Batch Receptacle Storage for Order Fulfillment
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Solution Overview
Problem
Existing order fulfillment systems face challenges in managing large numbers of small orders with varying item characteristics and fluctuating demand, leading to inefficiencies in space utilization and labor management, particularly in manual storage facilities.
Innovation Solution
Implementing a hybrid system that combines manual picking with automated storage and retrieval, using batch receptacles to group items from multiple orders, which reduces the number of containers handled and improves storage efficiency, and utilizing cross-conveyance locations within the racking system to streamline the sorting and retrieval process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual picking is used to handle individual items from large inventory warehouses, then flexibility in handling various item characteristics is improved, but labor costs and processing time increase
Solution Approach 1:
The system segments the order fulfillment process into two distinct phases: batch picking phase where multiple items for multiple orders are collected together, and sorting phase where items are separated into individual orders. This segmentation allows manual pickers to efficiently gather items without worrying about individual order sorting, improving productivity while maintaining flexibility in handling various item characteristics.
Solution Approach 2:
The patent introduces an intermediary sorting station or system that acts as a mediator between the batch picking process and final order assembly. This intermediary handles the complex sorting task, allowing manual pickers to focus solely on efficient item collection, thereby reducing labor costs and processing time while maintaining adaptability.
2Manufacturing precision
If items are picked individually and stored in separate containers, then order accuracy is improved, but the number of containers handled increases and space utilization decreases
Solution Approach 1:
The system merges multiple items destined for different orders into single batch containers during the picking phase. This consolidation dramatically reduces the total number of containers that need to be handled and stored, improving space utilization. The merged containers are later sorted at an intermediary station to ensure order accuracy is maintained.
Solution Approach 2:
The patent transitions from a one-to-one mapping (one item per container per order) to a many-to-many mapping (multiple items per batch container serving multiple orders). This dimensional change in the container-item-order relationship allows efficient space utilization while maintaining order accuracy through the subsequent sorting process.
3Productivity
If automated storage facilities are used to increase throughput, then processing speed is improved, but the system complexity and initial costs increase
Solution Approach 1:
The system segments automation into a dedicated sorting station rather than automating the entire order fulfillment process. This selective automation approach increases throughput at the critical sorting bottleneck while keeping overall system complexity manageable by leaving the batch picking process manual.
Solution Approach 2:
The patent introduces an intermediary automated sorting station that bridges the manual batch picking process and final order assembly. This intermediary handles the complex sorting task automatically, increasing throughput without requiring full automation of the entire system, thereby balancing productivity improvement with acceptable system complexity.
4Area of stationary object
If batch receptacles are used to group items from multiple orders, then the number of containers handled is reduced and storage efficiency improves, but the sorting process complexity increases
Solution Approach 1:
The patent introduces an intermediary automated sorting station that handles the complexity of sorting batch receptacles into individual orders. This intermediary absorbs the sorting complexity, allowing the batch picking and storage processes to remain simple and efficient. The intermediary station manages the complex decision-making required for accurate sorting without burdening the manual pickers or storage systems.
Data Source
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AI summary
Method of fulfilling orders comprising: manually picking items batch-wise by combining several items from several different orders into a common container from inventory according to orders for the items; - forwarding the common container to an unloading station, wherein the items are placed into receptacles by placing multiple items into each of batch receptacles; - routing at least some of the batch receptacles to a pack stations and storage facility and storing the batch receptacles therein; - when all of the individual items stored in the automated storage facility are available to complete an order, retrieving and transporting the stored batch receptacles containing these items to one of plurality of pack stations for specific item retrieval for fulfilling said order; packing retrieved items with other retrieved items of an order at a pack station; and routing the batch receptacles to further pack stations.