Warehouse system and bin arrangement determination method

Abstract

Provided is a warehouse system comprising a plurality of work areas in which commodity picking work is performed, the warehouse system comprising: an allocation unit that allocates an order, which designates one or a plurality of commodities, to any one of the plurality of work areas; and an instruction unit that, on the basis of the allocation result of the allocation unit, issues an instruction of the picking work for the one or plurality of commodities designated in the order. When a commodity stored in a storage bin shared in a first order and a second order is designated, the allocation unit allocates the first order and the second order to a first work area and a second work area, respectively, so that the storage bin in which the commodity is stored is disposed in a common area that can be used between the first work area and the second work area to which the first order and the second order are respectively allocated.

Description

Warehouse system and method for determining bin placement

[0001] The present disclosure relates to a warehouse system and a method for determining bin placement.

[0002] In recent years, automated warehouses for receiving and shipping packaged goods have become widespread. For example, Patent Literature 1 discloses a configuration for controlling the transport of cases on multiple lines in order to improve the efficiency of picking work by workers in a warehouse.

[0003] Japanese Patent Application Laid-Open No. 2020-125191

[0004] The present disclosure has been devised in view of the above-described conventional situation, and aims to achieve improved work efficiency related to picking work in a warehouse.

[0005] The present disclosure provides a warehouse system having a plurality of work areas where product picking work is performed, the warehouse system including: an allocation unit that allocates an order specifying one or more products to one of the plurality of work areas; and an instruction unit that issues instructions for the picking work for the one or more products specified in the order based on the allocation result by the allocation unit, wherein when a first order and a second order specify products stored in a common storage bin, the allocation unit allocates the first order and the second order to the first work area and the second work area, respectively, so that the storage bin containing the products is placed in a common area available between the first work area and the second work area to which the first order and the second order are assigned, respectively.

[0006] The present disclosure also provides a bin placement determination method, which includes an allocation step in which a processor and a memory cooperate to allocate an order specifying one or more products to one of a plurality of work areas, and an instruction step in which, based on the allocation result from the allocation step, an instruction is given for picking work for the one or more products specified in the order, and in the allocation step, if a product stored in a common storage bin is specified in a first order and a second order, the first order and the second order are allocated to the first work area and the second work area, respectively, so that the storage bin containing the product is placed in a common area available between the first work area and the second work area to which the first order and the second order are assigned, respectively.

[0007] According to the present disclosure, it is possible to improve the efficiency of picking work within a warehouse.

[0008] Schematic diagram showing an example of the configuration of a picking station according to an embodiment of the present invention. Schematic diagram showing an example of the layout of a picking station according to a conventional configuration. Schematic diagram showing an example of the layout of a picking station according to an embodiment of the present invention. Schematic diagram showing an example of the layout of a picking station according to an embodiment of the present invention. Schematic diagram showing an example of the layout of a picking station according to an embodiment of the present invention. Schematic diagram showing an example of the layout of a picking station according to an embodiment of the present invention. Schematic diagram showing an example of the layout of a picking station according to an embodiment of the present invention. Schematic diagram showing an example of the layout of a picking station according to an embodiment of the present invention. Flowchart showing the overall process of bin placement according to an embodiment of the present invention.

[0009] (Background to the Contents of Each Embodiment) Warehouses that handle receiving, storing, packaging, shipping, and the like of packages require automation using robots and the like to reduce the manual workload. With the recent increase in packages, further efficiency improvements in a series of operations are required. In such warehouses, items (hereinafter also referred to as "products") of various shapes and attributes are handled, so it is necessary for people and robots to share tasks and perform them in consideration of the characteristics of the products. One such task is picking, based on shipping instructions, from a storage unit where products are stored (hereinafter referred to as a "storage bin") to a storage unit (hereinafter referred to as a "shipping bin") that will store one or more products to be shipped.

[0010] When performing picking work, storage bins and shipping bins are placed around the worker, and the worker moves items from the storage bin to the shipping bin. In this process, storage bins containing items with high shipping frequency are competed for among the picking stations performing each picking work. As a result, waiting times may occur at some picking stations until the storage bin is placed. For example, one method to reduce waiting times is to assign multiple orders for items stored in the same storage bin to the same picking station. However, this method may result in multiple orders being concentrated at one picking station, making it difficult to efficiently utilize multiple picking stations. As a result, the time required for shipping work throughout the warehouse increases and productivity decreases.

[0011] Therefore, in the following embodiment, an example of a warehouse system and a method of determining bin placement that allows operators to perform picking work more efficiently will be described.

[0012] Hereinafter, with reference to the drawings as appropriate, detailed descriptions of embodiments that specifically disclose a warehouse system and a method for determining bin placement according to the present disclosure will be provided. However, unnecessary detailed descriptions may be omitted. For example, detailed descriptions of well-known matters or redundant descriptions of substantially identical configurations may be omitted. This is to avoid unnecessary redundancy in the following description and to facilitate understanding by those skilled in the art. Note that the accompanying drawings and the following description are provided to enable those skilled in the art to fully understand the present disclosure, and are not intended to limit the subject matter recited in the claims.

[0013] <First Embodiment> [System Configuration] Fig. 1 is a block diagram showing an overall overview of a warehouse system 1 according to this embodiment. Note that the system configuration shown in Fig. 1 is an example, and one system may be divided into multiple systems, or multiple systems may be integrated into one system. Also, one system or device shown in Fig. 1 may be provided multiple times. Furthermore, the processing entities shown below are an example, and some of the functions of one system may be realized as functions of another system.

[0014] The warehouse system 1 includes a warehouse management system 100, a warehouse operations management system 200, warehouse control systems 300, 400, and 500, a robot 600, an automated warehouse 700, an automated guided vehicle 800, and an operation terminal 900. Each component of the warehouse system 1 is configured to be able to communicate with each other via a network. The warehouse management system 100 is a system that manages and controls logistics within a warehouse and is positioned at the highest level in the configuration example shown in FIG. 1 . The warehouse management system 100 manages, for example, inventory management of items within the warehouse, as well as the inflow and outflow (receiving and shipping) and movement of items. The warehouse management system is sometimes referred to as a WMS (Warehouse Management System). The warehouse management system 100 may be configured to be able to communicate with external systems not shown in FIG. 1 to acquire and manage instructions related to the inflow and outflow of goods, product information, information about warehouse equipment such as robots, and information about workers.

[0015] The warehouse operations management system 200 is a system that manages and controls work within a warehouse, and in the example configuration shown in Fig. 1, is positioned below the warehouse management system 100. The warehouse operations management system is sometimes referred to as a WES (Warehouse Execution System). The warehouse operations management system 200 comprehensively controls, for example, the work content of various work entities within the warehouse and the equipment within the warehouse.

[0016] The warehouse control systems 300, 400, and 500 manage and control various pieces of equipment in the warehouse. The warehouse control system may also be referred to as a WCS (warehouse control system). In the example configuration shown in FIG. 1 , the warehouse control systems 300, 400, and 500 manage and control the robot 600, the automated warehouse 700, and the automated guided vehicle 800, respectively. The robot 600 is equipped with, for example, a direct-travel mechanism or a multi-axis arm and is configured to be able to hold products at its tip. The tip of the robot 600 may have, for example, a suction mechanism or a multi-fingered gripping mechanism, but is not particularly limited thereto. Multiple types of robots 600 may be installed in the warehouse to accommodate picking operations for various products. Furthermore, a camera may be installed around the robot 600 to capture images of the surrounding area, particularly images of bins placed nearby.

[0017] The automated warehouse 700 is configured to store multiple bins and transports the bins to a predetermined location upon request. The bins are transported by an AGV (Autonomous Mobile Robot) (not shown) that configures the automated warehouse 700, but the method is not limited to this. For example, the bins may be transported using a belt conveyor or the like. The automated warehouse 700 is configured, for example, with a lattice frame so that multiple bins can be stored. Examples of bins stored in the automated warehouse 700 include storage bins for storing products. The storage bins may also include empty bins that do not contain any products or bins for which no products have been determined to be stored. The bins used in the automated warehouse 700 also include shipping bins for bundling products together before shipping. The storage bins and shipping bins may have different shapes and dimensions, but are configured to be transportable by the AGVs provided in the automated warehouse 700. Here, the description will be given assuming that they have the same rectangular box-shaped configuration. Furthermore, as will be described in detail later, within the automated warehouse 700 there are travel areas where AGVs are allowed to travel and non-travel areas where AGVs are not allowed to travel.

[0018] The automated guided vehicle 800 is a vehicle that is provided outside the automated warehouse 700 and is used to transport various types of cargo outside the automated warehouse 700. The automated guided vehicle 800 is configured to include, for example, a traveling unit for performing operations related to movement, a sensor for acquiring peripheral information, and a communication unit for transmitting and receiving data to and from the warehouse control system 300, etc. Furthermore, the automated guided vehicle 800 may be configured to be manually operated in addition to being automatically driven.

[0019] The operation terminal 900 is an information processing device configured to be usable by workers both inside and outside the warehouse. The operation terminal 900 may be, for example, a stationary information processing device such as a PC (Personal Computer), or may be a mobile terminal such as a tablet terminal, POS terminal, handheld terminal, or smartphone. The operation terminal 900 transmits and receives data to and from the warehouse management system 100, warehouse operations management system 200, warehouse control systems 300, 400, and 500, and is used to receive notifications from each system and to configure and operate each system.

[0020] (Hardware Configuration Example) Each system shown in FIG. 1 may be configured as an on-premise server device at a base where a warehouse is located, or may be configured as a cloud-based system on a network. FIG. 2 is a diagram showing an example of the hardware configuration of an information processing device that can be used as a device constituting each system. Here, the devices constituting each system are described as having the same configuration, but some components may be omitted or other components may be added depending on the functions provided. An example of a component that may be added is a barcode reader used to acquire information from barcodes attached to products and bins in the warehouse.

[0021] The information processing device 10 includes a processing device 11, a storage device 12, a communication device 13, an input device 14, an image acquisition unit 15, an external interface 16, and a display device 17. Each component is configured to be able to communicate via an internal interface 18. The processing device 11 may be configured using, for example, a central processing unit (CPU), a graphic processing unit (GPU), a micro processing unit (MPU), a digital signal processor (DSP), or a field-programmable gate array (FPGA). The processing device 11 realizes various functions described below by, for example, referencing various databases (hereinafter, referred to as DBs) stored in the storage device 12 or reading programs. The storage device 12 is a storage unit for storing various data, programs, etc., and may be composed of volatile / non-volatile storage devices such as RAM (Random Access Memory), ROM (Read Only Memory), and HDD (Hard Disk Drive).

[0022] The communication device 13 is an interface for communicating with external devices via the network 35. There are no particular limitations on the communication standards that can be supported by the communication device 13, and the communication standards may be wired or wireless. The communication device 13 may also be capable of supporting multiple communication standards. Therefore, the network 35 may be configured by combining networks based on multiple communication standards.

[0023] The input device 14 accepts operations and instructions from warehouse users (e.g., managers and workers). The input device 14 may be composed of a mouse, a keyboard, a touch panel display, etc. The image acquisition unit 15 is an interface for acquiring images of the warehouse interior from cameras 30 installed in the warehouse. The external interface 16 is an interface for communicating with an external system 20. The external system 20 may be communicatively connected via the communication device 13 and a network 35. The external system 20 is not limited to the systems shown in FIG. 1 , and may be another system. The display device 17 displays various user interfaces to the user. The display device 17 may be composed of a liquid crystal display, a touch panel display, a lamp, etc.

[0024] 3 is a conceptual diagram showing an example of the configuration inside a warehouse of the warehouse system 1 according to this embodiment. An automated warehouse 700 and one or more robots 600 are installed inside the warehouse. The automated warehouse 700 is configured to manage multiple bins in which products are stored and to transport the products to a predetermined location upon request.

[0025] A work area 720 is configured around the automated warehouse 700 where a worker 710, who is the main operator of the picking work, works. A work area is also provided where the robot 600 works. Details of the setting of the work area will be described later, but the arrangement of bins 730 is determined so that the main operator can move products from storage bins to shipping bins more efficiently. Furthermore, from the perspective of improving the efficiency of the entire shipping work, if it is desirable to temporarily wait for the bins 730 instead of moving them within the automated warehouse 700, a waiting area 740 may be provided for waiting the bins. Hereinafter, the area where picking work is performed may be referred to as a picking station.

[0026] While the example in FIG. 3 shows an example in which one area is provided for the work of the human worker 710 and one area is provided for the work of the robot 600, this is not limiting. Multiple areas of each type may be provided. Furthermore, while the example shows a robot 600 equipped with a direct-acting mechanism, a robot equipped with a multi-axis arm may also be installed. In this embodiment, the description will be given assuming multiple picking stations where people work. However, the picking operation of products, etc. is not limited to being performed by humans, and some or all of the picking operation may be performed by a non-human worker.

[0027] [Picking Station] Figure 4 is a schematic diagram showing an example of the configuration of a picking station according to this embodiment. In Figure 4, three picking stations 41a to 41c where workers can work are provided within area 40. In this example, picking stations 41a to 41c can each accommodate up to seven bins. For example, picking station 41a can accommodate bins in dedicated areas 42a to 42g, respectively, and workers use these bins to pick up and store products. Each of dedicated areas 42a to 42g is a dedicated area for the worker working at picking station 41a.

[0028] Furthermore, common areas are provided between each picking station. In this example, a common area 43a is provided between picking stations 41a and 41b. A common area 43b is provided between picking stations 41b and 41c. Each of the common areas 43a and 43b can accommodate up to two bins. For example, the common area 43a can accommodate bins in areas 44a and 44b, respectively, and operators at picking stations 41a and 41b use these bins to pick up and store products. Similarly, the common area 43b can accommodate bins in areas 44c and 44d, respectively, and operators at picking stations 41b and 41c use these bins to pick up and store products.

[0029] 4, the dedicated areas within each picking station, the common areas outside each picking station, and the areas indicated by rectangles correspond to travel areas within which the AGVs constituting the automated warehouse 700 can travel. Therefore, the automated warehouse 700 can move bins through the travel areas for picking operations.

[0030] The number and layout of the picking stations and common area are merely examples and are not limited to these. In this embodiment, it is sufficient that workers at different picking stations can share bins and products in the common area.

[0031] [Examples of Bin Layout] Examples of bin layouts will be described using Figures 5A to 10. Here, the configuration of the picking station and common area shown in Figure 4 will be described as an example.

[0032] One order corresponds to one shipping operation. One or more products are specified for one order. Shipping operation for one order is carried out by picking the specified one or more products from a storage bin to one shipping bin. One picking operation for one product is also called a task.

[0033] FIG. 5A shows the allocation of picking stations to four orders 51a-51d, with the orders assigned from left to right. The numbers assigned to each product in each order uniquely indicate the storage bin in which the product is stored. First, an example will be described in which a common area is not used. Order 51a designates five products 52a-52e (storage bins "1"-"5") to be shipped. At the picking station assigned to order 51a, these products are picked from the storage bins in which they are stored to shipping bins. Similarly, order 51b designates three products 52f-52h (storage bins "1," "6," and "7") to be shipped. Order 51c designates four products to be shipped (storage bins "1," "8," "9," and "10"), and order 51d designates three products to be shipped (storage bins "1," "11," and "12").

[0034] In this example, all four orders specify a product in storage bin "1." In this case, first, order 51a is assigned to picking station 41b. Since moving a bin typically takes time, it is desirable to avoid moving bins as much as possible. If the orders were assigned using a method that minimizes the movement of shared storage bins, the other three orders 51b-51d would also be assigned to picking station 41b. In this case, the workload would be concentrated at picking station 41b, and it would be difficult to effectively utilize other picking stations.

[0035] Therefore, in this embodiment, a common area is introduced and used to distribute the workload and improve efficiency. Figure 5B shows an example of reallocation of each picking station according to this embodiment. Orders will be explained using the same example as in Figure 5A.

[0036] Four orders 51a to 51d share a common product 52a stored in storage bin "1." The order allocation and bin placement are determined so that storage bins storing such common products are placed in a common area. For example, if order 51a is assigned to picking station 41b, order 51b, which specifies a common product, is also assigned to the same picking station 41b. Furthermore, order 51c, which specifies a product in the common storage bin "1," is assigned to the adjacent picking station 41c, and storage bin "1" is instructed to be placed in common area 43b located between picking stations 41b and 41c (storage bin 53). Furthermore, order 51d, which specifies a product in the common storage bin "1," is assigned to a picking station 41c with a smaller number of allocations and in which common area 43b is available, in order to level out shipping operations.

[0037] Storage bin "1" corresponding to products common to the orders is placed in area 44c on the picking station 41b side in common area 43, but this is not limited to this. The placement of the bins in the common area may be determined based on the order of allocation, the placement order may be specified in advance, or the placement order may be determined according to the number of products to be picked, for example.

[0038] FIG. 6A is a diagram illustrating another example of allocation when a common area is not used. In this example, five picking stations 62a to 62e are provided. Order 61a specifies three products to be shipped (storage bins "1," "3," and "5"). Order 61b specifies four products to be shipped (storage bins "1," "2," "6," and "7"). Order 61c specifies three products to be shipped (storage bins "2," "9," and "10"), and order 61d specifies one product to be shipped (storage bin "3"). In this case, storage bins "1," "2," and "3" are common to the four orders 61a to 61c.

[0039] Let's assume that four orders 61a to 61d are assigned in order from left to right. First, let's assume that order 61a is assigned to picking station 62c. As described above, if the orders are assigned using a method that suppresses the movement of shared storage bins, order 61b is assigned to picking station 62c because it shares storage bin "1" with order 61a. Furthermore, order 61c is assigned to picking station 62c because it shares storage bin "2" with order 61b. Furthermore, order 61d is assigned to picking station 62c because it shares storage bin "3" with order 61a. As a result, the workload is concentrated at picking station 62c.

[0040] Allocation when using a common area according to this embodiment will be described below. Figure 6B shows an example of allocation of picking stations according to this embodiment to orders 61a to 61d similar to those in Figure 6A.

[0041] The allocation of each order is changed from the allocation shown in FIG. 6A as follows: Order 61a is assigned to picking station 62b. Order 61b is assigned to picking station 62b. Order 61c is assigned to picking station 62d. Order 61d is assigned to picking station 62a. Because orders 61a and 61b share the same product in storage bin "1," storage bin "1" is instructed to be placed in common area 63b provided between picking stations 62b and 62c (storage bin 65b). Because orders 61b and 61c share the same product in storage bin "2," storage bin "2" is instructed to be placed in common area 63c provided between picking stations 62c and 62d (storage bin 65c). Since orders 61a and 61d share the same product in storage bin "3," storage bin "3" is instructed to be placed in common area 63a located between picking stations 62a and 62b (storage bin 65a).

[0042] [Example of rearrangement of order and task sequences] After assigning orders to each picking station, the sequence of work for each order and the sequence of work for tasks within an order are determined. For example, when a common area is used between two picking stations, approximating the timing of order processing at each picking station allows storage bins to be moved out of the common area earlier. In other words, storage bins placed in the common area can be used earlier at other picking stations.

[0043] 7 illustrates an example using four orders 71a to 71d. Orders 71a and 71b are assigned to picking station 72a, and orders 71c and 71d are assigned to picking station 72b. Furthermore, because orders 71b and 71c share a product in storage bin "9," instructions are given to place storage bin "9" in common area 73 located between picking stations 72a and 72b (storage bin 75).

[0044] In this case, the timing of processing tasks corresponding to storage bins located in the common area is synchronized or approximated. In the allocation example shown in Figure 7, instructions are given to the workers at each picking station so that the timing of execution of orders 71b and 71c, which include storage bin "9," at picking station 72a and picking station 72b is synchronized.

[0045] In addition, the order in which each picking station performs tasks to move each of the multiple items included in a single order from a storage bin to a shipping bin can be configured to depend on the worker, but it is also possible to configure the order in which tasks within a single order are performed to be specified. For example, the workers at each picking station may be instructed to first perform the task of moving a common item from a storage bin to a shipping bin. In the example of FIG. 7 , the worker at picking station 72a may be instructed to first perform the task for the item in storage bin "9" out of the four tasks included in order 71b. Similarly, the worker at picking station 72b may be instructed to first perform the task for the item in storage bin "9" out of the three tasks included in order 71c.

[0046] The above-described common area is provided in an area where the AGVs constituting the automated warehouse 700 can place storage bins, i.e., an area where the AGVs can travel. In this embodiment, a common area (hereinafter referred to as a "non-travelable common area") is also provided in an area where the AGVs cannot travel. The non-travelable common area here corresponds to, for example, an area where any product can be temporarily placed manually.

[0047] 8 illustrates an example using four orders 81a to 81d. Orders 81a and 81b are assigned to picking station 82a, and orders 81c and 81d are assigned to picking station 82b. Furthermore, orders 81b and 81c share a product in storage bin "13."

[0048] For example, at a certain point in time, bins may already be placed in two areas 86a and 86b in the common area 85 between picking stations 82a and 82b due to another order that has already been assigned.

[0049] In such a case, the common storage bin is placed in the dedicated area of ​​one of the picking stations, and the non-traveling common area is utilized. Specifically, storage bin "13" is placed in one of the dedicated areas within picking station 82b (storage bin 87). Furthermore, the operator at picking station 82b is instructed to place the product stored in storage bin "13" (storage bin 87) in the non-traveling common area 88 (product 89). Furthermore, the operator at picking station 82a is instructed to move product 89 placed in the non-traveling common area 88 to a shipping bin placed in the dedicated area of ​​picking station 82a (in this example, shipping bin 84 placed in the dedicated area 83).

[0050] This configuration makes it possible to use this as an alternative method when, for example, the common area is full at a certain time. Furthermore, when this configuration is used, the order order is rearranged so that the order to move the corresponding product to the non-travelable common area is processed first. Specifically, instructions are given to the workers at each picking station so that order 81c assigned to picking station 82b is processed before order 81b assigned to picking station 82a.

[0051] At this time, the worker at picking station 82b is also tasked with moving the product in storage bin "13" to a shipping bin located in his / her own dedicated area for order 81c, which is assigned to picking station 82b, so order 81c is instructed to perform two tasks for the product in storage bin "13."

[0052] Furthermore, this embodiment also takes into consideration cases where the non-traveling common area cannot be used (for example, where products cannot be placed) or where the use of the non-traveling area is simplified. Examples of such cases will be described with reference to FIG. 9.

[0053] 9 illustrates an example using four orders 91a to 91d. Orders 91a and 91b are assigned to picking station 92a, and orders 91c and 91d are assigned to picking station 92b. Furthermore, orders 91b and 91c share a product in storage bin "13."

[0054] For example, assume that at a certain timing, bins have already been placed in two areas 94a and 94b in the common area 93 between picking stations 92a and 92b due to another order that has already been assigned. Furthermore, assume that the non-travelable common area 98 is not used.

[0055] In such a case, a common storage bin is placed in the dedicated area of ​​one of the picking stations, and instructions are given to have the workers at each picking station hand over the product instead of using the non-travelable common area. Specifically, storage bin "13" is placed in one of the dedicated areas within picking station 92b (storage bin 95). Furthermore, instructions are given to the worker at picking station 92b to personally hand over the product stored in storage bin "13" (storage bin 95) to the worker at picking station 92a (product 96). Furthermore, instructions are given to the worker at picking station 92a to receive product 907 from the worker at picking station 92b and store it in a shipping bin placed in the dedicated area within picking station 92a.

[0056] At this time, the worker at picking station 92b is also tasked with moving the product in storage bin "13" to a shipping bin located in his / her own exclusive area for order 91c, which is assigned to picking station 92b, so order 91c is instructed to perform two tasks for the product in storage bin "13."

[0057] This configuration makes it possible to use an alternative method when, for example, the common area is full at a certain time. Furthermore, when this configuration is used, the order of the orders is rearranged so that the timing of the handover of the corresponding products coincides. Specifically, the order of orders 91b and 91c is determined so that the timing of processing the products stored in storage bin "13" coincides between picking station 92a and picking station 92b. Furthermore, the order of the multiple tasks included in order 91b and the order of the multiple tasks included in order 91c are rearranged so that the handover timing coincides.

[0058] As described above, the order processing order and task processing order may be determined depending on the layout situation, such as whether or not the common area is available. In particular, when direct cooperation between workers at multiple picking stations is required, it is preferable to synchronize the timing of task processing as much as possible.

[0059] The above description has been given of an example in which storage bins are placed in a common area. Shipping bins may also be placed in the common area. FIG. 10 shows an example in which a single order 1001 specifies products in 15 storage bins "1" to "15." For such an order, it may be more efficient to have multiple picking stations work together rather than processing the order at a single picking station. In the configuration shown in FIG. 10 , one picking station has seven dedicated areas. When processing order 1001 at a single picking station, if the shipping bin is placed in one of the dedicated areas, the storage bins may be moved at least nine times within the dedicated area of ​​the picking station. Moving the storage bins takes time, and waiting times may occur.

[0060] In anticipation of such a situation, shipping bins corresponding to orders specifying more than a predetermined number of items are placed in a common area. Then, workers at adjacent picking stations share the work. The predetermined number here may be determined in advance depending on the number of picking stations, the number of dedicated areas provided within the picking stations, etc.

[0061] In the example of Fig. 10, shipping bin 1003 for order 1001 is placed in common area 1005 provided between picking station 1004a and picking station 1004. Then, tasks for storage bins 1002 for multiple products included in order 1001 are assigned to picking station 1004a and picking station 1004b. The assignment of each task here may be performed so that the load is the same for the order, or may be performed taking into consideration the assignment of other orders.

[0062] [Processing Flow] The flow of the order allocation process according to this embodiment will be described below with reference to FIG. 11. The description will be made assuming a configuration in which the above-mentioned common areas, non-travel common areas, and hand delivery can be used. Note that the allocation by sharing shown in FIG. 10 will be excluded from the description here. FIG. 11 is a flowchart for explaining the flow of the order allocation process by the warehouse operations management system 200 in the warehouse system 1 according to this embodiment. Note that in this example, the warehouse operations management system 200 will be described as the processing entity, but some of the functions may be configured to be executed by other systems.

[0063] The warehouse operations management system 200 acquires order information related to shipping work from the warehouse management system 100, which is a higher-level system (step S1101). In this embodiment, the order information is created and managed by the warehouse management system 100 based on external ordering instructions, etc. The order information may be provided to the warehouse operations management system 200 as appropriate.

[0064] Based on the orders acquired in step S1101, the warehouse operations management system 200 assigns orders including tasks using the same storage bin to the same picking station (step S1102). The assignment of the orders may be performed in the order in which the orders were acquired, or may be performed after sorting the orders by the order of the nearest shipping deadline.

[0065] The warehouse operations management system 200 determines whether the allocations are concentrated at one picking station as a result of the allocation in step S1102 (step S1103). The concentration here may be determined relatively based on the allocation status of multiple picking stations, or may be determined using an upper limit on the number of allocations, etc. If it is determined that the allocations are concentrated (step S1103: YES), the processing of the warehouse operations management system 200 proceeds to step S1104. On the other hand, if it is determined that the allocations are not concentrated (step S1103: NO), the processing of the warehouse operations management system 200 proceeds to step S1115.

[0066] The warehouse operations management system 200 assigns combinations of orders that use the same storage bin to each of the multiple picking stations that share the common area (step S1104). In other words, the warehouse operations management system 200 updates the assignment of each order as if it were using the common area.

[0067] The warehouse operations management system 200 rearranges the order and task order for the orders assigned in step S1104 so that the timing of picking operations is synchronized between the picking stations (step S1105). At this time, the timing does not need to be perfectly synchronized, but may be configured to approximate within a certain time range.

[0068] Based on the results of the order and task reordering performed in step S1105, the warehouse operations management system 200 determines whether the common area is available at the time of matching (step S1106). The common area here refers to an area where an AGV can travel by traveling through storage bins, such as common area 43a in FIG. 4. In this process flow, the determination of whether the common area is available is performed after the reordering in step S1105, but the process may be performed in the reverse order. If there is available space in the common area (step S1106: YES), the warehouse operations management system 200 proceeds to step S1107. On the other hand, if there is no available space in the common area (step S1106: NO), the warehouse operations management system 200 proceeds to step S1109.

[0069] The warehouse operations management system 200 outputs instructions to arrange storage bins for overlapping products in an empty area in the common area between the picking stations (step S1107). For example, the warehouse operations management system 200 generates and outputs instructions to the automated warehouse 700 to arrange the bins as shown in FIG. 5B. Then, the processing of the warehouse operations management system 200 proceeds to step S1108.

[0070] The warehouse operations management system 200 outputs instructions for picking the products from the storage bins located in the common area in step S1107 to shipping bins (step S1108). For example, the warehouse operations management system 200 generates and outputs instructions to the workers at the corresponding picking stations to pick the products from the storage bins located as shown in FIG. 5B. The process of the warehouse operations management system 200 then proceeds to step S1115.

[0071] Based on the results of the order and task reordering performed in step S1105, the warehouse operations management system 200 determines whether the non-traveling common area is available at the time of matching (step S1109). The non-traveling common area here refers to an area where an AGV cannot transport and place storage bins, such as the non-traveling common area 88 in FIG. 8. If there is available space in the non-traveling common area (step S1109: YES), the processing of the warehouse operations management system 200 proceeds to step S1110. On the other hand, if there is no available space in the non-traveling common area (step S1109: NO), the processing of the warehouse operations management system 200 proceeds to step S1115.

[0072] The warehouse operations management system 200 determines whether it is possible to synchronize the timing of picking the same product between picking stations (step S1110). That is, the warehouse operations management system 200 determines whether it is possible to synchronize the timing of processing tasks as shown in FIG. 9. This determination may be made based on, for example, whether already assigned orders can be rearranged or their processing status. If it is determined that the timing can be synchronized (step S1110: YES), the warehouse operations management system 200 proceeds to step S1111. On the other hand, if it is determined that the timing cannot be synchronized (step S1110: NO), the warehouse operations management system 200 proceeds to step S1113.

[0073] The warehouse operations management system 200 outputs instructions to place the overlapping products or storage bins containing the products in the empty common area that is not accessible to vehicles (step S1113). For example, the warehouse operations management system 200 generates and outputs instructions to the automated warehouse 700 to place the products as shown in FIG. 8. Then, the processing of the warehouse operations management system 200 proceeds to step S1114.

[0074] The warehouse operations management system 200 outputs instructions to store the products placed in the non-traveling common area in a shipping bin in step S1114. For example, the warehouse operations management system 200 generates instructions to pick products from storage bins arranged as shown in FIG. 8 and place them in the non-traveling common area, and instructions to pick products placed in the non-traveling common area and store them in a specified shipping bin. The warehouse operations management system 200 outputs these instructions to the workers at each corresponding picking station. The processing of the warehouse operations management system 200 then proceeds to step S1115.

[0075] The warehouse operations management system 200 synchronizes the timing of picking the same product among the picking stations (step S1111). Specifically, as shown in FIG. 9 , the order and task order are rearranged so that the timing of task processing is synchronized among the picking stations.

[0076] The warehouse operations management system 200 outputs instructions to the worker at one picking station to pick and transfer the overlapping items. The warehouse operations management system 200 also outputs instructions to the worker at the other picking station to receive the overlapping items and store them in a shipping bin (step S1112). For example, the warehouse operations management system 200 generates instructions to pick items from storage bins arranged as shown in FIG. 9 and hand them over to the worker at the adjacent picking station, and instructions to receive items from the worker at the adjacent picking station and store them in a shipping bin. The warehouse operations management system 200 outputs these instructions to the workers at the corresponding picking stations. The warehouse operations management system 200 also determines the locations of shipping bins and storage bins to be used for handover and outputs instructions to the automated warehouse 700. The warehouse operations management system 200 then proceeds to step S1115.

[0077] The warehouse operations management system 200 outputs the work instructions, including the order allocations and bin placements and picking work instructions that have been made so far, to the warehouse control system 400 that manages the automated warehouse 700 and to the operation terminals 900 operated by the workers at each picking station (step S1115).Then, this processing flow ends.

[0078] After this process is completed, the automated warehouse 700 moves the bins and the workers pick the items based on the instructions. This process flow may be repeated each time the warehouse management system 100 generates an order.

[0079] As described above, a warehouse system (e.g., 1, 200) according to this embodiment is a warehouse system having a plurality of work areas (e.g., 41a to 41c) in which product picking work is performed, and includes an allocation unit (e.g., 11) that allocates an order (e.g., 51a to 51d) specifying one or more products to one of the plurality of work areas, and an instruction unit (e.g., 11) that issues instructions for picking work for one or more products specified in the order based on the allocation result by the allocation unit. When a product (e.g., 52a) stored in a common storage bin is specified in a first order (e.g., 51a) and a second order (e.g., 51c), the allocation unit allocates the first order and the second order to the first work area and the second work area, respectively, so that the storage bin (e.g., 53) containing the product is placed in a common area (e.g., 43b) available between the first work area (e.g., 41b) and the second work area (e.g., 41c) to which the first order and the second order are assigned. This configuration improves the efficiency of picking operations by workers and robots in the warehouse. In particular, it can prevent orders from concentrating on a few picking stations, reducing the shipping capacity of the entire warehouse system.

[0080] In addition, in the warehouse system, the instruction unit further instructs the order of picking work for each of the multiple products included in one order. With this configuration, it is possible to adjust not only the order order but also the order of picking work for the multiple products included in each order, thereby further promoting work efficiency.

[0081] In addition, in the warehouse system, the instruction unit sets the order in which multiple orders are to be processed by a first worker in a first work area and a second worker in a second work area, respectively, in accordance with the arrangement of storage bins in the common area, and further sets the order in which picking work is to be performed for one or more products specified in each of the multiple orders. With this configuration, a more appropriate order for processing orders can be determined in accordance with the arrangement of storage bins in the common area, and further, a more appropriate order for picking work for each order can be determined.

[0082] In addition, in the warehouse system, when order allocation is concentrated in one work area, the allocation unit reallocates the orders using the common area. With this configuration, it is possible to determine whether to use the common area depending on the allocation load distribution status.

[0083] In addition, in the warehouse system, the common area includes a first area (e.g., 85) located in an area within the warehouse system where a device for transporting bins can travel and a second area (e.g., 88) located in an area where the device cannot travel. If there is no vacant space in the first area, the instruction unit further determines whether a transfer via a second area available to a first worker in the first work area (e.g., 82a) and a second worker in the second work area (e.g., 82b) is possible. If transfer via the second area is possible, the instruction unit places a storage bin (e.g., 87) containing the product in either the first work area or the second work area, picks the product from the storage bin and places the storage bin in the second area, and further issues instructions to receive the product from the storage bin placed in the second area and store it in a shipping bin. This configuration makes it possible to improve the efficiency of picking operations by utilizing the common area located in an area where an AGV cannot travel.

[0084] In addition, in the warehouse system, the instruction unit instructs either the first worker or the second worker on the order of processing so that an instruction to pick an item from a storage bin and place the storage bin in the second area is given before an instruction to receive the item placed in the second area and store it in a shipping bin. This configuration makes it possible to promote the efficiency of picking work by utilizing a common area set up in an area where AGVs cannot travel. In particular, it makes it possible to optimize the timing of product handover between workers.

[0085] In addition, in the warehouse system, when there is no free space in the common area, the instruction unit further determines whether a direct handover of the product is possible between a first worker in the first work area and a second worker in the second work area, and if a handover is possible, places a storage bin containing the product in either the first work area or the second work area and issues an instruction to hand over the product. This configuration can promote the efficiency of picking work even when a common area provided in an area where the AGV can travel is not available. In particular, it can enable direct handover of products between workers in a storage bin placed at one of the workers' picking stations.

[0086] In the warehouse system, the instruction unit instructs the order of processing the first order and the second order, or the order of processing the products included in the first order and the second order, so that a first timing at which a first worker picks a product approaches a second timing at which a second worker picks a product. This configuration makes it possible to synchronize the timing of direct product transfers between workers and reduce waiting times for workers.

[0087] Furthermore, in a warehouse system, when an order (e.g., 1001) specifies more than a predetermined number of items, the allocation unit allocates a shipping bin (e.g., 1003) corresponding to the order in a common area and allocates the picking work for the items for that order to multiple picking stations (e.g., 1004a, 1004b) that can use the common area. This configuration allows multiple workers to work together to ship an order that specifies many items. As a result, it is possible to reduce the workload at a single picking station and shorten the waiting time required for the bin to be moved.

[0088] (Other Embodiments) In the above example, a configuration example in which one common area is provided between two picking stations is shown, but this is not limited to this. Depending on the arrangement of the picking stations, one common area that can be used by three or more picking stations may be provided. Also, a dedicated area may be temporarily used as a common area.

[0089] Furthermore, in the dedicated area or common area within a picking station, it is more desirable to position the storage bins and shipping bins, which are the source and destination of the products, as close as possible to each other. In this case, the placement of the shipping bins may be determined based on the positions of the storage bins in the two picking stations and the common area between them, or the placement of the storage bins may be determined based on the positions of the shipping bins. Furthermore, the relative positions of the shipping bins and storage bins may be determined taking into account the characteristics of the products to be picked, such as size and weight.

[0090] Furthermore, the present invention is not limited to a single type of product being stored in one storage bin. For example, multiple types of products may be stored in one storage bin. When different types of products are stored in the same storage bin, the system may be controlled to use the common area described above as a common storage bin. Furthermore, one type of product may be stored in multiple storage bins. In such a case, when multiple orders specify a common product, separate storage bins may be assigned to the respective picking stations, or the common area may be assigned to the respective orders.

[0091] Furthermore, in the above-described embodiments, the objects of the picking operation are not limited to "products" that are commercially distributed. The configurations of the above-described embodiments can be applied to the picking operation of general items that may not be classified as "products," such as non-sale items and parts.

[0092] In this specification, the terms "first" and "second" are used merely for convenience to distinguish from other components, and are not intended to be interpreted as being limited to specific components. Therefore, it will be understood that these terms can be interpreted appropriately depending on the configuration to which the invention in this disclosure is applied.

[0093] The present disclosure also applies to programs and storage media that realize the functions of the devices of the above-mentioned embodiments, which are supplied to the device via a network or various storage media and that are read and executed by a computer within the device.

[0094] Although various embodiments have been described above with reference to the drawings, it goes without saying that the present disclosure is not limited to these examples. It is clear to those skilled in the art that various modifications, alterations, substitutions, additions, deletions, and equivalents may be made within the scope of the claims, and it is understood that these also fall within the technical scope of the present disclosure. Furthermore, the components of the various embodiments described above may be combined in any manner without departing from the spirit of the invention.

[0095] (Additional Notes) The above description of the embodiments discloses the following techniques.

[0096] (Technology 1) A warehouse system having a plurality of work areas for picking products, the warehouse system comprising: an allocation unit that allocates an order specifying one or more products to one of the plurality of work areas; and an instruction unit that issues instructions for the picking work for the one or more products specified in the order based on an allocation result by the allocation unit, wherein when a first order and a second order specify products stored in a common storage bin, the allocation unit allocates the first order and the second order to the first work area and the second work area, respectively, such that the storage bin containing the products is placed in a common area available between the first work area and the second work area to which the first order and the second order are assigned, respectively.

[0097] This configuration improves the efficiency of picking work by workers and robots in the warehouse, and in particular, it can prevent orders from concentrating on a few picking stations, reducing the shipping capacity of the entire warehouse system.

[0098] (Technology 2) The warehouse system according to Technology 1, wherein the instruction unit further instructs the order of picking work for each of a plurality of products included in one order.

[0099] This configuration makes it possible to adjust not only the order order but also the order of picking work for multiple products included in each order, thereby further improving work efficiency.

[0100] (Technology 3) In the warehouse system described in Technology 2, the instruction unit sets an order for processing multiple orders by a first worker in the first work area and a second worker in the second work area, respectively, according to the arrangement of storage bins in the common area, and further sets an order for picking work for one or more products specified in each of the multiple orders.

[0101] This configuration allows a more appropriate order processing order to be determined based on the arrangement of storage bins in the common area, and also allows a more appropriate order for picking work for each order to be determined.

[0102] (Technology 4) The warehouse system according to any one of Technology 1 to Technology 3, wherein the allocation unit reallocates the orders using the common area when order allocations are concentrated in one work area.

[0103] This configuration makes it possible to determine whether or not to use a common area depending on the load distribution status of the allocation.

[0104] (Technology 5) The warehouse system according to Technology 1 or Technology 2, wherein the common area includes a first area provided in an area within the warehouse system through which a device for transporting bins can travel, and a second area provided in an area through which the device cannot travel, and the instruction unit further determines, when there is no vacancy in the first area, whether delivery via the second area available to a first worker in the first work area and a second worker in the second work area is possible, and if delivery via the second area is possible, places a storage bin containing the product in either the first work area or the second work area, picks the product from the storage bin and places the storage bin in the second area, and further gives instructions to receive the product from the storage bin placed in the second area and store it in a shipping bin.

[0105] This configuration makes it possible to improve the efficiency of picking work by utilizing a common area set up in an area where AGVs cannot travel.

[0106] (Technology 6) The warehouse system described in Technology 3, wherein the instruction unit instructs either the first worker or the second worker on the order of processing so that an instruction to pick the product from the storage bin and place the storage bin in the second area is given before an instruction to receive the product placed in the second area and store it in a shipping bin.

[0107] This configuration makes it possible to utilize the common area set up in an area where AGVs cannot travel, thereby promoting the efficiency of picking work, and in particular optimizing the timing of product handover between workers.

[0108] (Technology 7) The warehouse system according to any one of Technology 1 to Technology 4, wherein the instruction unit further determines, when there is no vacant space in the common area, whether or not a direct handover of the product is possible between a first worker in the first work area and a second worker in the second work area, and, if possible, places a storage bin containing the product in either the first work area or the second work area and issues an instruction to hand over the product.

[0109] This configuration makes it possible to improve the efficiency of picking work even when a common area set up in an area where AGVs can travel is unavailable. In particular, it makes it possible for workers to directly hand over products stored in storage bins placed at each worker's picking station.

[0110] (Technology 8) The warehouse system according to Technology 5, wherein the instruction unit instructs the order of processing the first order and the second order, or the order of processing the products included in the first order and the second order, so that a first timing at which a first worker performs a picking operation on the product approaches a second timing at which the second worker performs a picking operation on the product.

[0111] This configuration allows the timing of direct product handover between workers to be synchronized, thereby reducing the waiting time of workers.

[0112] (Technology 9) A warehouse system according to any one of Technology 1 to Technology 6, wherein when a single order specifies more than a predetermined number of products, the allocation unit places shipping bins corresponding to the single order in the common area and allocates the common area so that the picking work of the products for the single order is shared among a plurality of picking stations that can use the common area.

[0113] This configuration allows multiple workers to work together to complete a single order that specifies many products, thereby reducing the workload at a single picking station and reducing waiting times associated with moving bins.

[0114] (Technology 10) A method for determining bin placement that is used in a warehouse system having multiple work areas where product picking work is performed, and is executed by a processor and a memory working together, comprising: an allocation step of allocating an order specifying one or more products to one of the multiple work areas; and an instruction step of issuing instructions for picking work for the one or more products specified in the order based on the allocation result from the allocation step, wherein in the allocation step, if a product stored in a common storage bin is specified in a first order and a second order, the first order and the second order are allocated to the first work area and the second work area, respectively, so that the storage bin containing the product is placed in a common area available between the first work area and the second work area to which the first order and the second order are assigned, respectively.

[0115] This configuration improves the efficiency of picking work by workers and robots in the warehouse, and in particular, it can prevent orders from concentrating on a few picking stations, reducing the shipping capacity of the entire warehouse system.

[0116] The present disclosure is useful for a warehouse system and a method for determining bin placement within a warehouse.

[0117] DESCRIPTION OF SYMBOLS 1...Warehouse system 10...Information processing device 11...Processing device 12...Storage device 13...Communication device 14...Input device 15...Image acquisition unit 16...External interface 17...Display device 18...Internal interface 20...External system 30...Camera 35...Network 100...Warehouse management system 200...Warehouse operation management system 300, 400, 500...Warehouse control system 600...Robot 700...Automated warehouse 800...Automated guided vehicle 900...Operation terminal

Claims

1. A warehouse system having a plurality of work areas for picking products, comprising: an allocation unit that allocates an order specifying one or more products to one of the plurality of work areas; and an instruction unit that issues instructions for the picking work for the one or more products specified in the order based on the allocation result by the allocation unit, wherein when a first order and a second order specify products stored in a common storage bin, the allocation unit allocates the first order and the second order to the first work area and the second work area, respectively, so that the storage bin containing the products is placed in a common area available between the first work area and the second work area to which the first order and the second order are assigned, respectively.

2. The warehouse system according to claim 1, wherein the instruction unit further instructs the order of picking work for each of a plurality of products included in one order.

3. The warehouse system of claim 2, wherein the instruction unit sets the order of processing of multiple orders by a first worker in the first work area and a second worker in the second work area, respectively, depending on the arrangement of storage bins in the common area, and further sets the order of picking work for one or more items specified in each of the multiple orders.

4. The warehouse system according to claim 1, wherein the allocation unit reallocates the orders using the common area when order allocations are concentrated in one work area.

5. The warehouse system of claim 1, wherein the common area includes a first area provided in an area within the warehouse system through which a device for transporting bins can travel, and a second area provided in an area through which the device cannot travel, and the instruction unit further determines, when there is no vacant space in the first area, whether or not delivery is possible via the second area available to a first worker in the first work area and a second worker in the second work area, and, if delivery via the second area is possible, places a storage bin containing the product in either the first work area or the second work area, picks the product from the storage bin and places the storage bin in the second area, and further issues instructions to receive the product from the storage bin placed in the second area and store it in a shipping bin.

6. The warehouse system of claim 5, wherein the instruction unit instructs either the first worker or the second worker on the order of processing so that an instruction to pick the product from the storage bin and place the storage bin in the second area is given before an instruction to receive the product placed in the second area and store it in a shipping bin.

7. The warehouse system of claim 1, wherein the instruction unit further determines, when there is no vacant space in the common area, whether a direct handover of the product is possible between a first worker in the first work area and a second worker in the second work area, and, if the handover is possible, places a storage bin containing the product in either the first work area or the second work area and issues instructions to hand over the product.

8. The warehouse system of claim 7, wherein the instruction unit instructs the order of processing the first order and the second order, or the order of processing the products included in the first order and the second order, so that a first timing at which the first worker performs picking work on the product approaches a second timing at which the second worker performs picking work on the product.

9. The warehouse system of claim 1, wherein when an order specifies more than a predetermined number of items, the allocation unit places shipping bins corresponding to the order in the common area and allocates the common area so that the picking work for the items for the order is shared among multiple picking stations that can use the common area.

10. A method for determining bin placement used in a warehouse system having multiple work areas where product picking work is performed, the method being executed by a processor and a memory working together, comprising: an allocation step for allocating an order specifying one or more products to one of the multiple work areas; and an instruction step for issuing instructions for picking work for the one or more products specified in the order based on the allocation result from the allocation step, wherein in the allocation step, if a first order and a second order specify products stored in a common storage bin, the method allocates the first order and the second order to the first work area and the second work area, respectively, so that the storage bin containing the products is placed in a common area available between the first work area and the second work area to which the first order and the second order are assigned, respectively.

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