Hierarchical Inventory Counting System for Parallel Warehouse Operations
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Solution Overview
Problem
Current inventory tracking systems are impractical for large warehouses, as they often require counting at the lowest level of resolution, leading to inefficiencies and incomplete counts, especially when counting locations like warehouses or resources like trucks, which can remain uncounted, and often necessitate halting stock movement until the entire count is finished.
Innovation Solution
A computer-implemented method and system for hierarchical inventory counting that allows counting at multiple levels, enabling parallel counting across different locations and facilitating flexible tracking using various parameters, including material, storage containers, locations, and resources, with the ability to generate reports at different hierarchical levels and support RFID tagging for increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If inventory counting is performed at the lowest level of resolution (individual items), then measurement precision is improved, but productivity deteriorates due to the extensive time and resources required
Solution Approach 1:
The patent segments the inventory counting process into multiple hierarchical levels (location level, resource level, and item level). Counting can be performed at different granularities depending on needs - counting entire locations or resources in bulk, or drilling down to individual items only when necessary. This segmentation allows the system to balance precision requirements with productivity constraints by avoiding unnecessary detailed counting.
2Measurement precision
If complete inventory counting is required for all locations, then measurement precision is improved, but loss of time increases due to the need to halt stock movement
Solution Approach 1:
The patent implements partial counting by allowing users to count only specific portions of inventory rather than requiring complete enumeration of all items. The system supports counting at aggregate levels (locations, resources) and only drills down to individual items when discrepancies are detected or detailed analysis is required. This partial action approach maintains adequate inventory accuracy while significantly reducing the time and operational disruption required.
3Device complexity
If inventory systems track only at the lowest level (bins), then device complexity is reduced, but adaptability deteriorates as the system cannot flexibly count at higher hierarchical levels
Solution Approach 1:
The patent adds a hierarchical dimension to the inventory system by organizing data across multiple levels (locations, resources, bins, items) rather than tracking only at the lowest level. This dimensional expansion allows the system to flexibly aggregate and report at any hierarchical level while maintaining the underlying detailed data structure. The system can adaptively switch between counting entire locations versus individual items based on operational needs without requiring structural changes.
Data Source
AI summary
A computer-implemented method for counting stock stored in hierarchical levels at a facility is described. The method includes receiving count initiation information at a counting module. The count initiation information includes at least one parameter associated with stock to be counted and one or more hierarchical levels for the stock to be counted. The method also includes receiving quantity information associated with the one or more hierarchical levels, and generating count results based on the received quantity information. In certain embodiments, the quantity information can be received by multiple count activity objects associated with the counting module. Each count activity object can independently track separate portions of the quantity information.