Dynamic Container Forming for Order Consolidation
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Solution Overview
Problem
Existing article shipping systems face challenges in efficiently forming shipment containers of the correct size to match the total size of articles indicated by order information, which complicates consolidation work and timing coordination.
Innovation Solution
An article shipping system that includes a container forming device to create shipment containers of various sizes, a housing work area for initial article placement, a consolidation work area for final assembly, a conveyance system, and a control system that determines the housing sequence and coordinates the arrival of containers to simplify consolidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a shipment container is formed to match the size of articles for specific order information, then the container size matches the articles, but it becomes difficult to adjust timing for conveying articles and container to consolidation work area
Solution Approach 1:
The container is formed in advance before the articles are conveyed to the consolidation work area. The container formation occurs at a different location and time, allowing the articles and container to be conveyed independently and arrive at the consolidation area ready for immediate consolidation work.
2Manufacturing precision
If a shipment container is formed for specific order information, then the container matches the article combination, but consolidation work becomes complex due to restricted usage
Solution Approach 1:
The system separates container formation from consolidation work into distinct processes. The container is formed as a separate entity that can be used across multiple order information types, while consolidation work focuses only on housing articles in the pre-formed container, simplifying the consolidation process.
Solution Approach 2:
The pre-formed container serves multiple functions: it can be used for various order information types and can accommodate different article combinations. This universal container can participate in multiple consolidation works, reducing overall system complexity.
3Ease of operation
If articles are housed in a pre-formed container, then consolidation work is simplified, but it requires coordinating arrival timing of container and articles
Solution Approach 1:
The system introduces a conveyance coordination mechanism that acts as an intermediary between container formation and article conveyance. This coordinator manages the timing and routing to ensure the pre-formed container and articles arrive at the consolidation work area in proper sequence, simplifying the overall operation.
4Adaptability or versatility
If the container is formed early, then it can be reused for multiple orders, but it occupies space and resources before needed
Solution Approach 1:
The container formation system operates dynamically, forming containers on-demand based on actual consolidation needs rather than maintaining a static inventory. This allows the system to adapt to varying order requirements while minimizing the quantity of containers that need to be maintained in the system.
Data Source
AI summary
In an article shipping system, a container forming device forms a shipment container that has a size necessary to house articles in a housing sequence determined in housing sequence determination processing, as a target shipment container relating to target order information. A control system controls a conveyance system in a manner such that (i) one or more target conveyance containers in which articles indicated by the target order information are housed arrive at a consolidation work area in a sequence corresponding to the housing sequence determined in the housing sequence determination processing, and (ii) the target shipment container arrives at the consolidation work area before the one or more target conveyance containers arrive.