Mobile Sort Wall for Order Batching and Picking Efficiency
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Solution Overview
Problem
Existing order processing methods, particularly those using batch picking and sort walls, face inefficiencies due to the need for double handling of products and limited warehouse space, which can lead to delays and confusion, especially when trying to maintain a small sort wall size and minimize the distance between sorting equipment and bin locations.
Innovation Solution
Implementing a system that uses mobile sort walls and a sorting kiosk to efficiently sort and package orders, where orders are batched and grouped into sets, with computerized pick carts guiding workers to collect items and a kiosk system facilitating the sorting of items into designated bins on moveable sort walls, allowing for efficient use of space and minimizing the need for frequent bin relocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch picking is used with a sort wall, then picking efficiency is improved by reducing walking time, but product handling time increases due to double handling (picking and sorting)
Solution Approach 1:
The patent extracts the sorting function from the traditional sort wall and relocates it to the picking cart. The cart now contains multiple bins for different orders, allowing items to be sorted directly at the shelf location during the picking process, eliminating the need for a separate sorting step at a centralized sort wall.
Solution Approach 2:
The picking cart serves as an intermediary between the warehouse shelves and the final delivery location. It combines both picking and sorting functions in a single mobile unit, allowing workers to collect items for multiple orders simultaneously and sort them on-the-go without returning to a centralized sort wall.
2Quantity of substance
If a large sort wall is used to accommodate multiple orders, then order capacity is improved, but the distance from sorting equipment to bin locations increases, reducing sorting efficiency
Solution Approach 1:
The patent transforms the static sort wall into a dynamic mobile cart system. The sorting surface moves with the worker throughout the warehouse, maintaining a constant, minimal distance between the sorting equipment (bins on the cart) and the worker's hands, regardless of the number of orders being processed.
Solution Approach 2:
The patent transitions from a two-dimensional sort wall layout to a three-dimensional mobile cart system with vertical bin arrangement. Multiple orders are accommodated by stacking bins vertically on the cart rather than spreading them horizontally across a large wall, maintaining compact dimensions while increasing capacity.
3Area of stationary object
If a compact sort wall is maintained to minimize space, then warehouse space utilization is improved, but bin relocation becomes necessary frequently, causing confusion and delays
Solution Approach 1:
The patent makes the sorting system universal by designing the cart with standardized, interchangeable bins that can accommodate any order configuration. The same cart and bin system handles all orders regardless of size or complexity, eliminating the need for reconfiguration or relocation of sorting infrastructure.
Solution Approach 2:
The system provides self-service through automated bin assignment and tracking. The cart and bins maintain their identity and configuration throughout the process, with the system automatically managing bin locations and assignments, eliminating the need for manual reconfiguration or worker memory of bin locations.
4Area of stationary object
If traditional sort walls are used with limited space, then space utilization is improved, but sorting efficiency decreases due to increased distance from sorting equipment to bin locations
Solution Approach 1:
The patent transforms the static sort wall into a dynamic mobile cart system. The sorting surface moves with the worker throughout the warehouse, maintaining a constant, minimal distance between the sorting equipment (bins on the cart) and the worker's hands, regardless of the number of orders being processed.
Data Source
AI summary
Methods and apparatus for efficiently fulfilling product orders corresponding to different customers are described. An order processing system receives product orders from customers and efficiently groups multiple orders into sets of orders. A set of orders is assigned to a mobile sort wall, and a group of robotic carts is assigned to be used to collect products. The products corresponding to a set of orders are picked from racks and collected in the robotic carts. The mobile sort wall includes a plurality of different placement locations, e.g. bins. Each placement location is associated with one of the customer orders in the set of customer orders assigned to the mobile sort wall. A sorting kiosk including a scanner identifies a collected product, identifies a placement location, and the product is placed on the mobile sort wall. A loaded mobile sort wall is moved to a packaging area.