Dynamic Put Wall Lighting for Scalable Warehouse Sorting
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Solution Overview
Problem
There is a need for a customizable, simplified sorting and optimized fulfillment approach with streamlined picking, sorting, and shipping efficiency for eCommerce and warehouse management, particularly in systems like Put Walls, which are not adequately scalable or efficient in handling changing demands.
Innovation Solution
A sorting system comprising sorter lights, compartments, and a controller that generates control signals for the sorter lights based on scans from a handheld device, with a graphical user interface to guide sorting operations and include shipper lights to indicate when orders are ready for shipping, allowing for customizable and efficient sorting and shipping processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional Put Wall system is used, then basic sorting functionality is provided, but the system lacks scalability and cannot efficiently handle changing demands
Solution Approach 1:
The system employs dynamic put wall lights that can be individually controlled and reconfigured. Each light unit can be assigned to different compartments based on changing sortation requirements, allowing the system to adapt to varying demands without physical reconfiguration of the entire wall structure.
Solution Approach 2:
The put wall is divided into multiple independently controllable light units or modules. Each module can be controlled separately through the controller, enabling selective activation of specific zones based on current sorting needs and allowing flexible scalability by adding or removing modules as demand changes.
2Productivity
If multiple operators work in the same zone, then labor utilization increases, but confusion and errors may occur due to overlapping work areas
Solution Approach 1:
The system assigns specific colors to different operators or groups of operators, and the put wall lights display these color assignments. Each operator can identify which compartments are assigned to them through color coding, allowing multiple operators to work in the same zone without confusion about where to place items.
Solution Approach 2:
The system provides real-time visual feedback through the put wall lights, displaying which compartments are active, which are assigned to specific operators, and which need attention. This feedback mechanism helps operators coordinate their activities and avoid conflicts when working in the same zone simultaneously.
Data Source
AI summary
A sorting system is provided comprising a sorter lights, compartments, and at least one controller. The controller(s) generate control signals for the sorter lights. Each of the sorter lights is configured to light up to signal which one of the compartments to place an item to be shipped.