Dynamic Buffer System for Partial Order Packaging
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Solution Overview
Problem
The existing goods storage systems, particularly batch buffers, face inefficiencies due to the need for large facilities, long buffer lengths, high energy consumption, and limited design flexibility, resulting in poor integration and low sorting efficiency within the system.
Innovation Solution
Implementing a dynamic buffer system that checks for sufficient goods to fill a specified number of shipping containers, allowing for partial packaging and transport to the picking workstation, thereby reducing the number of goods in transit and optimizing buffer lengths, and using a buffer tax calculator to manage the movement of ready-to-pack goods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire order is stored in the batch buffer, then the order can be completely packaged, but the buffer size and equipment size must be large
Solution Approach 1:
The batch buffer is divided into multiple buffer lanes (at least two), allowing different portions of orders to be stored simultaneously in different lanes. This enables the system to process multiple orders in parallel and reduces the required size of each individual buffer lane while maintaining overall order completion capability.
Solution Approach 2:
The system allows packaging to proceed with partial order quantities rather than waiting for complete order assembly. When sufficient goods for at least one shipping container are available in the buffer, packaging begins immediately, even if the entire order is not yet complete. This reduces buffer occupancy time and required buffer size.
2Reliability
If the entire order is stored in the batch buffer, then the order can be completely packaged, but the dwell time of goods in the buffer is long
Solution Approach 1:
The system initiates packaging operations as soon as sufficient goods for at least one shipping container are available in the buffer, rather than waiting for the entire order to be complete. This partial action approach significantly reduces the dwell time of goods in the buffer while still ensuring complete order fulfillment through subsequent packaging steps.
Solution Approach 2:
The packaging process continues continuously as goods become available in the buffer, rather than operating in discrete batches waiting for complete orders. Multiple shipping containers can be packaged in sequence, maintaining continuous useful action and minimizing idle time for both goods and packaging equipment.
3Quantity of substance
If long buffer lanes are used to store entire orders, then orders can be completely stored, but the length-to-width or length-to-height ratio is unfavorable
Solution Approach 1:
The buffer is segmented into multiple shorter buffer lanes arranged in parallel, rather than using a single long buffer lane. This segmentation allows the system to achieve the same total storage capacity while maintaining more favorable dimensional ratios for each individual lane, improving integration into warehouse structures.
4Quantity of substance
If long buffer lanes are used to store entire orders, then orders can be completely stored, but the integration into warehouse structure is difficult
Solution Approach 1:
The buffer system is divided into multiple modular buffer lanes that can be independently configured and integrated into existing warehouse structures. This modular approach provides greater design freedom and easier integration compared to a single long buffer lane, while maintaining the required storage capacity for order fulfillment.
5Device complexity
If continuous flow of goods is achieved without further measures, then the process is simple, but the flow efficiency and sorting degree are low
Solution Approach 1:
Goods are pre-sorted and grouped in the buffer lanes before entering the packaging station. The system prepares order portions in advance during buffer storage, so that when goods reach the packaging station, they are already organized and ready for efficient packaging. This preliminary action increases flow efficiency without significantly increasing process complexity.
Data Source
Figure 1
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AI summary
The invention relates to a method for picking order goods which are allocated to an order comprising a plurality of shipping containers. In the method, order goods allocated to the order are removed from a store (2), transported into a dynamic buffer (5), and stored there temporarily. The dynamic buffer (5) comprises an infeed section (6), an outfeed section (7), a plurality of buffer lanes (8) arranged between the infeed section (6) and the outfeed section (7), and at least one return lane (9) arranged therebetween. If a portion of the order goods available in the dynamic buffer (5) is sufficient to fill a predefinable number of shipping containers and is ready for packing, this portion of the order goods ready for packing is discharged from the dynamic buffer (5), transported to a picking workstation (10) and transferred there into the predefined number of shipping containers. The predefined number of shipping containers is smaller here than the total number of shipping containers necessary to fulfil the order. The invention also relates to a goods storage system for carrying out said method.