Direct Pallet Conveyor Order Picking System
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Solution Overview
Problem
Current automated order picking systems for FMCGs are economically unprofitable due to goods being handled multiple times, require complex and costly infrastructure, and result in poor ergonomics for workers, while manual systems suffer from long travel times and inefficiencies.
Innovation Solution
A method where goods are directly moved from a source pallet to customer transport aids in a single process step, using standard conveyor technology and ergonomic workstations, eliminating the need for complex destacking units, interim storage, and multiple handling, with automatic plausibility checks to prevent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated destacking units and intermediate storage systems are used, then goods handling automation is improved, but system complexity and infrastructure costs increase significantly
Solution Approach 1:
The invention extracts and eliminates the complex intermediate storage systems and destacking units from the order picking process. Instead of using traditional automated systems with multiple handling steps, the patent directly transports source pallets to picking workstations where goods are picked and immediately placed into customer transport aids, removing unnecessary system components while maintaining automation benefits
Solution Approach 2:
The source pallets serve multiple functions: they act as both the storage container for goods and the transport unit for delivering picked goods to customers. This multi-functionality eliminates the need for separate intermediate storage systems and reduces the number of handling operations, as the same pallet structure is used throughout the process
2Manufacturing precision
If multiple handling steps including destacking and intermediate storage are implemented, then order picking accuracy is improved, but handling costs and processing time increase
Solution Approach 1:
The invention implements continuous order picking by keeping source pallets in constant motion on the conveyor system from storage through picking to customer transport. This eliminates idle time between handling steps and maintains continuous productive action, reducing processing time while automated plausibility checks ensure picking accuracy throughout the continuous process
Solution Approach 2:
Source pallets are prepared in advance with goods arranged for efficient picking, and the conveyor system is pre-configured with multiple picking workstations. This preliminary preparation allows workers to immediately begin picking operations without waiting for goods to be brought to them, reducing processing time while maintaining accuracy through automated verification
3Productivity
If complex automated systems with multiple workstations are used, then order picking efficiency is improved, but infrastructure costs and system complexity increase
Solution Approach 1:
The invention merges multiple functions into a single integrated conveyor-based system. The conveyor line combines storage, transport, and multiple picking workstations into one continuous flow system, eliminating the need for separate automated systems for each function. This consolidation maintains high productivity while significantly reducing infrastructure complexity and costs
Solution Approach 2:
The system allows workers at picking workstations to independently complete order picking tasks using the goods presented on the conveyor belt. Each workstation is self-contained with necessary equipment and information displays, allowing workers to autonomously fulfill customer orders without requiring complex centralized control systems, thereby maintaining efficiency while reducing infrastructure requirements
Data Source
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AI summary
The method involves supplying a source-pallet (Q) by a supply-conveyor line (6) to one of order-picking work-stations of a set of work-stations (A1-Ai). Commissioned goods are received by a customer-transporting aid (T), and commissioning is achieved by an operator of the goods from the source-pallet into the customer-transporting aid at a packing station, which corresponds to a customer ordered goods from the source-pallet. The source pallet is removed from the order-picking work-station at an outlet conveying line (7) back into a pallet warehouse (3) or to another work-station. An independent claim is also included for a system for commissioning a source-pallet of goods in a pallet warehouse according to a customer order, comprising a supply-conveyor line.