Mobile Picker and Tote Conveyor Layout for 3D Warehouse Fulfillment
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Solution Overview
Problem
Current inventory management and movement systems in warehouses face inefficiencies in utilizing space, speed, and cost-per-order, particularly in fulfilling internet orders, as they are limited by fixed picker locations and ergonomic height constraints, leading to reduced throughput and increased costs.
Innovation Solution
The implementation of a picker automated vehicle (PAV) system that uses automated guided vehicles to move human pickers and totes within a warehouse, allowing for high-volumetric utilization of space, faster speed, and lower cost-per-order by optimizing the movement of pickers and totes through a network of aisles and conveyors, enabling efficient retrieval and placement of items in a three-dimensional warehouse environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a human picker is placed at a fixed location with robots moving containers to the picker, then the picker can select items and place them in shipping containers, but the system suffers from low space utilization, slow speed, and high cost-per-order
Solution Approach 1:
Instead of moving inventory containers to a fixed picker location (goods-to-picker), the system inverts the approach by moving the picker to the inventory containers (picker-to-goods). The picker travels on an automated vehicle through storage racks, allowing the picker to access multiple bins sequentially, thereby increasing throughput while maintaining ease of item selection.
Solution Approach 2:
The system transitions from a static fixed-picker location to a dynamic mobile picker system. The picker rides on an automated guided vehicle that can dynamically navigate through different aisles and locations within the warehouse, adapting to varying order requirements and optimizing travel paths in real-time.
2Adaptability or versatility
If the picker is moved to multiple locations to access different inventory bins, then more items can be retrieved, but travel time increases and throughput decreases
Solution Approach 1:
The system merges the picker's travel function with the inventory retrieval function by combining the picker's workstation with the automated vehicle. The picker remains at their workstation while the vehicle moves to different locations, or the picker travels on the vehicle, thereby combining transportation and picking operations into a single integrated system that reduces total travel time.
Solution Approach 2:
The system performs preliminary actions by pre-positioning multiple shipping containers at the picker's location before the picker begins their route. The control system plans the picker's path and prepares all necessary containers in advance, allowing the picker to continuously work without interruption for container changes or trips to retrieve items.
3Ease of operation
If fixed picker locations are used with ergonomic height constraints, then worker comfort is maintained, but space utilization and volumetric efficiency are reduced
Solution Approach 1:
The system transitions from two-dimensional horizontal picker locations to three-dimensional mobile access throughout the warehouse volume. The automated vehicle enables the picker to access inventory at various heights and locations throughout the vertical and horizontal space, dramatically increasing volumetric efficiency while maintaining ergonomic conditions through automated positioning and assistance.
Data Source
AI summary
A method and apparatus for a human picker on a picker automated vehicle (PAV) along with its vertical tote conveyors (VTCs) having totes to a successive plurality of inventory stock bins arranged in rows and columns along aisles to move the human picker both horizontally and vertically to successively retrieve each of a plurality of stock items from the bins and place the respective pp items in a preselected ones of totes. Items are later optionally transferred to shipping containers based on each customer order. In some embodiments, horizontal aisle conveyors (HACs) move totes from a configurator along the aisles to the moving PAVs, then back after tote loading by the picker. Totes are transferred from the HACs to upward VTCs, then crossover to downward VTCs, are loaded with stock items by the picker on upward or downward paths, and then transferred back to the HACs to move to shipping station.