High-Density Micro-Fulfillment G2P Replenishment from Store Shelves
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Solution Overview
Problem
Supermarket operators face challenges in fulfilling online grocery orders profitably due to high labor costs, inaccurate inventory management, and customer dissatisfaction from chaotic in-store picking, which traditional P2G picking methods exacerbate.
Innovation Solution
Implementing a goods-to-picker (G2P) order-picking process with an automated system that stores inventory separately, using a micro-fulfillment center (MFC) for efficient order fulfillment, reducing labor costs and improving inventory accuracy by integrating robotic pickers and a hybrid storage system for static and transient inventory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If P2G picking is used in self-service stores, then customers can pick their own orders, but labor costs for picking and handling orders increase significantly
Solution Approach 1:
The system segments the fulfillment process by creating a dedicated automated picking area separate from customer shopping areas. Pickers work at stationary stations within the automated system rather than traveling through store aisles, dividing labor into specialized zones for receiving, picking, and dispensing orders.
Solution Approach 2:
An automated order fulfillment system acts as an intermediary between customers and store inventory. The system includes automated receiving of goods, stationary picking stations with robotic assistance, and automated order assembly, mediating the fulfillment process to reduce manual labor while maintaining customer service capability.
2Productivity
If pickers are deployed on store floor for online order fulfillment, then orders can be picked, but the store environment becomes chaotic and customer experience degrades
Solution Approach 1:
The picking operation is extracted from the customer-facing store environment and relocated to a dedicated automated fulfillment area. Pickers remain at stationary workstations within the automated system, completely separated from customer shopping aisles, eliminating the chaotic interaction between pickers and customers while maintaining full order fulfillment capability.
3Ease of operation
If inventory is stored on store shelves for customer access, then customers can shop, but inventory accuracy for online ordering becomes difficult to maintain
Solution Approach 1:
The system segments inventory management by maintaining separate tracking systems for customer-facing shelf inventory and fulfillment-bound inventory. The automated system tracks inventory at receiving and picking stations independently, providing precise inventory data for online orders without interfering with customer shopping access to store shelves.
4Productivity
If automated G2P system is installed, then picking efficiency increases, but space requirements for the system increase
Solution Approach 1:
The automated system utilizes vertical space through multi-level picking stations and stacked storage configurations. The system extends in the vertical dimension with multiple tiers of product storage and picking surfaces, allowing high-density inventory storage and efficient picking within a compact horizontal footprint.
Data Source
AI summary
A micro-fulfillment center fulfills orders for goods including both in-store picking of goods and online ordering of goods. Orders are fulfilled using both a picker to goods (P2G) model and an automated goods to picker (G2P) model. In examples, goods are replenished to the automated G2P system from store shelves which also serve the P2G model.