Picking system

Abstract

In this picking system, in exponential calculation processing, the control system ranks kinds by adding a kind value (Va) to a kind of object to be handled, sets a kind value (Va) of each kind of object to be handled such that the kind value (Va) of each kind becomes larger than the total of the kind value (Va) of all other kinds with a lower rank than the kind, and calculates the total value of the kind values (Va) for all kinds included in each piece of order information (In) as a similarity index (Ex) of each piece of the order information (In). In batch generation processing, the control system aggregates a plurality of pieces of order information (In) to be processed within a unit period in the order of proximity of the similarity index (Ex).

Description

Picking System

[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.

[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 retrieve the type and number of items specified in the order information. A plurality of picking operations occurring 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.

[0003] JP 2015-199562 A

[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.

[0006] a control system for controlling the automated warehouse and the transport system; a batch generation process for aggregating a set number of order information items and grouping the picking operations corresponding to the aggregated order information into one batch operation; a work assignment process for assigning each of the plurality of batch operations generated by the batch generation process to one of the plurality of work areas; a transport process for transporting the item required for the batch operation assigned by the work assignment process to each of the plurality of work areas; and an index calculation process for calculating a similarity index indicating the degree to which each of the plurality of order information items is similar to one another; and the control system is configured to execute the following in the index calculation process: assigning type values ​​to the types of objects to rank the types; setting the type value of each type of object to be handled so that the type value of each type is greater than the sum of the type values ​​of all types ranked lower than the type in question; calculating the sum of the type values ​​for all the types included in each piece of order information as the similarity index for each piece of order information; and in the batch generation process, the control system aggregates the multiple pieces of order information to be processed within a unit period in order of the closest 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 operations, the likelihood of consolidating picking operations corresponding to a set number of order information including items of the same type into the same batch operation is increased. Furthermore, if picking operations for items of the same type can be consolidated into the same batch operation, picking operations for items of that type 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.

[0009] Plan view of the picking system Control block diagram of the picking system Explanation of picking work Explanation of batch work Explanation of calculation of similarity index Explanation of sorting of order information based on similarity index Explanation of aggregation of multiple order information by batch generation process

[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 a plurality of mounting bodies 5, each with a plurality of items W placed on it; a plurality of work areas 2 in which picking work is performed to extract 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 plurality of 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. The goods W may also include finished products and semi-finished products. The goods W are stored in the automated warehouse 1 while being placed on the receiving bodies 5, and are transported to various locations by the transport system T.

[0013] The mounting body 5 includes a container or a pallet. The container also includes a folding container or a cardboard box. In this embodiment, the mounting body 5 is configured using a storage container for storing 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 intra-shelf transport device that transports the objects 5 within the automated warehouse 1. Examples of the intra-shelf transport device include a stacker crane, a lifter, a transport cart arranged on each shelf of the storage shelf, and a conveyor. The intra-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 intra-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 mounted object 5 is formed to connect multiple automated warehouses 1 and multiple work areas 2. The mounted object 5, which has been removed from one of the multiple automated warehouses 1, is transported to one of the multiple work areas 2 via the transport path of the conveyor Ta. The mounted object 5, from which the required item W has been removed by a picking operation in the work area 2, is transported to one of the multiple automated warehouses 1 via the transport path of the conveyor Ta and stored there. The transport system T may include another type of transport device, 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 mounted object 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 single objects 5 required for picking work in each work area 2, and transports the selected objects 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 memory, etc. Each function is realized by cooperation between this 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, the picking work is performed based on the order information In. In the picking work, multiple or single items W specified in the order information In are collected. For example, the order information In is generated for each shipping destination. Therefore, the picking work can be said to be the work of collecting the items W requested for each shipping destination.

[0023] Multiple or a single loading body 5 carrying items W of the type and number specified in the order information In is 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 “items A”), two items W of type B (hereinafter, sometimes referred to as “items 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 three or more items A, a mounting body 5 for mounting two or more items B, and a mounting body 5 for mounting 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 execute a batch generation process that aggregates a set number of order information In and groups the picking operations corresponding to the aggregated order information In into one batch operation; a work allocation process that assigns each of the multiple batch operations generated by the batch generation process to one of multiple work areas 2; and a transport process that transports the mounting bodies 5 required for the batch operations 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 uniformly determined. 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 flexibly determined 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 each 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." 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 each type as a target type (a type of interest) and the type value Va of the type to be handled so 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 a value corresponding to the ranking. This makes it easy to set type values ​​Va such that the type value Va of each of multiple types is greater than the sum of the type values ​​Va of all types lower than that type. In this example, M is set to "2." N is set to a value that increases as the ranking of a type increases, and is set to "0 to 5" in this example. Specifically, N is set to a value obtained by subtracting a number representing the ranking of each type of item W (e.g., "1" for the top item) from the number of types of items W to be handled ("6" in this example). Therefore, the type value Va of each type is expressed as 2 to the power of 0 to 2 to the power of 5.

[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 uses a binary value for the similarity index Ex in the exponent calculation process. That is, in this embodiment, the control system 3 executes a process of converting 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, and makes 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." As such, in this example, since N ranges from 0 to 5, the value converted into a binary number is a six-digit value.

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

[0036] The above-mentioned "unit period" is arbitrarily determined depending on the operation, and may be, for example, one hour. Alternatively, this "unit period" 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 exponential calculation process to calculate a binary similarity index Ex for each of the seven order information In. The similarity index Ex for each order information In (a six-digit binary similarity index Ex in this example) is then compared in order, starting from the first digit, with the largest value being moved to the top, and this process is continued until the final sixth digit.

[0038] In the example shown in Figure 6, when the first digits of the similarity indexes Ex for the seven pieces of order information In are compared, the similarity index Ex for 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.

[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 these similarity indexes Ex are shifted to the top while the order of these similarity indexes Ex remains the same.

[0040] In the example shown, when this process is performed up to the sixth digit, the similarity index Ex associated with the fifth order information In will ultimately be the highest, and the similarity index Ex associated with 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 (in this example, the first to seventh pieces of order information In) to be processed within a unit period in order of decreasing similarity index Ex. For example, the multiple pieces of order information In are aggregated in sets of a set number of aggregations (two pieces in the example shown in FIG. 7 ) in order of decreasing (or increasing) 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 pieces of order information In are treated as a single batch task by the batch generation process.

[0042] In this embodiment, the control system 3 aggregates order information In that are adjacent in rank in terms of similarity index Ex in the batch generation process, and treats the picking tasks related to each order information In as one batch task. Then, the control system 3 executes a task allocation process to assign the batch task to one of the multiple task areas 2.

[0043] 7, multiple pieces of order information In are aggregated into groups of two in descending order of similarity index Ex to form one batch operation. Specifically, the fifth piece of order information In and the sixth piece of order information In (indicated by a circle 6 in the figure) are adjacent to each other in terms of similarity index Ex, and the picking operations associated with each of these pieces of order information In are treated as one batch operation and assigned to the first operation 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 the 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 a batch job by aggregating multiple pieces of order information In with similar indexes Ex, it is possible to increase the possibility that picking jobs 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 job. If picking jobs for the same type of items W can be aggregated into the same batch job, it is possible to perform the picking jobs for the items W of that type collectively in one work area 2. This increases the efficiency of the picking jobs 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 disclosure 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 has been described in which the types of items W are ranked in order of shipping frequency, which is the frequency specified by the order information In. However, the present disclosure is not limited to such an example, and the ranking may be based on the particularity (shape or packaging style) of the items W.

[0050] (3) In the above embodiment, an example has been described in which a type with a higher shipping frequency is ranked higher and a type with a lower shipping frequency is ranked lower. However, the present disclosure is not limited to such an example, and the ranking may be the opposite of the above, in which a type with a higher shipping frequency is ranked lower and a type with a lower shipping frequency is 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, the present disclosure is not limited to such an example, and M can be set arbitrarily, such as “3,” “4,” or “5.”

[0052] (5) In the above embodiment, an example has been described in which N increases as the ranking of the type increases. However, the present disclosure is not limited to such an example, and N may decrease as the ranking of the type increases, as opposed to the above. Furthermore, N may increase or decrease by 2 or 3 depending on the ranking.

[0053] (6) The configurations disclosed in the above-described embodiments can be applied in combination 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 can be made as appropriate within the scope of the present disclosure.

[0054] Summary of the Present Embodiment The summary of the present embodiment will be described below.

[0055] a control system for controlling the automated warehouse and the transport system; a batch generation process for aggregating a set number of order information items and grouping the picking operations corresponding to the aggregated order information into one batch operation; a work assignment process for assigning each of the plurality of batch operations generated by the batch generation process to one of the plurality of work areas; a transport process for transporting the object required for the batch operation assigned by the work assignment process to each of the plurality of work areas; and an index calculation process for calculating a similarity index indicating the degree to which each of the plurality of order information items is similar to one another; and the control system is configured to perform the index calculation process for assigning a type value to the type of object to be handled and ranking the types, The type value of each of the types to be handled is set 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; the sum of the type values ​​for all of the types included in each of the order information is calculated as the similarity index for each of the order information; and in the batch generation process, the control system aggregates the multiple order information to be processed within a unit period in order of the closest 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 operations, the likelihood of consolidating picking operations corresponding to a set number of order information including items of the same type into the same batch operation is increased. Furthermore, if picking operations for items of the same type can be consolidated into the same batch operation, picking operations for items of that type 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] Preferably, the type value is a value of M (where M is an integer of 2 or more) raised to the power N (where N is an integer of 0 or more), and N is a value corresponding to the ranking order.

[0060] According to this configuration, it is possible to easily set type values ​​such that each type value of a 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, and the control system, in the batch generation process, preferably performs stable sorting of the similarity indexes for the plurality of order information to be processed within the unit period, arranging them in ascending order of the number of digits and descending order of value, and aggregates the plurality of order information that are close in order obtained by the stable sorting.

[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.

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

[0064] 100: Picking system 1: Automated warehouse 2: Work area 3: Control system 5: Placement body T: Transport system W: Item In: Order information Va: Type value Ex: Similarity index

Claims

1. A picking system comprising: an automated warehouse storing a plurality of mounting bodies, each mounting body having a plurality of articles placed thereon; a plurality of work areas in which a picking operation is performed to extract, from the mounting bodies released from the automated warehouse, the type and number of articles specified by order information based on the order information specifying the type and number of articles required for each shipping destination; a transport system transporting the mounting bodies between the automated warehouse and the plurality of work areas; and a control system for controlling the automated warehouse and the transport system, wherein the control system is configured to execute a batch generation process of aggregating a set number of the order information and treating the picking operations corresponding to the aggregated order information as one batch operation; a work assignment process of assigning each of the plurality of batch operations generated by the batch generation process to one of the plurality of work areas; a transport process of transporting the mounting bodies required for the batch operation assigned by the work assignment process to each of the plurality of work areas; and an index calculation process of calculating a similarity index indicating the degree to which each of the plurality of order information is similar to one another, and the control system is configured to execute a picking system comprising: assigning a type value to the type of object to rank the type; setting the type value of each of the types of objects to be handled such 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 said type; calculating the sum of the type values ​​for all of the types included in each of the order information as the similarity index for each of the order information; and in the batch generation process, the control system aggregates the multiple order information to be processed within a unit period in order of the proximity of the similarity index.

2. A picking system as described in claim 1, wherein the ranking is performed in order of shipping frequency, which is the frequency specified by the order information.

3. A picking system as described in claim 1, wherein the type value is a value of M (M is an integer equal to or greater than 2) to the power N (N is an integer equal to or greater than 0), and N is a value corresponding to the ranking order.

4. A picking system as described in any one of claims 1 to 3, wherein the similarity index is a binary value, and the control system, in the batch generation process, performs stable sorting of the similarity indexes for the multiple order information to be processed within the unit period in ascending order of value, starting with the order with the smallest number of digits, and aggregates the multiple order information whose orders obtained by the stable sorting are close to each other.

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