed to pick out the items of the type and number specified in the order information. A plurality of picking operations that occur as tasks in the picking system are assigned to a plurality of work areas, respectively. An example of such a picking system is disclosed in Japanese Patent Application Laid-Open No. 2015-199562. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-199562 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, various types of goods are stored in the automated warehouse of the picking system, and the shipping frequency and picking work format vary depending on the type of goods. Therefore, by devising a way to allocate picking work related to each order information to a work area depending on the type of goods, the efficiency of picking work can be improved for the entire system.

[0005] In view of the above situation, it is desirable to realize a picking system that can improve the efficiency of picking work. [Means for solving the problem]

[0006] an automated warehouse that stores a plurality of mounting bodies, each of which has a plurality of articles mounted thereon; a plurality of work areas in which a picking operation is performed to pick out the items of the type and number specified by order information from the storage objects delivered from the automated warehouse based on order information specifying the type and number of the items required for each shipping destination; a transport system that transports the object between the automated warehouse and a plurality of the work areas; A picking system including a control system that controls the automated warehouse and the conveyance system, The control system includes: a batch generation process for aggregating a set number of pieces of order information and grouping the picking operations corresponding to the aggregated order information into one batch operation; a task allocation process for allocating each of the plurality of batch tasks generated by the batch generation process to one of the plurality of task areas; a transport process for transporting the objects required for the batch work assigned by the work allocation process to each of the plurality of work areas; an index calculation process for calculating a similarity index indicating the degree to which each of the plurality of pieces of order information is similar to each other, The control system, in the index calculation process, assigning a type value to the type of object to be handled and ranking the type; setting the type value of each of the types to be handled so that the type value of each of the types is greater than the sum of the type values ​​of all of the types that are ranked lower than the type in question; calculating a sum of the type values ​​for all the types included in each of the order information as the similarity index for each of the order information; In the batch generation process, the control system aggregates the plurality of pieces of order information to be processed within a unit period in descending order of the similarity index.

[0007] According to this configuration, each type value of multiple types is greater than the sum of the type values ​​of all types lower than that type. Therefore, for example, the similarity index of order information including an item of the highest type is greater than the similarity index of order information for all type combinations that do not include the item of the highest type. Similarly, for example, the similarity index of order information including an item of the second highest type but not the item of the highest type is greater than the similarity index of order information for all type combinations that do not include the items of the highest and second highest types. Therefore, by aggregating multiple order information with similar similarity indices to generate batch jobs, the possibility of consolidating picking operations corresponding to a set number of order information including items of the same type into the same batch job is increased. Furthermore, if picking operations for items of the same type can be consolidated into the same batch job, picking operations for those types of items can be performed together in a single work area. This improves the efficiency of picking operations in the work area. It also improves the efficiency of transporting objects in the transport process.

[0008] Further features and advantages of the techniques according to the present disclosure will become more apparent from the following description of exemplary and non-limiting embodiments, which proceeds with reference to the drawings. [Brief explanation of the drawings]

[0009] [Figure 1] Plan view of the picking system [Figure 2] Picking system control block diagram [Figure 3] Illustration of picking work [Figure 4] Batch work illustration [Figure 5] Illustration of the calculation of the similarity index [Figure 6] Illustration of sorting order information based on similarity index [Figure 7] Diagram of consolidating multiple order information using batch generation processing DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an embodiment of a picking system will be described with reference to the drawings.

[0011] As shown in Figures 1 to 3, the picking system 100 includes an automated warehouse 1 that stores multiple mounting bodies 5, each with multiple items W placed on it, multiple work areas 2 in which picking work is performed to remove items W of the type and number specified by order information In from the mounting bodies 5 released from the automated warehouse 1 based on order information In that specifies the type and number of items W required for each shipping destination, a conveying system T that transports the mounting bodies 5 between the automated warehouse 1 and the multiple work areas 2, and a control system 3 that controls the automated warehouse 1 and the conveying system T.

[0012] The goods W include industrial products, daily necessities, foodstuffs, etc. They may also include finished products and semi-finished products. The goods W are stored in the automated warehouse 1 while placed on the mounting body 5, and are transported to various locations by the transport system T.

[0013] The mounting body 5 includes a container and a pallet. The container also includes a folding container and a cardboard box. In this embodiment, the mounting body 5 is configured using a storage container for storing the items in the automated warehouse 1 (see FIG. 3).

[0014] Although detailed illustration is omitted, the automated warehouse 1 includes storage shelves that store the objects 5, and an in-shelf transport device that transports the objects 5 within the automated warehouse 1. Examples of the in-shelf transport device include a stacker crane, a lifter, a transport cart arranged on each shelf of the storage shelf, and a conveyor. The in-shelf transport device constitutes part of the transport system T. In this embodiment, the picking system 100 includes multiple such automated warehouses 1. Note that if the automated warehouse 1 includes a conveyor as the in-shelf transport device, the automated warehouse 1 may be configured to store the objects 5 on the conveyor. In this case, the automated warehouse 1 may be configured without including a stacker crane or a transport cart.

[0015] In this embodiment, the transport system T includes a conveyor Ta. The transport path of the conveyor Ta for the mount 5 is formed to connect multiple automated warehouses 1 and multiple work areas 2. The mount 5, which has been removed from one of the multiple automated warehouses 1, is transported to one of the multiple work areas 2 along the transport path of the conveyor Ta. The mount 5, from which the required item W has been picked in the work area 2, is transported to one of the multiple automated warehouses 1 along the transport path of the conveyor Ta and stored there. The transport system T may include other types of transport devices, such as an automated guided vehicle, instead of or in addition to the conveyor Ta. As described above, the transport system T includes an intra-shelf transport device that transports the mount 5 within the automated warehouse 1.

[0016] 2, the control system 3 is configured to control the automated warehouse 1, the work area 2, and the transport system T based on the order information In. The control system 3 also controls the work instruction output devices (monitors, etc.) and picking robots, etc., arranged in the work area 2.

[0017] The order information In is information that specifies the type and number of items W required for each shipping destination. The order information In is information that is generated based on the needs of the customer and is stored in the server 4. The control system 3 obtains the order information In from the server 4.

[0018] The control system 3 is configured to perform inventory management of the items W in the automated warehouse 1. The control system 3 is configured to manage at least the type and number of the items W placed on each of the placement bodies 5 stored in the automated warehouse 1.

[0019] Based on the order information In, the control system 3 selects multiple or a single object 5 required for the picking operation in each work area 2, and transports the selected object 5 to each work area 2 using the transport system T.

[0020] The control system 3 can be configured using multiple pieces of hardware and multiple pieces of software. The control system 3 includes, for example, a processor such as a microcomputer, peripheral circuits such as a memory, etc. Each function is realized by the cooperation of these pieces of hardware and a program executed on a processor such as a computer.

[0021] Next, the picking work performed in work area 2 will be described.

[0022] As shown in FIG. 3, picking work is performed based on order information In. In the picking work, multiple or single items W specified in the order information In are collected. For example, order information In is generated for each shipping destination. Therefore, the picking work can be said to be a task of collecting items W requested for each shipping destination.

[0023] Multiple or single mounting bodies 5 carrying items W of the type and number specified in the order information In are transported to a specific work area 2, and in the picking operation, these items W related to the order information In are removed and collected in a shipping container 6.

[0024] In the example shown in FIG. 3 , the order information In specifies three items W of type A (hereinafter, sometimes referred to as “item A”), two items W of type B (hereinafter, sometimes referred to as “item B”), and one item W of type C (hereinafter, sometimes referred to as “item C”). In this example, each mounting body 5 is configured to mount a single type of item W, and a mounting body 5 for mounting at least three or more items A, a mounting body 5 for mounting at least two or more items B, and a mounting body 5 for mounting at least one or more items C are transported to the work area 2. Then, in the picking operation in the work area 2, three items A, two items B, and one item C are collected into a shipping container 6. The picking operation may be performed by a worker or may be performed unmanned by a picking robot or the like. Alternatively, the picking operation may be performed by both a worker and a picking robot.

[0025] As shown in Figure 4, the control system 3 (see Figure 2) is configured to perform a batch generation process that aggregates a set number of order information In and groups the picking work corresponding to the aggregated order information In into one batch work, a work allocation process that assigns each of the multiple batch works generated by the batch generation process to one of multiple work areas 2, and a transport process that transports the mounting body 5 required for the batch work assigned by the work allocation process to each of the multiple work areas 2.

[0026] FIG. 4 illustrates four batch operations. Each of the four batch operations is assigned to one of four operation areas 2 by the operation allocation process. The batch operation includes a set number of picking operations related to the order information In. That is, the batch operation includes a set number of picking operations. The "set number" is not determined uniformly. As shown in FIG. 4, one batch operation may include two picking operations, three picking operations, or four picking operations. That is, in the example shown in FIG. 4, the "set number" is 2 to 4. The "set number" may be determined flexibly as appropriate, or may be an unchanging constant.

[0027] As shown in FIG. 5, the control system 3 is configured to execute an index calculation process for calculating a similarity index Ex that indicates the degree to which each of a plurality of pieces of order information is similar to one another.

[0028] In the index calculation process, the control system 3 assigns a type value Va to the type of the item W to be handled and ranks the types. Then, in the index calculation process, the control system 3 sets the type value Va of each type to be handled so that the type value Va of each type is greater than the sum of the type values ​​Va of all types ranked lower than that type.

[0029] For example, as shown in FIG. 5, assume that there are types A to F of items W, each ranked 1 to 6. When focusing on type A, the type value Va of type A is "32," and the sum of the type values ​​Va of the lower-ranking types B to F is "31 (=16+8+4+2+1)," which is less than "32." Also, when focusing on type D, for example, the type value Va of type D is "4," and the sum of the type values ​​Va of the lower-ranking types E and F is "3 (=2+1)," which is less than "4." In other words, the control system 3 sets the type value Va of the type to be handled as a target type (a type of interest) such that the type value Va of the target type is greater than the sum of the type values ​​Va of all types lower than the target type.

[0030] In this embodiment, the type value Va is set to the Nth power (N is an integer equal to or greater than 0) of M (M is an integer equal to or greater than 2), where N is set to a value according to the ranking order. This makes it possible to easily set type values ​​Va such that the type value Va of each of multiple types is greater than the total type values ​​Va of all types lower than that type. In this example, M is set to "2." N is set to a larger value as the ranking of the type increases, and is set to "0 to 5" in this example. In other words, the type value Va of each type is expressed as 2 to the 0th power to 2 to the 5th power.

[0031] In this embodiment, the ranking is performed in order of shipping frequency, which is the frequency specified by the order information In. The higher the shipping frequency, the higher the ranking, and the lower the shipping frequency, the lower the ranking. In other words, the ranking is performed in order of increasing need, so the higher the need, the higher the ranking, and the lower the need, the lower the ranking.

[0032] In the index calculation process, the control system 3 calculates the sum of the type values ​​Va for all types included in each piece of order information In as the similarity index Ex for each piece of order information In. Because the type values ​​Va are decimal values, the sum of the type values ​​Va is also a decimal value.

[0033] In this embodiment, the control system 3 converts the similarity index Ex into a binary value in the index calculation process. That is, in this embodiment, the control system 3 converts the sum of the type values ​​Va, which are expressed in decimal, into a binary value. This simplifies the calculation process of the similarity index Ex, making it easier to reduce the calculation load on the control system 3.

[0034] In the example shown in FIG. 5, the order information In specifies four items W of type A, two items W of type C, and one item W of type D. In this case, the types of items W included in the order information In are "A," "C," and "D." Based on the table at the top of FIG. 5, the type value Va of type A is "32," the type value Va of type C is "8," and the type value Va of type D is "4," so the sum of these type values ​​Va is "44." The control system 3 converts this sum into a binary number to obtain a six-digit similarity index Ex of "101100." In this example, since N ranges from 0 to 5, the value converted into binary is a six-digit value.

[0035] As shown in FIG. 6, in this embodiment, in the batch generation process, the control system 3 performs stable sorting of the binary similarity indexes Ex for the multiple pieces of order information In to be processed within a unit period, arranging them in ascending order of the number of digits and descending order of value.

[0036] The above-mentioned "unit period" is arbitrarily determined depending on the operation, and may be, for example, one hour, or may be half a day or one day.

[0037] 6 shows an example in which the number of order information In to be processed within a unit period is seven. The control system 3 executes the exponent calculation process to calculate a binary similarity exponent Ex for each of the seven order information In. The similarity exponent Ex for each order information In is then compared in order, starting from the first digit, with the largest value being moved to the top, and this process is continued up to the final sixth digit.

[0038] In the example shown in Figure 6, when the first digits of the similarity indexes Ex associated with the seven pieces of order information In are compared, the similarity index Ex associated with the second order information In (the order information In indicated by a circle 2 in the figure) has the largest value and is shifted to the top digit.

[0039] Next, when the second digits are compared, the similarity index Ex associated with the fourth order information In (order information In indicated by a circle 4 in the figure) and the similarity index Ex associated with the fifth order information In (order information In indicated by a circle 5 in the figure) have the largest values, and the order of these similarity indices Ex remains the same, but these similarity indices Ex are shifted to the top.

[0040] In the example shown, when this process is performed up to the sixth digit, the similarity index Ex relating to the fifth order information In will ultimately be the highest, and the similarity index Ex relating to the third order information In (order information In indicated by a circle 3 in the figure) will be the lowest.

[0041] As shown in Fig. 7, in the batch generation process, the control system 3 aggregates multiple pieces of order information In (first to seventh pieces of order information In in this example) to be processed within a unit period in order of decreasing similarity index Ex. In this embodiment, the control system 3 aggregates multiple pieces of order information In that are similar in order obtained by stable sorting. The picking tasks associated with each of the aggregated multiple pieces of order information In are treated as one batch task by the batch generation process.

[0042] In this embodiment, the control system 3 aggregates order information In having adjacent rankings of similarity index Ex in the batch generation process, and treats the picking work related to each order information In as one batch work. Then, the control system 3 executes a work allocation process to allocate the batch work to one of the multiple work areas 2.

[0043] In the example shown in Figure 7, the fifth order information In and the sixth order information In (order information In indicated by a circle 6 in the figure) are adjacent to each other in terms of the ranking of similarity index Ex, and the picking work related to each of these order information In is considered to be one batch work and assigned to the first work area 2.

[0044] In addition, the seventh order information In (order information In indicated by a circle 7 in the figure) and the second order information In are adjacent to each other in terms of the ranking of similarity index Ex, and the picking work related to each of these order information In is considered to be one batch work and assigned to the second work area 2.

[0045] In this way, the plurality of batch jobs generated by the batch generation process are assigned to one of the plurality of work areas 2 by the job assignment process.

[0046] According to the picking system 100 described above, by generating batch operations by aggregating multiple pieces of order information In with similar indexes Ex, it is possible to increase the possibility that picking operations corresponding to a set number of pieces of order information In containing the same type of items W can be aggregated into the same batch operation. If picking operations for the same type of items W can be aggregated into the same batch operation, the picking operations for the items W of that type can be performed together in one work area 2. This increases the efficiency of picking operations in the work area 2. It also makes it possible to increase the efficiency of transporting the mounting objects 5 in the transport process.

[0047] Other Embodiments Next, other embodiments will be described.

[0048] (1) In the above embodiment, an example has been described in which each of the mounting bodies 5 is configured to mount a single type of item W. However, the present invention is not limited to such an example, and some or all of the multiple mounting bodies 5 may be configured to mount multiple types of items W.

[0049] (2) In the above embodiment, an example was described in which the types of items W were ranked in order of shipping frequency, which is the frequency specified by the order information In. However, the present invention is not limited to this example, and the ranking may be based on the specific characteristics (shape or packaging style) of the items W.

[0050] (3) In the above embodiment, an example was described in which a type with a higher shipping frequency was ranked higher and a type with a lower shipping frequency was ranked lower. However, the present invention is not limited to this example, and the ranking may be the opposite, i.e., a type with a higher shipping frequency may be ranked lower and a type with a lower shipping frequency may be ranked higher.

[0051] (4) In the above embodiment, an example was described in which M constituting the type value Va was set to "2." However, this is not limited to this example, and M can be set arbitrarily, for example, "3," "4," "5," etc.

[0052] (5) In the above embodiment, an example was described in which N is set to a larger value as the ranking of the type becomes higher. However, the present invention is not limited to such an example, and N may be set to a smaller value as the ranking of the type becomes higher, as opposed to the above. Furthermore, N may be set to increase or decrease by 2 or 3 depending on the ranking.

[0053] (6) The configurations disclosed in the above-described embodiments may be combined with configurations disclosed in other embodiments as long as no contradictions arise. Regarding other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications may be made as appropriate within the scope of the present disclosure.

[0054] [Summary of this embodiment] The summary of this embodiment will be described below.

[0055] an automated warehouse that stores a plurality of mounting bodies, each of which has a plurality of articles mounted thereon; a plurality of work areas in which a picking operation is performed to pick out the items of the type and number specified by order information from the storage objects delivered from the automated warehouse based on order information specifying the type and number of the items required for each shipping destination; a transport system that transports the object between the automated warehouse and a plurality of the work areas; A picking system including a control system that controls the automated warehouse and the conveyance system, The control system includes: a batch generation process for aggregating a set number of pieces of order information and grouping the picking operations corresponding to the aggregated order information into one batch operation; a task allocation process for allocating each of the plurality of batch tasks generated by the batch generation process to one of the plurality of task areas; a transport process for transporting the objects required for the batch work assigned by the work allocation process to each of the plurality of work areas; an index calculation process for calculating a similarity index indicating the degree to which each of the plurality of pieces of order information is similar to each other, The control system, in the index calculation process, assigning a type value to the type of object to be handled and ranking the type; setting the type value of each of the types to be handled so that the type value of each of the types is greater than the sum of the type values ​​of all of the types that are ranked lower than the type in question; calculating a sum of the type values ​​for all the types included in each of the order information as the similarity index for each of the order information; In the batch generation process, the control system aggregates the plurality of pieces of order information to be processed within a unit period in descending order of the similarity index.

[0056] According to this configuration, each type value of multiple types is greater than the sum of the type values ​​of all types lower than that type. Therefore, for example, the similarity index of order information including an item of the highest type is greater than the similarity index of order information for all type combinations that do not include the item of the highest type. Similarly, for example, the similarity index of order information including an item of the second highest type but not the item of the highest type is greater than the similarity index of order information for all type combinations that do not include the items of the highest and second highest types. Therefore, by aggregating multiple order information with similar similarity indices to generate batch jobs, the possibility of consolidating picking operations corresponding to a set number of order information including items of the same type into the same batch job is increased. Furthermore, if picking operations for items of the same type can be consolidated into the same batch job, picking operations for those types of items can be performed together in a single work area. This improves the efficiency of picking operations in the work area. It also improves the efficiency of transporting objects in the transport process.

[0057] The ranking is preferably performed in order of shipping frequency, which is the frequency specified by the order information.

[0058] This configuration increases the likelihood that picking operations corresponding to a set number of order information items containing items with similar shipping frequencies can be consolidated into the same batch operation. Therefore, for example, by performing picking operations for items with a high shipping frequency in the same work area, the efficiency of transporting the items and the efficiency of work in the work area can be improved. Furthermore, for example, by performing picking operations for items with a low shipping frequency in the same work area, even if the number of items containing the items is small due to the low shipping frequency, the possibility of waiting for work in other work areas due to a shortage of items can be reduced.

[0059] The type value is a value of M (M is an integer of 2 or more) to the Nth power (N is an integer of 0 or more), Preferably, N is a value according to the ranking.

[0060] According to this configuration, it is possible to easily set type values ​​such that the type value of each of the plurality of types is greater than the total type values ​​of all types lower than that type.

[0061] the similarity index is a binary value, The control system, in the batch production process, performing a stable sorting of the similarity indexes for the plurality of pieces of order information to be processed within the unit period in order of decreasing number of digits and decreasing value; It is preferable that a plurality of pieces of order information that are close in order obtained by the stable sorting are aggregated.

[0062] This configuration simplifies the calculation process for aggregating multiple pieces of order information with similar indices in the batch generation process, thereby facilitating a reduction in the calculation load on the control system. [Industrial Applicability]

[0063] The technology disclosed herein can be used in a picking system. [Explanation of symbols]

[0064] 100: Picking system 1: Automated warehouse 2:Work area 3: Control system 5: Mounting body T:Transportation system W:Goods In: Order Information Va: Type value Ex: Similarity index

Claims

1. an automated warehouse that stores a plurality of mounting bodies, each of which has a plurality of articles mounted thereon; a plurality of work areas in which a picking operation is performed to pick out the items of the type and number specified by order information from the storage objects delivered from the automated warehouse based on order information specifying the type and number of the items required for each shipping destination; a transport system that transports the object between the automated warehouse and a plurality of the work areas; A picking system including a control system that controls the automated warehouse and the conveyance system, The control system includes: a batch generation process for aggregating a set number of pieces of order information and grouping the picking operations corresponding to the aggregated order information into one batch operation; a task allocation process for allocating each of the plurality of batch tasks generated by the batch generation process to one of the plurality of task areas; a transport process for transporting the objects required for the batch work assigned by the work allocation process to each of the plurality of work areas; an index calculation process for calculating a similarity index indicating the degree to which each of the plurality of pieces of order information is similar to each other, The control system, in the index calculation process, assigning a type value to the type of object to be handled and ranking the type; setting the type value of each of the types to be handled so that the type value of each of the types is greater than the sum of the type values ​​of all of the types that are ranked lower than the type in question; calculating a sum of the type values ​​for all the types included in each of the order information as the similarity index for each of the order information; In the batch generation process, the control system aggregates the plurality of pieces of order information to be processed within a unit period in order of proximity of the similarity index.

2. The picking system according to claim 1 , wherein the ranking is performed in order of shipping frequency, which is the frequency specified by the order information.

3. The type value is a value of M (M is an integer of 2 or more) raised to the power N (N is an integer of 0 or more), The picking system according to claim 1 , wherein N is a value according to the ranking.

4. the similarity index is a binary value, The control system, in the batch production process, performing a stable sorting of the similarity indexes for the plurality of pieces of order information to be processed within the unit period in order of decreasing number of digits and decreasing value; The picking system according to claim 1 , wherein the order information obtained by the stable sorting is similar in order to the order information obtained by the stable sorting is aggregated.

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