Dynamic Picking Schedule Balancing Workload in Assorting Systems
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Solution Overview
Problem
Conventional total picking methods lead to uneven workload distribution across picking zones, resulting in reduced efficiency and potential overflow at sorting stations due to inadequate space, which hampers the overall picking and sorting process.
Innovation Solution
A picking and assorting system that includes a picking schedule making unit, an automatic storage system, and a controller to manage workload across zones by using first and second containers, with a moving device to redistribute containers and trays, ensuring balanced workload and preventing overflow at sorting stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the total picking method is used to collectively pick articles for multiple shipping destinations, then picking efficiency is improved, but uneven workload distribution across picking zones occurs
Solution Approach 1:
The picking schedule making unit receives feedback information about the number of unassorted articles from the automatic storage system, and uses this feedback to dynamically adjust and regenerate picking schedules. This closed-loop feedback mechanism ensures that picking workloads are continuously balanced across zones while maintaining high collective picking efficiency.
Solution Approach 2:
The system dynamically regens picking schedules based on real-time workload conditions and feedback from the sorting process. Rather than using static schedules, the system adapts picking assignments to current zone capacities and sorting progress, maintaining optimal workload distribution throughout the operation.
2Productivity
If the picking quantity is increased to improve overall picking efficiency, then more articles can be processed, but the assorting station lacks enough space and containers pile up or overflow
Solution Approach 1:
The system performs preliminary actions by proactively moving containers with unassorted articles from the assorting station to the storage area before the station becomes overloaded. The controller monitors article quantities and triggers container movement in advance, preventing space overflow while maintaining high picking throughput.
Solution Approach 2:
The storage area acts as an intermediary buffer between the picking zones and the assorting station. Containers with unassorted articles are temporarily stored in this intermediate area, allowing the assorting station to maintain its space capacity while continuing to receive high volumes of picked articles for processing.
3Productivity
If containers with unassorted articles remain at the assorting station, then sorting can continue, but the station runs out of space to place new containers
Solution Approach 1:
The storage area serves as an intermediary holding zone for containers that have completed picking but not yet finished sorting. This intermediary space allows the assorting station to maintain its operational capacity by offloading finished-picking containers to storage, preventing placement capacity exhaustion while preserving sorting continuity.
Data Source
AI summary
In a picking and assorting system, a control unit makes, based on a volume of buckets, a picking schedule for one batch to be picked from article racks into the buckets. If there are articles that have been loaded into the buckets based on the picking schedule for one batch but remain in trays after sorting, then a warehouse control unit causes carriers to move work-in-progress trays from work shelves to a third tray storage space.