Dynamically Configurable Put Wall for Order Fulfillment
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Solution Overview
Problem
Traditional put walls have statically sized slots that are not configurable based on orders, leading to low density and inefficient use of space, as they are designed for maximum capacity orders rather than the smaller items typical of e-commerce orders.
Innovation Solution
A dynamically configurable put wall system with slots that can be adjusted in real-time based on the dimensions of the items to be placed, using a light bar and put wall controller to guide workers in configuring the slot sizes and placing items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed size slots are used in put walls, then the structure is simple and easy to manufacture, but the space utilization is low and the number of slots is limited
Solution Approach 1:
The patent implements movable dividers that allow slot widths to be dynamically adjusted based on item dimensions. Workers can reposition dividers to create slots of varying widths, transforming the static put wall into a dynamic system that adapts to different order requirements, thereby increasing space utilization and the number of可同时处理的订单
Solution Approach 2:
The patent changes the physical parameter of slot width from fixed to variable by introducing movable dividers. The light bar system provides visual guidance for the desired slot width parameter, enabling workers to adjust slot dimensions to match item sizes, optimizing space usage and increasing the number of slots that can be effectively utilized
2Adaptability or versatility
If large fixed size slots are used to accommodate maximum capacity orders, then all order sizes can be handled, but the density of the put wall is low with great deal of unused space
Solution Approach 1:
The movable divider system allows the put wall to dynamically adapt to different order sizes. Small e-commerce orders can be accommodated in narrow slots, while larger orders can use wider slots, eliminating the need to size slots for maximum capacity and thereby significantly improving space utilization across all order types
Solution Approach 2:
The patent applies different slot widths locally across the put wall based on specific order requirements. Instead of uniform large slots, each slot can be locally optimized to the precise width needed for its intended items, maximizing the effective use of the put wall volume
3Productivity
If the number of slots is increased to handle more orders, then order fulfillment efficiency improves, but the physical space requirements increase
Solution Approach 1:
By making slot widths dynamic and adjustable, the put wall can pack more slots into the same physical space. Narrow slots for small items allow increased slot density without increasing the put wall's footprint, thereby handling more orders within the same area
Data Source
AI summary
This system is a dynamically sized put wall comprising: a put wall having a plurality of slots; a slot defined by a first end and a laterally movable/removable divider; a light bar attached to the put wall and in communications with a put wall controller and a server; a set of server computer readable instructions that, when executed by a server processor included in the server, are adapted for receiving or determining a desired width for one or more slots in the put wall; actuating a light segment within a light bar representing a desired slot dimension; receiving an acknowledgement that the laterally movable/removable divider(s) were positioned according to the light segments actuated by the put wall controller, and, placing the put wall controller into put mode.