Dual-Carrier Order Picking for Mixed Goods and Returns
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Solution Overview
Problem
Existing storage and picking systems fail to optimally adapt to the differences between fast-moving and slow-moving items, as well as new and returned goods, leading to inefficiencies and higher costs.
Innovation Solution
A storage and picking system utilizing two distinct types of loading aids - first loading aids with rigid structures for fast-moving and slow-moving items, and hanging bags made of flexible material for new and returned goods - with dedicated conveyor systems for each, enabling coordinated retrieval and loading into or onto target carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single type of loading aid is used for all items, then device complexity is reduced, but productivity decreases due to inefficient handling of different item types
Solution Approach 1:
The system divides loading aids into two distinct segments: rigid loading aids for fast-moving and slow-moving items, and flexible hanging bags for new and returned goods. This segmentation allows each type to be optimized for its specific function, improving overall picking efficiency without creating excessive complexity through standardized differentiation
Solution Approach 2:
The picking station is designed as a universal interface that can handle both rigid loading aids and flexible hanging bags through the same conveyor system and picking interface. This multi-functionality allows the system to process different item types through a single standardized workstation, maintaining productivity while managing complexity
2Adaptability or versatility
If separate storage areas with different loading aids are used, then adaptability to different item types improves, but device complexity increases
Solution Approach 1:
The storage system is segmented into two distinct areas: a first storage area for rigid loading aids containing fast-moving and slow-moving items, and a second storage area for flexible hanging bags containing new and returned goods. Each segment is optimized for its specific item type while both connect to the same conveyor and picking station through standardized interfaces
Solution Approach 2:
The conveyor system acts as an intermediary that bridges the two different storage areas and the picking station. It provides a standardized transport interface that can handle both rigid loading aids and flexible hanging bags, allowing the system to maintain adaptability while managing complexity through a unifying transport mechanism
3Productivity
If optimized retrieval processes are implemented, then productivity increases, but loss of time in coordination increases
Solution Approach 1:
The system performs preliminary actions by pre-sorting items into appropriate loading aids based on their movement patterns and storage requirements. Fast-moving and slow-moving items are pre-placed in rigid loading aids, while new and returned goods are pre-placed in flexible hanging bags, so that when picking occurs, the items are already optimally positioned and ready for immediate retrieval without coordination delays
Data Source
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AI summary
The invention relates to a storage and order-picking system (1a..1f) and to an order-picking method for picking ordered articles into or onto a target load carrier (4, 4'), wherein at least one of the picking orders includes several order lines (6, 7) specifying an ordered article (2, 3) in terms of article type (8) and number (9) of articles to be picked. When a picking order is carried out, a first load carrier (11, 11a..11c), which is different from a suspension pocket, is retrieved from a first storage area (10) together with the ordered article (2) of the first order line (6). A suspension pocket (13) containing ordered articles (3) of the second order line (7) is retrieved from a second storage area (12). The ordered article (2) of the first order line (6) and the ordered article (3) of the second order line (7) are then loaded into or onto a target load carrier (4, 4') in accordance with the at least one picking order.