Picking system

Abstract

To provide a picking system that can improve efficiency of a picking work.SOLUTION: A control system executes batch generation processing that aggregates a set number of order information In, and treats a picking work corresponding to the aggregated order information In as one batch work. The control system aggregates order information In so as to make the number of target batch works to be a delivery possible total number or less when the number of target batch works can be made to be the delivery possible total number or less in the batch generation processing, and executes delivery possible total number increase processing for increasing the delivery possible total number when the number of target batch works cannot be made to be the delivery possible total number or less.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to a picking system including an automated warehouse for storing a plurality of carriers each having a plurality of articles placed thereon, a plurality of work areas where a picking operation of taking out the articles of the types and quantities specified for each shipping destination based on order information specifying the types and quantities of the articles required for each shipping destination is performed from the carriers shipped out from the automated warehouse, a conveying system for conveying the carriers between the automated warehouse and the plurality of work areas, and a control system for controlling the automated warehouse and the conveying system.

Background Art

[0002] In a picking system used in a logistics center or the like, a carrier on which articles of the types specified by order information are placed is conveyed from an automated warehouse to a work area. And in the work area, a picking operation of taking out the articles of the types and quantities specified by the order information is performed. A plurality of picking operations generated as tasks in the picking system are assigned to each of the plurality of work areas. An example of such a picking system is disclosed in Japanese Unexamined Patent Application Publication No. 2015-199562.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Incidentally, the types of goods stored in an automated warehouse for a picking system vary, and the needs (e.g., shipping frequency and quantity) also vary depending on the type of goods. While inventory management in the automated warehouse is usually performed according to these needs, the needs for goods can change in response to changes in the market environment. For example, if the needs exceed what was originally anticipated, the supply of goods from the automated warehouse to the work area may be disrupted, making it difficult to carry out picking operations smoothly in the work area.

[0005] In light of the above situation, there is a need for a picking system that can improve the efficiency of picking operations. [Means for solving the problem]

[0006] An automated warehouse that stores multiple storage units, each containing multiple items, Multiple work areas where picking operations are performed to retrieve the aforementioned items of the type and quantity specified by order information from the aforementioned automated warehouse, based on order information that specifies the type and quantity of the aforementioned items required for each shipping destination, A transport system for transporting the aforementioned objects between the automated warehouse and a plurality of work areas, A picking system comprising a control system for controlling the automated warehouse and the transport system, The control system is A batch generation process that aggregates the order information of the set number and sets the picking operations corresponding to the aggregated order information into a single batch operation, A work assignment process that assigns each of the multiple batch tasks generated by the batch generation process to one of the multiple work areas, The system is configured to perform a transport process for each of the multiple work areas, which transports the aforementioned equipment required for the batch work assigned by the work assignment process, Each of the aforementioned types is defined as a target type, the aforementioned container on which the articles of the target type are placed is defined as a target container, the total number of the target containers that can be retrieved from the automated warehouse is defined as the total number of retrieveable containers, and the number of batch operations in which the articles of the target type are included in the picking operation is defined as the number of target batch operations. The control system, in the batch generation process, If the number of target batch operations can be reduced to less than or equal to the total number of items that can be shipped, the order information is aggregated so that the number of target batch operations is less than or equal to the total number of items that can be shipped. If the number of target batch operations cannot be reduced to less than or equal to the total number of items that can be shipped, a process to increase the total number of items that can be shipped is executed.

[0007] According to this configuration, in the batch generation process, if the number of target batch operations, which is the number of batch operations that include items of the target type in the picking operation, can be kept below the total number of items that can be issued, then order information that includes items of the target type is aggregated so that the number of target batch operations is below the total number of items that can be issued. This prevents a shortage of target containers relative to the number of work areas where picking operations for the target items are performed. Therefore, it is possible to suppress the occurrence of waiting for target containers required for picking operations in work areas. Furthermore, according to this configuration, if the number of target batch operations, which is the number of batch operations that include items of the target type in the picking operation, cannot be kept below the total number of items that can be issued, then a process to increase the total number of items that can be issued is executed. This allows the total number of items that can be issued to be increased in accordance with the number of work areas where picking operations for the target items are performed, thus preventing a shortage of target containers relative to the number of work areas where picking operations for the target items are performed. Therefore, even in this case, it is possible to suppress the occurrence of waiting. As described above, this configuration can improve the efficiency of picking operations.

[0008] Further features and advantages of the technology relating to this disclosure will become clearer from the following description of exemplary and non-limiting embodiments, with reference to the drawings. [Brief explanation of the drawing]

[0009] [Figure 1] Floor plan of the picking system [Figure 2] Control block diagram of the picking system [Figure 3] Diagram illustrating the picking process. [Figure 4] Diagram illustrating batch processing [Figure 5] A diagram showing examples of order quantities for each type of item. [Figure 6] Diagram explaining the calculation of the overlapping risk index [Figure 7] Diagram illustrating the process for increasing the total number of items that can be shipped out. [Modes for carrying out the invention]

[0010] The following describes an embodiment of the picking system 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 loading units 5, each on which multiple items W are placed; multiple work areas 2 where picking operations are performed to retrieve the type and number of items W specified by order information In from the loading units 5 that have been dispatched 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 transport system T that transports the loading units 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 transport system T.

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

[0013] The placement body 5 includes containers and pallets. The containers include folding containers and cardboard boxes. In the present embodiment, the placement body 5 is configured using a storage container for storing in the automated warehouse 1 (see FIG. 3). In this example, a single type of article W is placed on the placement body 5. However, a plurality of types of articles W may be placed on the placement body 5.

[0014] Although detailed illustration is omitted, the automated warehouse 1 includes a storage shelf for storing the placement body 5 and an in-shelf transfer device for transferring the placement body 5 within the automated warehouse 1. Examples of the in-shelf transfer device include a stacker crane, a lifter, a transfer cart arranged on each stage of the storage shelf, a conveyor, and the like. The in-shelf transfer device constitutes a part of the transfer system T. In the present embodiment, the picking system 100 includes a plurality of such automated warehouses 1. When the automated warehouse 1 includes a conveyor as the in-shelf transfer device, it may be configured to store the placement body 5 on the conveyor. In this case, it can also be configured without a stacker crane or a transfer cart.

[0015] In the present embodiment, the transfer system T includes a conveyor Ta. The transfer route of the placement body 5 by the conveyor Ta is formed so as to connect a plurality of automated warehouses 1 and a plurality of work areas 2. The placement body 5 shipped from any one of the plurality of automated warehouses 1 is transferred to any one of the plurality of work areas 2 through the transfer route of the conveyor Ta. The placement body 5 from which the necessary article W has been taken out by the picking operation in the work area 2 is transferred to and stored in any one of the plurality of automated warehouses 1 through the transfer route of the conveyor Ta. The transfer system T may include other types of transfer devices such as an automated guided vehicle instead of or in addition to the conveyor Ta. As described above, the transfer system T includes an in-shelf transfer device for transferring the placement body 5 within the automated warehouse 1.

[0016] In the present embodiment, the transfer system T includes a first transfer route T1 for transferring the placement body 5 between the automated warehouse 1 and the plurality of work areas 2, and in addition to the first transfer route T1, includes a second transfer route T2 for transferring the placement body 5 between the plurality of work areas 2.

[0017] The second transfer path T2 is a path that does not connect to the automated warehouse 1. In this example, the second transfer path T2 is a path that only connects between a plurality of work areas 2. As will be described later, the second transfer path T2 is a path used in direct transfer processing that does not pass through the automated warehouse 1.

[0018] As shown in FIG. 2, the control system 3 is configured to control the automated warehouse 1, the work area 2, and the transfer system T based on the order information In. Further, the control system 3 also controls a work instruction output device (such as a monitor) and a picking robot arranged in the work area 2.

[0019] The order information In is information in which the type and quantity of the goods W required for each shipping destination are specified. The order information In is information generated based on customer needs and is stored in the server 4. The control system 3 acquires the order information In from the server 4.

[0020] The control system 3 is configured to manage the inventory of the goods W in the automated warehouse 1. The control system 3 is configured to manage at least the type and quantity of the goods W placed on each placement body 5 stored in the automated warehouse 1.

[0021] Based on the order information In, the control system 3 selects a plurality of or a single placement body 5 required for the picking operation in each work area 2, and conveys the selected placement body 5 to each work area 2 using the transfer system T. The conveyance of the placement body 5 from the automated warehouse 1 to the work area 2 is performed using the above-described first transfer path T1.

[0022] The control system 3 can be configured using a plurality of hardware and a plurality of software. The control system 3 includes, for example, a processor such as a microcomputer and peripheral circuits such as a memory. Then, each function is realized by the cooperation of these hardware and a program executed on a processor such as a computer.

[0023] Next, we will explain the picking process that takes place in work area 2.

[0024] As shown in Figure 3, the picking operation is performed based on order information In. In the picking operation, multiple or single items W specified in order information In are aggregated. For example, order information In is generated for each shipping destination. Therefore, the picking operation can be described as the operation of aggregating the items W requested for each shipping destination.

[0025] Multiple or single loading units 5, on which items W of the type and quantity specified in order information In are placed, are transported to a specific work area 2. During the picking operation, these items W related to order information In are taken out and consolidated into a shipping container 6.

[0026] When all items W placed on the storage unit 5 have been removed through the picking operation, the storage unit 5 becomes empty. In this embodiment, the work area 2 is provided with an empty storage unit holding unit 20 for holding the empty storage units 5 generated by the picking operation. This allows the empty storage units 5 to be stored in the work area 2. If the storage units 5 are made using folding containers, stacking multiple storage units 5 in a folded state can improve space efficiency. As will be described later, in this example, the empty storage units 5 stored in the work area 2 are used in the storage unit division operation.

[0027] In the example shown in Figure 3, order information In specifies three items of type A (hereinafter sometimes referred to as "item A"), two items of type B (hereinafter sometimes referred to as "item B"), and one item of type C (hereinafter sometimes referred to as "item C"). In this example, each loading platform 5 is configured to load a single type of item W. Loading platforms 5 that load at least three or more items A, loading platforms 5 that load at least two or more items B, and loading platforms 5 that load at least one or more items C are transported to the work area 2. In the picking operation in the work area 2, the three items A, two items B, and one item C are collected into the shipping container 6. The picking operation may be performed by a worker, or it may be performed unmanned by a picking robot, etc. Alternatively, it may be performed by both a worker and a picking robot.

[0028] In Figure 3, the loading platform 5 for transporting item C has the same number of items C (one item C in the illustrated example) as specified in the order information In. Therefore, when a picking operation is performed on this loading platform 5, the loading platform 5 becomes empty and is held by the empty loading platform holding unit 20.

[0029] As shown in Figure 4, the control system 3 (see Figure 2) is configured to perform the following: batch generation processing, which aggregates a set number of order information In and combines the picking operations corresponding to the aggregated order information In into a single batch operation; work assignment processing, which assigns each of the batch operations generated by the batch generation processing to one of the multiple work areas 2; and transport processing, which transports the mounting bodies 5 required for the batch operations assigned by the work assignment processing to each of the multiple work areas 2.

[0030] A batch operation includes picking operations related to a set number of order information entries. In other words, a batch operation includes a set number of picking operations. In this embodiment, this "set number" is the maximum number of picking operations that can be included in one batch operation. In this example, the set number is set to 4. In this case, the number of picking operations that can be included in one batch operation is 1 to 4. However, the set number may be other than "4", for example, "1". Thus, in this embodiment, the set number is a fixed value, but it may be a value that changes depending on the situation.

[0031] In the example shown in Figure 4, four batch operations are illustrated. Each of the four batch operations contains four picking operations. Each of the four batch operations is assigned to one of the four work areas 2 by the work assignment process. However, as mentioned above, the number of picking operations included in one batch operation does not need to exceed the set number, and in this example it may be 1 to 3.

[0032] Here, the types of goods W stored in the automated warehouse 1 of the picking system 100 are diverse, and the needs vary depending on the type of goods W.

[0033] For example, as shown in Figure 5, let's assume there are types of goods W from A to Z. The right column of the table shows the order number Na for each type of goods W. The order number Na indicates the number of times a particular type of goods W is involved in order information In that needs to be processed within a unit period. In the example shown, type A is included in each of the 200 order information In. In other words, goods W of type A are requested in the picking operations related to each of the 200 order information In. For types X, Y, and Z, the order number Na is relatively small, with order number Na being "6", "5", and "4" respectively.

[0034] In the picking system 100, inventory management is performed in the automated warehouse 1. In this inventory management, the number of items W of high-demand types with relatively high order quantities Na is increased (i.e., the number of items W stored in the automated warehouse 1), while the number of items W of low-demand types with relatively low order quantities Na is decreased. This makes it easier to improve the storage efficiency of items W in the automated warehouse 1.

[0035] Here, each of the multiple types is designated as a target type, the mounting body 5 on which the item W of the target type is placed is designated as the target mounting body 5, the total number of target mounting bodies 5 that can be retrieved from the automated warehouse 1 is designated as the total number of retrieveable items Nb, and the number of batch operations that include the item W of the target type as part of the picking operation is designated as the number of target batch operations Nc. The total number of retrieveable items Nb is, for example, the total number of target mounting bodies 5 currently stored in the automated warehouse 1. The number of target batch operations Nc is, for example, the number of batch operations required to process all orders that specify the item W of the target type. Note that "target type" refers to some or all of the types of items handled by the picking system 100 that are subject to batch generation processing or the total number of retrieveable items increase processing described later.

[0036] Figure 6 shows the total number of items that can be issued Nb, the number of target batch operations Nc, and the overlap risk index Nd (described later) for each type of item W, particularly for types X, Y, and Z with a relatively small number of orders Na. In this embodiment, since the setting number is "4", one batch operation includes four picking operations (order information In). The number of target batch operations Nc is the value obtained by dividing the number of orders Na by the setting number (in this example, "4"). If the divided value includes a decimal part, the value is rounded up to ensure that the number of batch operations necessary to handle all orders of the specified item W is rounded up. In the case where one batch operation is performed in one work area 2, the above-mentioned number of target batch operations Nc can be rephrased as the number of work areas 2 in which the batch operation is performed.

[0037] As mentioned above, the inventory of low-demand items W, which tend to have a relatively small order number Na, is small. Therefore, in the example shown in Figure 6, the total number of items Nb that can be issued from the target mounting unit 5 on which item X is placed is "2", the total number of items Nb that can be issued from the target mounting unit 5 on which item Y is placed is "1", and the total number of items Nb that can be issued from the target mounting unit 5 on which item Z is placed is "1".

[0038] The number of orders Na for which item W of type X is specified is "6". The number of batch operations Nc, that is, the number of batch operations required to process 6 orders, is "2", which is the value obtained by dividing the number of orders Na "6" by the setting number "4" (1.5) and then rounding up to the nearest whole number. In other words, in this embodiment where the setting number is "4", two work areas 2 are required to process 6 orders simultaneously. Since the total number of items W of type X that can be issued Nb is "2", a mounting body 5 on which item W of type X is placed can be provided in each of the two work areas 2.

[0039] The number of orders Na for which item W of type Y is specified is "5". The number of batch operations Nc, that is, the number of batch operations required to process 5 orders, is "2", which is the value obtained by dividing the number of orders Na "5" by the setting number "4" (1.25) and rounding up to the nearest whole number. In other words, in this embodiment where the setting number is "4", two work areas 2 are required to process 5 orders simultaneously. For item W of type Y, the total number that can be issued Nb is "1", so it is not possible to provide a loading platform 5 on which item W of type Y is placed in each of the two work areas 2. Therefore, a waiting period occurs in one of the two work areas 2, waiting for the target loading platform 5 (in this case, a loading platform 5 on which item W of type Y is placed) required for the picking operation.

[0040] The number of orders Na for which item W of type Z is specified is "4". The number of batch operations Nc, that is, the number of batch operations required to process 4 orders, is "1", which is obtained by dividing the number of orders Na "4" by the set number "4". In other words, in this embodiment where the set number is "4", one work area 2 is required to process 4 orders simultaneously. Since the total number of items W of type Z that can be issued Nb is "1", a mounting body 5 on which item W of type Z is placed can be provided in one work area 2.

[0041] As described above, in this example, for item W of type Y, the number of target placement units 5 is insufficient compared to the number of work areas 2 where picking operations for item W are performed (a situation where waiting times may occur).

[0042] The control system 3 is configured to increase or decrease the target batch work number Nc by changing the number of order information In to be aggregated (hereinafter referred to as the "order aggregation number"), within a range that does not exceed a set number. The target batch work number Nc is calculated by dividing the order number Na by the order aggregation number, as shown in equation (1) below. Target batch work Nc = Number of orders Na / Number of order aggregations ... (1) *The number of orders to be aggregated is less than or equal to the set number. Therefore, the larger the number of orders to aggregate, the smaller the number of batch operations Nc will be, and the smaller the number of orders to aggregate, the larger the number of batch operations Nc will be. The control system 3 can set an appropriate number of batch operations Nc for the total number of items that can be shipped out Nb by controlling the increase or decrease of the number of batch operations Nc.

[0043] In the batch generation process, the control system 3 aggregates order information In so that the number of target batch tasks Nc can be kept below the total number of tasks that can be dispatched Nb, if possible. In other words, the control system 3 sets the order aggregation number so that the number of target batch tasks Nc is below the total number of tasks that can be dispatched Nb. This suppresses the occurrence of waiting times in the work area 2. The case in which the number of target batch tasks Nc can be kept below the total number of tasks that can be dispatched Nb refers to the case in which the number of target batch tasks Nc can be kept below the total number of tasks that can be dispatched Nb by increasing the order aggregation number up to the set limit and reducing the number of target batch tasks Nc.

[0044] In the batch generation process, if the number of target batch operations Nc cannot be kept below the total number of available items Nb, the control system 3 executes a process to increase the total number of available items Nb. That is, even if the number of target batch operations Nc is minimized by setting the order aggregation number to the maximum number that can aggregate order information In, if the number of target batch operations Nc exceeds the total number of available items Nb, the control system 3 executes a process to increase the total number of available items Nb. For example, in this example, for item W of type Y, the minimum number of target batch operations Nc that can be made for 5 orders is "2", which is greater than the total number of available items Nb (here, "1"). In such a case, as described above, the number of target placement units 5 that can be provided is insufficient for the number of work areas 2 where picking operations for item W of type Y are performed, resulting in a waiting period.

[0045] In this embodiment, the control system 3 performs an index calculation process to calculate an overlap risk index Nd for all types of target mounting units 5, which indicates the likelihood of a shortage relative to the number of work areas 2 where picking operations for the target type of item W are performed. The control system 3 then identifies types for which the overlap risk index Nd is less than a predetermined threshold as overlap risk types, and performs a batch generation process for order information In that specifies overlap risk types, and also performs a process to increase the total number of items that can be issued for target mounting units 5 on which items W of the overlap risk types are placed.

[0046] The duplicate risk index Nd is calculated by dividing the total number of items that can be issued Nb by the number of batch operations Nc. In this example, the threshold for judgment is set to "1.0".

[0047] In the example shown in Figure 6, the overlap risk index Nd for type Y is "0.5", which is below the judgment threshold. Therefore, type Y is classified as an overlap risk type. The control system 3 can provide an appropriate number of target mounting units 5 for the target batch work number Nc by performing a process to increase the total number of items that can be issued for the target mounting units 5 on which the overlap risk type items W are placed.

[0048] Furthermore, in this embodiment, if the control system 3 cannot make the target batch work count Nc less than or equal to the total number of items that can be shipped out Nb during the batch generation process, it aggregates the order information In to minimize the target batch work count Nc and then executes the process to increase the total number of items that can be shipped out. This makes it possible to minimize the increase in the total number of items that can be shipped out Nb, even when the process to increase the total number of items that can be shipped out is executed.

[0049] As shown in Figure 7, in this embodiment, the process of increasing the total number of items that can be shipped includes a mounting body division operation, which is the operation of dividing and placing multiple items W of the target type that are placed on one target mounting body 5 onto multiple mounting bodies 5.

[0050] In this embodiment, the mounting body splitting operation is performed in one of the multiple work areas 2. The control system 3 designates one of the multiple work areas 2 and issues instructions to the worker or picking robot performing the work in the designated work area 2. For example, the control system 3 issues instructions to workers using a work instruction output device (monitor, etc.) installed in the work area 2. For picking robots, it transmits an instruction signal to the control device that controls the picking robot.

[0051] As described above, in the target work area 2, empty loading units 5 generated by the picking operation are held in the empty loading unit holding section 20. In the loading unit splitting operation, multiple items W of the target type placed on the target loading unit 5 are distributed to the empty loading units 5 held in the empty loading unit holding section 20.

[0052] In the example shown in Figure 7, in addition to the target work area 2 where picking operations for item W of type Y, which is a duplicate risk type, are performed, there is another work area 2 where picking operations for item W of type Y should be performed. In the target work area 2 where a target loading platform 5 for placing item W of type Y is provided, a loading platform splitting operation is performed, and some of the multiple items W placed on the target loading platform 5 are transferred to an empty loading platform 5 that was held in the target work area 2. As a result, the number of loading platforms 5 for item W of type Y, which was "1" in total available quantity Nb, increases to 2.

[0053] In this embodiment, after the loading body splitting operation is completed in the target work area 2, the control system 3 controls the transport system T to transport at least one of the loading bodies 5 on which the target type of item W is placed, to a work area 2 other than the target work area 2, where batch work is performed and the target of picking includes the target type of item W, using the second transport path T2. The control system 3 transports the loading bodies 5 generated by the loading body splitting operation along the second transport path T2 by performing a direct transport process that transports the loading bodies 5 between different work areas 2 without going through the automated warehouse 1.

[0054] In the example shown in Figure 7, one of the two mounting bodies 5 on which an item W of type Y is placed is transported from the target work area 2 to another work area 2 via the second transport path T2.

[0055] In this embodiment, during the mounting body division operation, the required number of items W of the target type from a different work area 2 other than the target work area 2 are transferred to the mounting body 5.

[0056] In the example shown in Figure 7, in a work area 2 other than the target work area 2 where picking of item W of type Y is performed, two items of item W of type Y are specified by order information In. That is, the required number of item W of type Y in this other work area 2 is "2". Therefore, in the loading body splitting operation performed in the target work area 2, two items W are transferred from the target loading body 5, which holds 10 items W of type Y, to an empty loading body 5. The loading body 5 with the two items W of type Y is then transported from the target work area 2 to the other work area 2 via the second transport path T2. With this configuration, picking of item W of type Y can be performed simultaneously in both the target work area 2 and the other work area 2.

[0057] In this embodiment, after the mounting body division operation is performed in the target work area 2, a picking operation for the target type of goods W is performed. In the example shown in Figure 7, the picking operation is performed in the target work area 2 using the eight goods W placed on the target mounting body 5 after the mounting body division operation. This makes it possible to provide the target type of goods W to another work area 2 at an early stage.

[0058] The picking system 100 relating to this disclosure uses the algorithm described above to aggregate multiple order information In specifying at least one item W of a duplicate risk type into one batch. Order information In specifying an item W of a type other than the duplicate risk type may be aggregated into one batch using a different algorithm, for example, depending on the shipping frequency.

[0059] [Other Embodiments] Next, other embodiments will be described.

[0060] (1) In the above embodiment, an example was described in which an empty mounting body 5 held in the empty mounting body holding section 20 of the target work area 2 where the mounting body splitting operation is performed is used. However, the invention is not limited to this example, and the empty mounting body 5 used in the mounting body splitting operation may be transported to the target work area 2 from a location other than the target work area 2 (for example, an empty space in the automated warehouse 1). In this case, the control system 3 controls the automated warehouse 1 and the transport system T to transport the target mounting body 5 and the mounting body 5 without the item W on it to the target work area 2 in order to perform the mounting body splitting operation in the target work area 2, which is one of the work areas 2 where batch work is performed in which the item W of the target type is included as the target of the picking operation.

[0061] (2) In the above embodiment, an example was described in which the total number of items that can be retrieved Nb is increased by dividing the loading body. However, the total number of items that can be retrieved Nb is not limited to such an example, and the total number of items that can be retrieved Nb may also be increased by replenishing the automated warehouse 1 with target loading bodies 5 on which items of the target type W are loaded from a location other than the automated warehouse 1 (for example, an auxiliary warehouse).

[0062] (3) In the above embodiment, an example was described in which, in the mounting body division operation performed in the target work area 2, some of the multiple articles W placed on the target mounting body 5 are transferred to an empty mounting body 5 that was held in the target work area 2. However, the mounting body division operation may be performed by distributing and transferring all the articles W placed on the target mounting body W to multiple empty mounting bodies 5.

[0063] (4) In the above embodiment, an example was described in which the mounting body splitting operation is performed in one of the multiple work areas 2. However, the example is not limited to this example, and the mounting body splitting operation may be performed in an area dedicated to mounting body splitting, separate from the work area 2 in which the picking operation is performed.

[0064] (5) In the above embodiment, an example was described in which, after the mounting body division work is performed in the target work area 2, picking work is performed on the target type of items W. However, the example is not limited to this example, and after the picking work is performed, the mounting body division work may be performed using the remaining number of items W.

[0065] (6) In the above embodiment, the control system 3 has been shown to transport the mounted bodies 5 generated by the mounted body splitting operation along the second transport path T2 by performing a direct transport process that transports the mounted bodies 5 between different work areas 2 without going through the automated warehouse 1. However, the control system 3 is not limited to this example, and may transport the mounted bodies 5 generated by the mounted body splitting operation along the first transport path T1 via the automated warehouse 1 to another work area 2.

[0066] (7) In the above embodiment, an example was described in which the judgment threshold for the overlap risk index Nd is set to "1.0". However, the example is not limited to this example, and the judgment threshold may be set to less than "1.0". In this case, the number of target batch operations Nc will exceed the total number of available inventory Nb, so it will not be possible to perform all target batch operations at the same time. However, by performing these target batch operations at different times, all target batch operations can be completed. However, even in this case, the judgment threshold should be set to "0.5", preferably a value greater than that, so that the time required to complete all target batch operations does not become significantly longer. This makes it possible to minimize the degree of shortage of the total number of available inventory Nb relative to the number of target batch operations Nc, and to minimize the time required to complete all target batch operations.

[0067] (8) The configurations disclosed in the embodiments described above can be applied in combination with configurations disclosed in other embodiments, as long as no inconsistencies arise. With regard to other configurations, the embodiments disclosed herein are merely illustrative in all respects. Therefore, various modifications can be made as appropriate without departing from the spirit of this disclosure.

[0068] [Summary of this embodiment] The following is a summary of this embodiment.

[0069] An automated warehouse that stores multiple storage units, each containing multiple items, Multiple work areas where picking operations are performed to retrieve the aforementioned items of the type and quantity specified by order information from the aforementioned automated warehouse, based on order information that specifies the type and quantity of the aforementioned items required for each shipping destination, A transport system for transporting the aforementioned objects between the automated warehouse and a plurality of work areas, A picking system comprising a control system for controlling the automated warehouse and the transport system, The control system is A batch generation process that aggregates the order information of the set number and sets the picking operations corresponding to the aggregated order information into a single batch operation, A work assignment process that assigns each of the multiple batch tasks generated by the batch generation process to one of the multiple work areas, The system is configured to perform a transport process for each of the multiple work areas, which transports the aforementioned equipment required for the batch work assigned by the work assignment process, Each of the aforementioned types is defined as a target type, the aforementioned container on which the articles of the target type are placed is defined as a target container, the total number of the target containers that can be retrieved from the automated warehouse is defined as the total number of retrieveable containers, and the number of batch operations in which the articles of the target type are included in the picking operation is defined as the number of target batch operations. The control system, in the batch generation process, If the number of target batch operations can be reduced to less than or equal to the total number of items that can be shipped, the order information is aggregated so that the number of target batch operations is less than or equal to the total number of items that can be shipped. If the number of target batch operations cannot be reduced to less than or equal to the total number of items that can be shipped, a process to increase the total number of items that can be shipped is executed.

[0070] According to this configuration, in the batch generation process, if the number of target batch operations, which is the number of batch operations that include items of the target type in the picking operation, can be kept below the total number of items that can be issued, then order information that includes items of the target type is aggregated so that the number of target batch operations is below the total number of items that can be issued. This prevents a shortage of target containers relative to the number of work areas where picking operations for the target items are performed. Therefore, it is possible to suppress the occurrence of waiting for target containers required for picking operations in work areas. Furthermore, according to this configuration, if the number of target batch operations, which is the number of batch operations that include items of the target type in the picking operation, cannot be kept below the total number of items that can be issued, then a process to increase the total number of items that can be issued is executed. This allows the total number of items that can be issued to be increased in accordance with the number of work areas where picking operations for the target items are performed, thus preventing a shortage of target containers relative to the number of work areas where picking operations for the target items are performed. Therefore, even in this case, it is possible to suppress the occurrence of waiting. As described above, this configuration can improve the efficiency of picking operations.

[0071] In the batch generation process, if the number of target batch operations cannot be kept below the total number of available inventory, the control system preferably aggregates the order information to minimize the number of target batch operations and then performs the process to increase the total number of available inventory.

[0072] With this configuration, order information is aggregated in the batch generation process to minimize the number of target batch operations. Therefore, even when the process of increasing the total number of items that can be shipped can be executed, the degree of increase in the total number of items that can be shipped can be kept to a minimum.

[0073] The process of increasing the total number of items that can be shipped includes a storage unit division operation, which is the operation of dividing and placing multiple items of the target type that are placed on one of the target storage units into multiple storage units. The control system preferably controls the automated warehouse and the transport system to transport the target transport body and the transport body without the item on it to the target transport area in order to perform the transport body division operation described above in the target transport area, which is one of the transport areas where the batch work is performed and in which the item of the target type is included as the target of the picking operation.

[0074] This configuration allows for the distribution of target items across multiple loading units by performing a loading unit splitting operation. This increases the number of loading units on which the target items are placed. Therefore, even if no new target loading units are added to the automated warehouse, the total number of items that can be retrieved can be increased. Furthermore, this configuration allows for the loading unit splitting operation to be performed using the work area where the target items are picked. This reduces the need to transport the target loading units solely for the purpose of loading unit splitting, and also reduces the need to add new work areas or equipment.

[0075] The transport system includes a first transport route for transporting the aforementioned objects between the automated warehouse and a plurality of work areas, as well as a second transport route for transporting the aforementioned objects between the plurality of work areas. It is preferable that the control system controls the transport system to transport, after the object division operation described above is completed in the target work area, at least one of the objects described above on which the object of the target type of article is placed, to a work area other than the target work area, where the batch operation is performed and the object of the picking operation includes the object of the target type of article, using the second transport path.

[0076] With this configuration, after the loading unit is divided, the loading unit on which the target items are placed can be transported to other work areas where the target items are needed, without having to return the loading unit to the automated warehouse. Therefore, the efficiency of loading unit transport can be increased, and the occurrence of waiting times in other work areas can be easily minimized.

[0077] In the aforementioned mounting body division operation, it is preferable to transfer the required number of the items of the target type from another work area other than the target work area to the aforementioned mounting body.

[0078] This configuration prevents the generation of leftover items after work is completed in a work area other than the target work area. Therefore, it is less likely to strain the capacity of the automated warehouse and eliminates the need for tasks such as consolidating items.

[0079] The control system performs an exponential calculation process to calculate an overlap risk index for all types, which indicates the likelihood of a shortage of the target mounting body relative to the number of work areas where the picking work for the target type of article is performed. The type in which the overlapping risk index is less than a predetermined threshold is defined as the overlapping risk type. Preferably, the control system performs the batch generation process on the order information specifying the overlapping risk type, and also performs the total number of items that can be issued increase process on the target mounting body on which the items of the overlapping risk type are placed.

[0080] This configuration allows for the aggregation of order information specifying duplicate risk types, making it possible to keep the number of work areas for picking items of duplicate risk types (those with a low total number of available items relative to the number of orders) below the total number of available items. Furthermore, even if it is not possible to keep the number below the total number of available items, the total number of available items can be increased by executing a process to increase the total number of available items. Therefore, the possibility of waiting times occurring in work areas for picking items of duplicate risk types can be reduced. [Industrial applicability]

[0081] The technology disclosed herein can be used in picking systems. [Explanation of Symbols]

[0082] 100: Picking System 1: Automated warehouse 2: Work Area 3: Control System T: Conveying system T1: First transport route T2: Second transport route 5: Mounting body W:Goods In: Order Information Nb: Total number of items available for pickup Nc: Number of batch operations Nd: Overlapping Risk Index

Claims

1. An automated warehouse that stores multiple storage units, each containing multiple items, Multiple work areas where picking operations are performed to retrieve the aforementioned items of the type and quantity specified by order information from the aforementioned automated warehouse, based on order information that specifies the type and quantity of the aforementioned items required for each shipping destination, A transport system for transporting the aforementioned objects between the automated warehouse and a plurality of work areas, A picking system comprising a control system for controlling the automated warehouse and the transport system, The control system is A batch generation process that aggregates the order information of the set number and sets the picking operations corresponding to the aggregated order information into a single batch operation, A work assignment process that assigns each of the multiple batch tasks generated by the batch generation process to one of the multiple work areas, The system is configured to perform a transport process for each of the multiple work areas, which transports the aforementioned equipment required for the batch work assigned by the work assignment process, Each of the aforementioned types is defined as a target type, the aforementioned container on which the articles of the target type are placed is defined as a target container, the total number of the target containers that can be retrieved from the automated warehouse is defined as the total number of retrieveable containers, and the number of batch operations in which the articles of the target type are included in the picking operation is defined as the number of target batch operations. The control system, in the batch generation process, If the number of target batch operations can be reduced to less than or equal to the total number of items that can be shipped, the order information is aggregated so that the number of target batch operations is less than or equal to the total number of items that can be shipped. A picking system that, if the number of target batch operations cannot be kept below the total number of items that can be dispatched, executes a process to increase the total number of items that can be dispatched.

2. The picking system according to claim 1, wherein, in the batch generation process, if the number of target batch operations cannot be made less than or equal to the total number of available inventory, the control system aggregates the order information to minimize the number of target batch operations and then executes the process to increase the total number of available inventory.

3. The process of increasing the total number of items that can be shipped includes a storage unit division operation, which is the operation of dividing and placing multiple items of the target type that are placed on one of the target storage units into multiple storage units. The picking system according to claim 1 or 2, wherein the control system controls the automated warehouse and the transport system to transport the target transport body and the transport body without the articles on it to the target transport area in order to perform the transport body division operation described above in the target transport area, which is one of the transport areas where the batch work is performed and in which the articles of the target type are included as targets for the picking operation.

4. The transport system includes a first transport route for transporting the aforementioned objects between the automated warehouse and a plurality of work areas, as well as a second transport route for transporting the aforementioned objects between the plurality of work areas. The picking system according to claim 3, wherein the control system controls the transport system to transport, after the object division work described above is completed in the target work area, at least one of the objects described above on which the articles of the target type are placed, to a work area other than the target work area, where the batch work is performed and the picking work is performed and which includes the articles of the target type.

5. The picking system according to claim 3, wherein in the mounting body division operation, the required number of the items of the target type in a different work area other than the target work area is transferred to the mounting body described above.

6. The control system performs an exponential calculation process to calculate an overlap risk index for all types, which indicates the likelihood of a shortage of the target mounting body relative to the number of work areas where the picking work for the target type of article is performed. The type in which the overlapping risk index is less than a predetermined threshold is defined as the overlapping risk type. The picking system according to claim 1 or 2, wherein the control system performs the batch generation process on the order information specifying the overlapping risk type, and performs the total number of items that can be picked up on the target loading platform on which the items of the overlapping risk type are placed.

Images