Automated Container Selection for Unpacked Merchandise Packing
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Solution Overview
Problem
In the retail setting, there is a need for efficiently assembling and arranging unpacked merchandise items in containers to minimize damage during transport and optimize container usage, particularly in fulfillment centers handling large orders, where existing methods often result in wasted space and inefficient use of containers.
Innovation Solution
A system that selects the optimal type and size of containers (boxes or deformable bags) based on merchandise characteristics, using algorithms like best fit decreasing and extreme points heuristics to pack items efficiently, and allows for customization of container sizes and arrangements to accommodate different merchandise types and protect fragile items, while also considering cavity filling and shipping costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual packing methods are used, then flexibility in handling different merchandise types is maintained, but container space utilization is inefficient and packing time increases
Solution Approach 1:
The patent replaces manual mechanical packing operations with an automated system that uses computer algorithms (best fit decreasing, extreme points heuristics) to calculate optimal container assignments and item arrangements. This substitution enables efficient processing of large orders while maximizing container space utilization through automated decision-making.
Solution Approach 2:
The system dynamically adjusts packing parameters such as container size selection, item orientation, and stacking arrangements based on merchandise characteristics and container dimensions. By changing these parameters optimally, the system achieves both high productivity and efficient space utilization.
2Reliability
If more containers are used to ensure adequate protection for merchandise, then item safety during transport is improved, but shipping costs and container waste increase
Solution Approach 1:
The system applies different protection strategies to different merchandise items based on their specific characteristics. Fragile items are assigned to more protective containers or positioned strategically within containers, while robust items can share containers more efficiently. This localized quality approach ensures adequate protection without uniformly over-packaging all items.
Solution Approach 2:
The patent optimizes container selection by nesting items efficiently within appropriately sized containers. The system selects the smallest container that adequately protects each item or group of items, avoiding the use of excessively large containers that would result in waste. This nesting principle ensures protection while minimizing container waste.
3Speed
If rapid packing decisions are made to handle large volumes of orders, then processing speed increases, but packing precision and optimization decrease
Solution Approach 1:
The system performs preliminary calculations of optimal packing arrangements using algorithms before actual packing begins. By pre-calculating the best container assignments and item arrangements based on order data and container specifications, the system enables rapid execution without sacrificing optimization precision during the actual packing process.
Solution Approach 2:
The patent uses virtual modeling and simulation to create digital representations of packing scenarios. The algorithms simulate different packing arrangements in a virtual environment to determine optimal solutions, allowing rapid evaluation of multiple options without physical trial-and-error, thus maintaining precision while increasing speed.
Data Source
AI summary
There are provided systems and methods relating to assembling unpacked merchandise in containers. In one form, the system includes an order of merchandise items to be assembled in containers, and a predetermined set of containers defining different sizes and including at least two different types of containers. The system also includes a control circuit configured to: receive notification of the order, select a first type of container, determine a first subset of the plurality of merchandise items to be received in the selected type of container, select a size of the selected type of container to receive the first subset of merchandise items, and instruct the disposition of the first subset of merchandise items within the selected type and size of container.