Automated Container Replenishment Sequence Generation

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Solution Overview

Problem

The existing methods for replenishing containers with goods in a distribution center are inefficient, as they require manual identification of appropriate containers based on size and type, leading to time-consuming and labor-intensive processes.

Innovation Solution

A method and system that utilize a central controller to receive data on stock keeping units (SKUs) and correlate it with container identifiers, generating an ordered sequence of containers to be retrieved for replenishment, ensuring optimal container selection based on predefined threshold values for both SKUs and containers, thereby automating the replenishment process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual identification of containers is used, then container selection can be made, but the process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvecontainer selection processVSAvoidreplenishment time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system enables self-service by automatically generating the ordered sequence of container identifiers through the central controller, which correlates SKU data with container data and determines the optimal container sequence without requiring manual identification or selection by operators

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical process of identifying and selecting containers is replaced with an automated electronic system that uses a central controller to receive data, perform correlations, and generate the ordered sequence of container identifiers, thereby eliminating manual labor and reducing time

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If manual container selection is used, then containers can be assigned to SKUs, but the process requires significant manpower

Engineering Contradiction:

Improvereplenishment processVSAvoidreplenishment efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The system performs the replenishment assignment automatically through the central controller, which correlates SKU data with container data and generates the ordered sequence without requiring human operators to manually assign containers to SKUs

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual labor component is extracted from the replenishment process by implementing an automated system that handles data reception, correlation, and container sequence generation, leaving only the essential function of replenishment while removing the inefficient manual selection step

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10579964B1Method, apparatus and system for goods replenishment

Publication Date: 2020.03.03 INTELLIGRATED HEADQUARTERS LLC

AI summary

The present disclosure relates to a method for replenishing containers with goods from stock keeping units (SKUs) arriving at a replenishment area in a distribution center. A central controller receives a first set of data comprising a plurality of first predefined threshold values, each indicative of a maximum capacity of goods in a corresponding SKU. The central controller associates the first set of data to a second set of data comprising one or more container identifiers having a second predefined threshold value indicative of a capacity of a corresponding container. Further, the central controller generates an ordered sequence of container identifiers indicative of the containers to be retrieved to the replenishment area for receiving goods from the plurality of SKUs based on the association of the first set of data with the second set of data.