Inventory System Segmentation for Order Fulfillment

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Solution Overview

Problem

Modern inventory systems face inefficiencies in order fulfillment due to complex and diverse inventories, leading to lower throughput, delayed tasks, and unacceptable response times, necessitating better resource utilization.

Innovation Solution

An inventory system with mobile drive units and inventory holders that dynamically assign and transport inventory items based on product velocity, allowing stationary holders to maintain high-demand items while mobile units replenish and repurpose inventory, using a combination of stationary and mobile inventory holders and arrays to optimize inventory management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If all inventory items are transported to the inventory station using mobile drive units, then order fulfillment flexibility is improved, but system resource efficiency deteriorates due to continuous transportation overhead

Engineering Contradiction:

Improveorder fulfillment flexibilityVSAvoidtransportation overhead

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The inventory system is segmented into stationary inventory holders at the inventory station and mobile inventory holders. High-velocity items are kept in stationary holders to eliminate continuous transportation overhead, while mobile holders are used selectively for other items, thus segmenting the transportation function based on item characteristics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically determines whether to use stationary or mobile inventory holders based on product velocity calculations. This dynamic approach allows the system to adapt resource allocation to actual demand patterns, improving efficiency while maintaining flexibility.

Inventive Principle:

Principle #15Dynamics

2Productivity

If stationary inventory holders are used for high-demand items, then system efficiency is improved by reducing transportation overhead, but adaptability deteriorates due to fixed positioning

Engineering Contradiction:

Improvesystem efficiencyVSAvoidinventory holder flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the operational parameter of inventory holders from mobile to stationary based on product velocity thresholds. High-velocity items trigger stationary positioning to maximize efficiency, while lower-velocity items remain mobile, allowing parameter changes that optimize both efficiency and adaptability.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If mobile drive units continuously transport inventory holders, then inventory availability is improved, but resource utilization deteriorates due to idle mobile units

Engineering Contradiction:

Improveinventory availabilityVSAvoidresource utilization

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system segments inventory holders into stationary and mobile categories based on demand patterns. Stationary holders continuously supply high-velocity items without requiring mobile unit intervention, freeing mobile units to handle other tasks and improving overall resource utilization while maintaining inventory availability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Stationary inventory holders at the inventory station enable self-service for high-velocity items, allowing the system to fulfill orders for these items without requiring mobile drive unit intervention. This self-service mechanism improves resource utilization by eliminating idle mobile units while maintaining inventory availability.

Inventive Principle:

Principle #25Self-service

4Productivity

If inventory items are dynamically reassigned based on product velocity, then order fulfillment rate is improved, but system complexity increases due to reallocation logic

Engineering Contradiction:

Improveorder fulfillment rateVSAvoidreallocation logic

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system uses product velocity as a key parameter to determine inventory holder positioning. By monitoring changes in product velocity and dynamically adjusting the stationary/mobile status of inventory holders, the system optimizes order fulfillment rates while managing complexity through parameter-based decision rules.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9346620B2System and method for order fulfillment

Publication Date: 2016.05.24 AMAZON TECH INC

AI summary

A system includes a first mobile drive unit and a second mobile drive unit. The system also includes a first inventory holder, a second inventory holder, and a third inventory holder. An inventory station includes a first location and a second location and the inventory station operable to receive a first inventory item from the first inventory holder at the first location. The first inventory holder is transported by the first mobile drive unit. The inventory station is also operable to receive a second inventory item from the second inventory holder at the first location. The second inventory holder is transported by the second mobile drive unit. The inventory station is also operable to receive a third inventory item from the third inventory holder at the second location. The third inventory holder is fixed at the second location while the inventory station receives the first inventory item and the second inventory item.