Merchandise Order Assembly for Mixed Automated and Manual Retrieval
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Solution Overview
Problem
Existing systems struggle to efficiently assemble merchandise orders that require retrieval from multiple systems, including both automated and offline/manual methods, particularly when handling large or oversized items, leading to inefficient use of containers and unnecessary transfers.
Innovation Solution
A system and method that utilizes an automated retrieval system, a control circuit, and a merchandise database to optimize the arrangement of merchandise in order containers by distinguishing between items retrievable by the automated system and those requiring manual retrieval, and reassigning storage containers as order containers for oversized items, thereby minimizing unnecessary transfers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all merchandise items are retrieved using the automated retrieval system, then retrieval efficiency is improved, but items not capable of automated retrieval cannot be collected
Solution Approach 1:
The system divides merchandise items into two categories: those capable of automated retrieval and those requiring manual retrieval. This segmentation allows the automated retrieval system to efficiently handle eligible items while manual processes handle the remainder, resolving the contradiction between retrieval efficiency and system coverage versatility.
2Quantity of substance
If merchandise items are arranged optimally in order containers, then container utilization is improved, but handling complexity increases
Solution Approach 1:
The system performs preliminary arrangement planning by determining the optimal arrangement of merchandise items in order containers before actual assembly. This advance planning maximizes container utilization while simplifying the physical handling process, as items are already positioned for efficient assembly.
3Ease of operation
If oversized merchandise items are transferred to order containers, then order assembly is improved, but unnecessary transfers and handling occur
Solution Approach 1:
The system extracts oversized merchandise items from the standard automated retrieval and transfer process. These items are identified and handled separately, eliminating unnecessary transfers through the automated system and reducing handling time while maintaining proper order assembly.
4Loss of substance
If storage containers are reassigned as order containers for oversized items, then container waste is reduced, but system complexity increases
Solution Approach 1:
The system implements multi-functionality by allowing storage containers to serve dual purposes: as storage vessels and as order containers for oversized items. This eliminates container waste by reusing existing containers rather than requiring separate order containers, while the control system manages the reassignment complexity.
Data Source
AI summary
There are provided systems and methods for assembling merchandise ordered by customers, such as at shopping facilities. In one form, the system includes: a shopping order interface for receiving merchandise orders; a shopping facility including a merchandise pickup area and a merchandise assembly area; an automated retrieval system for transporting merchandise to the assembly area; an automated retrieval inventory database; an offline retrieval inventory database; and a merchandise database containing dimensions of merchandise. The system also includes a control circuit configured to: receive a merchandise order, determine dimensions of the items in the order, determine an arrangement of the items in order containers, instruct retrieval of items by the automated retrieval system; instruct retrieval of a second set of items not capable of retrieval by the automated retrieval system; and instruct transfer and deposit of the items in the order containers.