Warehouse control system, warehouse control method, and program

Abstract

[Problem] To take out a case from a picking system and to change a location of an inventory product stored in the picking system even when a delivery instruction is not received. [Solution] This warehouse control system comprises: a reception unit for receiving an inventory change mode that issues, to a picking system that stores and picks a case in which a product is stored, an instruction for taking out the case; and a processor for issuing an instruction for taking out a designated case to the picking system in the inventory change mode.

Description

Warehouse control system, warehouse control method and program

[0001] The present invention relates to a warehouse control system, a warehouse control method, and a program for efficiently operating a picking system.

[0002] Logistics centers receive consignments from shippers and manage the inbound and outbound shipments of their goods (cargo). When automating product picking in a warehouse, a picking system with product storage functions, such as an automated case warehouse, is effective, as it allows for the automation of both inventory storage and shipping operations.

[0003] The WMS (Warehouse Management System), which is a warehouse management system for a logistics center, is a system that manages inventory (products, location) and has the functions of managing the inbound and outbound shipments of goods within the warehouse. The WMS can centrally manage inventory information within the warehouse, and when it receives a shipping order from a shipper, it issues a shipping instruction to the WCS (Warehouse Control System), which is the warehouse control system.

[0004] A WCS is a system that controls the "equipment" in a warehouse in real time, and is an IT system specialized for controlling warehouse equipment. Therefore, a WCS issues shipping operation commands to various material handling equipment and remotely controls material handling equipment and IoT devices, but because it controls machines, it cannot manage employee work like a WMS can.

[0005] The WCS outputs picking control instructions for the products to be shipped to the picking system, and the picking system dispenses a predetermined case (bin) in accordance with the instructions (see Patent Document 1).

[0006] Cases removed from the storage shelves of the picking system are sent to a work station by a conveyor, mobile transport vehicle, etc. At the work station, a worker removes the required number of items from the case, and the case is transported to a specified location. If there are any inventory items in the case, the case is stored again in the storage area (storage shelf) of the picking system.

[0007] In such a picking system, the standard method for receiving products is to place them in empty cases (containers) and store them on storage shelves. However, picking systems have a limited storage capacity, and if inventory increases and there are not enough empty containers, the receiving process becomes impossible.

[0008] This problem can be addressed by consolidating products into one case and increasing the number of empty cases (see Patent Document 1).

[0009] Japanese Patent Application Publication No. 1-220610

[0010] To consolidate products, it is necessary to remove cases from the picking system. However, it was not anticipated that cases would be removed from the picking system's storage shelves in cases that do not involve changes in the number of products in stock, such as changes to the cases of inventory products (replacement, consolidation, division, etc.) (in other words, cases other than product inbound and outbound).

[0011] Therefore, the present invention aims to provide a warehouse control system that can eject cases from a picking system even when no loading / unloading instructions have been received, and can also change the location of inventory items stored in the picking system (such as replacing, consolidating, or dividing items).

[0012] The present invention provides a warehouse control system comprising: a reception unit that receives an inventory change mode that issues a case dispensing instruction to a picking system that stores and picks cases containing products; and a processor that issues a specified case dispensing instruction to the picking system in the inventory change mode.

[0013] According to the present invention, it is possible to provide a warehouse control system that can eject cases from a picking system even when no loading / unloading instructions have been received, and can also change the location of inventory items stored in the picking system (such as replacing or consolidating items).

[0014] 1A and 1B are diagrams for explaining an overview of the warehouse control system 1, where (1a) is an overview of the entire system and (1b) is a diagram showing the computer in isolation. FIG. 1B is a diagram showing the instruction configuration in the shipping mode of the warehouse control system 1. FIG. 1C is a diagram showing the instruction configuration in the inventory change mode of the warehouse control system 1. FIG. 1D is a diagram showing a flowchart of the case transport instruction process in the inventory change mode executed by the warehouse control system 1. FIG. 1E is a diagram showing a flowchart of the inventory information update process in the inventory change mode executed by the warehouse control system 1. FIG. 1F is a diagram showing the replacement work of the products 110. FIG. 1G is a diagram showing the aggregation work of the products 110. FIG. 1H is a diagram showing the division work of the products 110. FIG. 1H is a diagram showing how a worker rearranges the products 110.

[0015] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following drawings, the same elements are designated by the same numbers or symbols throughout the description of the embodiments.

[0016] [Overview of Warehouse Control System 1] FIG. 1a is a block diagram illustrating an overview of the warehouse control system 1, and FIG. 1b is a diagram illustrating a computer 10. The components of the warehouse control system 1 will be described with reference to FIGS. 1a and 1b. The warehouse control system 1 is a system that controls "equipment" in a warehouse in real time and issues shipping operation commands to various material handling devices. It includes a computer 10. The computer 10 includes, for example, a processor 11, a reception unit 12 that accepts data in cooperation with a communication unit 15 via data communication, an output unit 13 that outputs signals, data, etc., a display unit 14 that displays inventory information in cooperation with the output unit 13, the communication unit 15, and a storage unit 16 that stores inventory information, etc. The computer 10 may be implemented by a single computer or by multiple computers, such as a cloud computer. Note that the cloud computer in this specification may refer to either a computer that uses any computer in a scalable manner to perform a specific function or a system that includes multiple functional modules and uses the functions in any combination to realize a system.

[0017] The computer 10 executes each process executed by the warehouse control system 1. The computer 10 includes a memory unit 16 such as a hard disk, semiconductor memory, recording medium, memory card, etc. as a data storage unit. The computer 10 includes a processor 11 such as various devices that execute various processes. The computer 10 is connected to a picking system 2, a warehouse management system (WMS) 3, and an external input 4 via a network 5.

[0018] The picking system 2 is an automated case warehouse with a product storage function, and when the warehouse control system 1 outputs a picking control instruction for a product to be shipped, the picking system 2 dispenses a specified case (bin or container) in accordance with the instruction.

[0019] The warehouse management system (WMS) 3 is a system having functions such as general warehouse entry / exit management and inventory management.

[0020] 1, the warehouse control system 1 is a system that controls the "equipment" in a warehouse in real time and issues shipping operation commands to various material handling devices, and is connected to at least a picking system 2, a WMS 3, and an external input 4 via a network 5 such as a public line network or an intranet so that data communication is possible. Note that the components of the warehouse control system 1 are merely examples, and the number, types, and functions of terminals, devices, and other unmanned transport vehicles not shown can be changed as appropriate.

[0021] The computer 10 includes a processor 11 such as a CPU (Central Processing Unit), a GPU (Graphics Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory), etc., and a communication unit 15 such as a device that enables communication with other terminals, devices, etc.

[0022] The external input 4 is used to input data from devices external to the warehouse control system 1, and location change instructions, case removal instructions, placement change notifications, etc. are sent from workers and robots through the external input 4.

[0023] An overview of the processing steps performed by the warehouse control system 1 when rearranging the products 110 will be described. The control modes of the warehouse control system 1 according to this embodiment include a shipping mode and an inventory change mode. First, the instruction configuration in the shipping mode of the warehouse control system 1 according to this embodiment will be described with reference to FIG. 2. In the shipping mode, the products 110 stored on the storage shelves are shipped based on a shipping order for the products 110.

[0024] In the shipping mode, the WMS 3 issues a shipping instruction for the product 110 to the warehouse control system 1 based on a shipping order. When the warehouse control system 1 receives the shipping instruction from the WMS 3, it further transmits the shipping instruction to the picking system 2. When the picking system 2 receives the shipping instruction from the warehouse control system 1, it controls its own automated case warehouse to dispense the cases 100 containing the product 110 to be shipped.

[0025] Thereafter, the picking system 2 updates the inventory information and transmits the updated inventory information to the warehouse control system 1. The warehouse control system 1 updates the inventory information stored therein and transmits the updated inventory information to the WMS 3. Upon receiving the inventory information 200, the WMS 3 updates the inventory information 200 stored therein.

[0026] 3 is a diagram illustrating the inventory change mode of the warehouse control system 1 according to this embodiment. In the inventory change mode, when a shipping instruction for the product 110 has not been received, the product 110 is removed from the case 100 by the picking system 2 and the location of the product 110 stored on the storage shelf is changed. The case 100 is a container for storing the product 110.

[0027] The warehouse control system 1 receives an instruction to change the location of the product 110 stored on a storage shelf from an external input 4 (S1). Specifically, the warehouse control system 1 receives an instruction to change the location of the product 110 from a worker's terminal or a robot via the external input 4.

[0028] The warehouse control system 1 outputs a removal instruction for the case 100 to the picking system 2 (S2). Specifically, the warehouse control system 1 outputs a removal instruction for the case 100 specified in the location change instruction received in S1 to the picking system 2. As a result, the picking system 2 removes the specified case 100.

[0029] The warehouse control system 1 receives a notification of a change in the arrangement of the products 110 stored on the storage shelves from the external input 4 (S3). The notification of the change in arrangement is sent via the external input 4 when the worker's terminal or the robot completes the work of changing the arrangement of the products 110.

[0030] The warehouse control system 1 outputs a storage instruction for the case 100 to the picking system 2 (S4). Specifically, after receiving the above-mentioned notification of the change in arrangement in S3, the warehouse control system 1 outputs to the picking system 2 a storage instruction for the case 100 in which the arrangement of the products 110 has been changed by a worker or a robot, and an instruction to change the location information in the inventory information 200.

[0031] The warehouse control system 1 sends an instruction to the picking system 2 to output the inventory information 200 (S5), receives the inventory information 200 from the picking system 2 (S6), and stores it in its own storage unit (S7).

[0032] The warehouse control system 1 displays the inventory information 200 stored in its own memory unit 16 on its own display unit 14 (S8). This allows a user of the warehouse control system 1 to view the inventory information stored by the warehouse control system 1 on the display unit 14. At this time, the warehouse control system 1 may output the inventory information 200 received from the picking system 2 to a worker's terminal or a robot from the output unit 13 or the communication unit 15.

[0033] The picking system 2 receives the case 100 removal record data 300 from the picking system 2 (S9), stores it in the memory unit 16 (S10), and creates and stores in the memory unit 16 (S11) the product 110 rearrangement record data 400. After the picking system 2 removes the case 100, the picking system 2 transmits the case 100 removal record data 300 to the warehouse control system 1.

[0034] The warehouse control system 1 transmits the product 110 rearrangement performance data 400 stored in its own storage unit 16 to the WMS 3 (S12). As a result, the WMS 3 performs inventory transfer processing and updates the inventory transfer data, inventory data, and inventory receipt and payment data stored therein.

[0035] The warehouse control system 1 transmits the inventory information 200 stored in its own storage unit 16 to the WMS 3 (S13).

[0036] The warehouse control system 1 transmits an instruction to output the inventory information 200 to the WMS 3 and receives the inventory information 200 from the WMS 3 system 2 (S14).

[0037] The warehouse control system 1 creates inventory report data based on the inventory information 200 acquired from the picking system 2, and transmits the created inventory report data to the WMS 3 and stores it in the memory unit 16 (S15).

[0038] 6 to 8 are diagrams illustrating the work involved in changing the location of products 110 stored on a storage shelf. In each diagram, there is one case 100A before the location change and one case 100B after the location change, each with four openings. An opening is a partitioned area of ​​any volume within the case 100. The openings where the products 110 are stored are shown shaded. FIG. 9 is a diagram illustrating the work of changing the location of the products 110 by a worker.

[0039] 6 is a diagram illustrating the work of replacing the products 110. In FIG. 6, before the consolidation work, the packages are stored in the opening a-1 of case 100A and the opening b-3 of case 100B. When a worker or a robot replaces the products 110, the products 110 in the opening a-1 of case 100A are moved to the open opening b-3 of case 100B, and the products 110 in the opening b-3 of case 100B are moved to the open opening a-1 of case 100A. Note that there is no change in the inventory quantity of the moved products 110.

[0040] 7 is a diagram illustrating the consolidation work of products 110. In FIG. 7, before the consolidation work, products 110 are stored in the opening a-1 of case 100A and in the opening b-3 of case 100B. When a worker or a robot consolidates the products 110, the products 110 in the opening a-1 of case 100A are moved to the open opening b-1 of case 100B, and the products 110 are consolidated in case 100B. Note that there is no change in the inventory quantity of the moved products 110.

[0041] 8 is a diagram illustrating the division of products 110. In FIG. 8, before the division, products 110 are stored in opening a-1 of case 100A and opening b-3 of case 100B. When a worker or a robot divides the products 110, the products 110 in opening a-1 of case 100A are divided into open openings b-1 and b-4 of case 100B. Note that the inventory quantity of the moved products 110 remains unchanged.

[0042] The above is an overview of the warehouse control system 1.

[0043] According to the warehouse control system 1, it is possible to dispense cases 100 from the picking system 2 even when no loading / unloading instructions have been received, and further, it is possible to change the location of inventory items 110 stored in the picking system 2 (replacement, consolidation, division, etc. of the items 110).

[0044] [Warehouse Control Processing in Inventory Change Mode] The warehouse control processing executed by the computer 10 of the warehouse control system 1 when inventory is changed will be described with reference to FIG.

[0045] By the above-mentioned S1, the reception unit 12 of the computer 10 receives an inventory change mode in which an instruction to dispense the case 100 is issued to the picking system 2, which stores and picks the case 100 containing the product 110, and by the above-mentioned S2, the processor 11 of the computer 10 issues an instruction to the picking system 2 to dispense the specified case 100 in the inventory change mode.

[0046] In the inventory change mode, the processor 11 of the computer 10 outputs to the picking system 2 an instruction to output inventory information 200 of the products 110 stored on the storage shelves in the above-mentioned S5. Specifically, a user of the warehouse control system 1 performs an input to acquire the inventory information 200 on the display unit 14 of the computer 10, whereby a request to acquire the inventory information 200 is output to the picking system 2. Next, in the above-mentioned S6 and S7, the inventory information 200 received from the picking system 2 is stored in the memory unit 16. The inventory information 200 includes product information 220 and case information 210.

[0047] The processor 11 of the computer 10 causes the display unit 14 to display the inventory information 200 received from the picking system 2 through the above-described steps S6 and S8. This allows a user of the warehouse control system 1 to view the inventory information displayed on the display unit 14. At this time, the processor 11 of the computer 10 may also output the inventory information 200 received from the picking system 2 from the output unit 13 or the communication unit 15 to a worker's terminal or a robot.

[0048] In the inventory change mode, the reception unit 12 of the computer 10 receives an instruction to change the location of the product 110 from the external input 4 in accordance with the above-mentioned S1. Specifically, the aggregation conditions for the inventory products 110 are set by a worker's terminal or a robot, and the reception unit 12 of the computer 10 receives the instruction to change the location of the product 110 via the external input 4. Next, in the above-mentioned S2, the processor 11 of the computer 10 outputs an instruction to the picking system to remove the target case 100.

[0049] The processor 11 of the computer 10 receives the actual dispensing data 300 for the case 100 from the picking system 2 by the above-mentioned S9, stores the data in the memory unit 16 by the above-mentioned S10, and creates the actual placement change data 400 for the product 110 by the above-mentioned S11 and stores the data in the memory unit 16.

[0050] In accordance with S12 described above, the processor 11 of the computer 10 outputs the product 110 rearrangement performance data 400 to the WMS 3. As a result, the WMS 3 performs inventory movement processing and updates the inventory movement data, inventory data, and inventory receipt and payment data stored therein.

[0051] The processor 11 of the computer 10 outputs an instruction to the picking system 2 to output the inventory information 200 by the above-mentioned S5, and creates inventory report data by the above-mentioned S15 based on the inventory information 200 obtained from the picking system 2 by the above-mentioned S6, and sends the created inventory report data to the WMS 3 and stores it in the memory unit 16.

[0052] [Case Transport Instruction Processing in Inventory Change Mode] The case transport instruction processing in the inventory change mode executed by the computer 10 of the warehouse control system 1 will be described with reference to FIG.

[0053] First, the computer 10 acquires location information of the stock items 110 from the picking system 2 (step S21). Specifically, in step S5, the computer 10 sends an output instruction for the stock information 200 to the picking system 2, and in step S6, the computer 10 receives the stock information 200 from the picking system 2. The stock information 200 includes location information of the stock items 110.

[0054] Next, the computer 10 displays the location information of the stock items 110 (step S22). Specifically, by performing step S8, the computer 10 displays the inventory information 200 of the stock items 110 received in step S21 on its own display unit 14. At this time, the computer 10 may output the location information of the stock items 110 received from the picking system 2 to a worker's terminal or a robot from the output unit 13 or the communication unit 15.

[0055] Next, the computer 10 receives an instruction to change the location of the stock item 110 (step 23). Specifically, in step S1, the computer 10 receives an instruction to change the location of the item 110 via the external input 4 from the worker's terminal or the robot.

[0056] Next, the computer 10 outputs a removal instruction for the case whose location is to be changed to the picking system (step S24). Specifically, in step S2 described above, the warehouse control system 1 outputs a removal instruction for the case 100 specified in the location change instruction for the product 110 to the picking system 2. As a result, the picking system 2 removes the specified case 100.

[0057] The above is an outline of the case transport instruction process in the inventory change mode.

[0058] [Inventory Information Update Process in Inventory Change Mode] The inventory update process in the inventory change mode executed by the computer 10 of the warehouse control system 1 will be described with reference to FIG.

[0059] First, after changing the location of the inventory items in the dispensed case, the computer 10 instructs the picking system 2 to change the location information of the inventory items 110 (step 31). Specifically, after receiving the location change notification in S3 above, the computer 10 instructs the picking system 2 to update the inventory information 200 when issuing the storage instruction in S4 above.

[0060] Next, the computer 10 instructs the WMS 3 to change the location information of the inventory items 110 (step S32). Specifically, in step S12, the computer 10 transmits the product 110 location change performance data 400 stored in its own memory unit 16 to the WMS 3.

[0061] The above is an outline of the inventory update process in the inventory change mode.

[0062] The above-described means and functions are realized by a computer (including a CPU, an information processing device, and various terminals) reading and executing a predetermined program. The program may be provided, for example, from a computer via a network (Software as a Service (SaaS)) or as a cloud service. The program may also be provided in a form recorded on a computer-readable recording medium. In this case, the computer reads the program from the recording medium, transfers it to an internal or external recording device, records it, and executes it. The program may also be pre-recorded on a recording device (recording medium) and provided to the computer from the recording device via a communication line.

[0063] Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments. Furthermore, the effects described in the embodiments of the present invention are merely a list of the most preferable effects resulting from the present invention, and the effects of the present invention are not limited to those described in the embodiments of the present invention.

[0064] According to the present invention, it is possible to dispense cases 100 from the picking system 2 even when no loading / unloading instructions have been received, and furthermore, it is possible to change the location of inventory items 110 stored in the picking system 2 (replacement, consolidation, division, etc. of items 110).

[0065] Embodiments of the present invention are briefly described below.

[0066] (1) A warehouse control system comprising: a reception unit that receives an inventory change mode that issues a case dispensing instruction to a picking system that stores and picks cases containing products; and a processor that issues a specified case dispensing instruction to the picking system in the inventory change mode.

[0067] (2) The warehouse control system described in (1) further comprises a memory unit, wherein the processor, in the inventory change mode, outputs an instruction to the picking system to output inventory information including product and case information stored on storage shelves, and stores the inventory information received from the picking system in the memory unit.

[0068] (3) The warehouse control system according to (2), further comprising a display unit, wherein the processor displays the inventory information received from the picking system on the display unit.

[0069] (4) The warehouse control system described in (1) is characterized in that, in the inventory change mode, the reception unit receives an instruction to change the product placement from an external input, and the processor outputs an instruction to the picking system to remove the target case.

[0070] (5) The warehouse control system described in (2) is characterized in that the processor receives case removal performance data from the picking system and stores it in the memory unit, and creates product placement change performance data and stores it in the memory unit.

[0071] (6) The warehouse control system according to (5), wherein the processor outputs the product placement change performance data to a warehouse management system.

[0072] (7) The warehouse control system described in (2) is characterized in that the processor outputs an instruction to the picking system to output inventory information including product and case information stored on storage shelves, creates inventory report data based on the inventory information obtained from the picking system, transmits the inventory report data to the warehouse management system, and stores it in the memory unit.

[0073] (8) A warehouse control method executed by a warehouse control system that issues case transport instructions to a picking system that stores and manages cases containing products on storage shelves, the warehouse control method including: an information acquisition step that acquires location information of inventory products from the picking system; a display step that displays the location information of the inventory products; a reception step that receives an instruction to change the location of the inventory products; and an instruction step that outputs a dispensing instruction for the case whose location is to be changed to the picking system.

[0074] (9) The warehouse control method described in (8) further includes a first inventory information update step of instructing the picking system to change the location information of the inventory items after the location of the inventory items in the dispensed case has been changed, and a second inventory information update step of instructing the warehouse management system to change the location information of the inventory items.

[0075] (10) A computer-readable program that causes a computer to execute the following steps: an information acquisition step of acquiring location information of inventory items from a picking system; a display step of displaying the location information of the inventory items; a reception step of receiving an instruction to change the location of the inventory items; and an instruction step of outputting an instruction to the picking system to dispense cases whose locations are to be changed.

[0076] (11) The computer-readable program described in (10) further causes the computer to execute: a first inventory information update step of instructing the picking system to change the location information of the inventory items after the location of the inventory items in the dispensed case is changed; and a second inventory information update step of instructing the warehouse management system to change the location information of the inventory items.

[0077] REFERENCE SIGNS LIST 1 Warehouse control system 2 Picking system 3 WMS 4 External input 5 Network 10 Computer 11 Processor 12 Reception unit 13 Output unit 14 Display unit 15 Communication unit 16 Storage unit 100 Case 110 Product 200 Inventory information 210 Case information 220 Product information 300 Dispense record data 400 Placement change record data

Claims

1. A warehouse control system comprising: a reception unit that receives an inventory change mode that issues a case dispensing instruction to a picking system that stores and picks cases containing products; and a processor that issues a specified case dispensing instruction to the picking system in the inventory change mode.

2. The warehouse control system of claim 1, further comprising a memory unit, wherein the processor, in the inventory change mode, outputs an instruction to the picking system to output inventory information including product and case information stored on storage shelves, and stores the inventory information received from the picking system in the memory unit.

3. The warehouse control system according to claim 2, further comprising a display unit, wherein the processor causes the inventory information received from the picking system to be displayed on the display unit.

4. The warehouse control system described in claim 1, characterized in that the reception unit receives instructions to change the product placement from an external input in the inventory change mode, and the processor outputs instructions to the picking system to remove the target case.

5. The warehouse control system described in claim 2, characterized in that the processor receives case removal performance data from the picking system and stores it in the memory unit, and creates product placement change performance data and stores it in the memory unit.

6. The warehouse control system according to claim 5, wherein the processor outputs the product placement change performance data to a warehouse management system.

7. The warehouse control system according to claim 2, wherein the processor outputs an instruction to the picking system to output inventory information including product and case information stored on storage shelves, creates inventory report data based on the inventory information obtained from the picking system, transmits the inventory report data to the warehouse management system, and stores it in the memory unit.

8. A warehouse control method executed by a warehouse control system that issues case transport instructions to a picking system that stores and manages cases containing products on storage shelves, the warehouse control method including: an information acquisition step of acquiring location information of inventory products from the picking system; a display step of displaying the location information of the inventory products; a reception step of receiving an instruction to change the location of the inventory products; and an instruction step of outputting an instruction to the picking system to dispense the cases whose locations are to be changed.

9. The warehouse control method according to claim 8, further comprising: a first inventory information update step of instructing the picking system to change the location information of the inventory items after the location of the inventory items in the dispensed case has been changed; and a second inventory information update step of instructing the warehouse management system to change the location information of the inventory items.

10. A computer-readable program that causes a computer to execute an information acquisition step of acquiring location information of inventory items from a picking system, a display step of displaying the location information of the inventory items, a reception step of receiving an instruction to change the location of the inventory items, and an instruction step of outputting an instruction to the picking system to dispense cases whose locations are to be changed.

11. The computer-readable program according to claim 10, further causing a computer to execute: a first inventory information update step of instructing a picking system to change the location information of the inventory items after the location of the inventory items in the dispensed case has been changed; and a second inventory information update step of instructing a warehouse management system to change the location information of the inventory items.

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