Custom Container Forming for Cost-Optimized Materials Handling
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Solution Overview
Problem
Existing systems face challenges in optimizing the picking and packaging of items in materials handling facilities, particularly in selecting appropriate containers for shipping that minimize transportation and fulfillment costs while ensuring efficient use of resources and customer satisfaction.
Innovation Solution
A packaging information system that includes an inventory management system, container recommendation service, and custom container forming devices to recommend standard or custom containers based on item dimensions and shipping costs, forming custom containers on demand to optimize packaging operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard containers are used for packaging items, then packaging speed is improved, but transportation costs increase due to excessive container size
Solution Approach 1:
The system dynamically selects between standard and custom containers based on real-time analysis of item dimensions, destination, and cost parameters. Custom containers are formed on-demand with dimensions precisely matched to the items being shipped, transforming the static container selection process into a dynamic optimization system that adapts to each specific shipping scenario.
Solution Approach 2:
The system changes the dimensional parameters of containers by forming custom containers with specific length, width, and height parameters that precisely fit the items. This parameter optimization reduces empty space in containers, thereby reducing transportation costs while maintaining packaging efficiency through automated formation processes.
2Loss of energy
If custom containers are formed on-demand, then transportation costs are reduced, but device complexity increases
Solution Approach 1:
The system incorporates automated container selection and routing logic that self-manages the decision-making process between standard and custom containers. The packaging information system automatically analyzes shipping parameters, selects the optimal container type, and routes items to appropriate formation devices or standard container stations, eliminating the need for manual intervention and reducing operational complexity.
Solution Approach 2:
The packaging information system acts as an intermediary between item data, container options, and formation devices. It receives item dimensional information, evaluates multiple container scenarios, and generates routing instructions to intermediate packing stations or formation devices, simplifying the overall system architecture by centralizing the decision-making function.
3Manufacturing precision
If item dimensions are precisely measured and analyzed, then container fit is optimized, but measurement and processing time increases
Solution Approach 1:
The system performs preliminary dimension analysis and container selection before the actual packaging process. By pre-calculating the optimal container dimensions and selecting the appropriate container type in advance, the system eliminates time-consuming on-site decision-making and ensures precise container fit without adding significant processing time to the overall packaging operation.
Solution Approach 2:
The system replaces manual measurement and container selection processes with automated optical scanning and computer-based optimization algorithms. This substitution of mechanical/manual operations with automated systems enables precise dimensional analysis and container matching to occur rapidly, maintaining high precision while minimizing processing time.
Data Source
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AI summary
Described herein are systems and techniques for determining a pack station for storing inventory in a materials handling facility, routing item packages to pack stations based on size ranges for custom containers and optimizing dimensions of custom containers based on dimensions of a shipping container. For example, the systems described herein may allocate a percentage of inventory to a custom inventory location that is physically near custom container forming devices, thereby reducing the cost to pick, sort, pack and route items for shipment, storing or otherwise handling in a custom container.