Modular Pick Wall with Reconfigurable Light Modules
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Solution Overview
Problem
Existing pick walls in order fulfillment systems are rigid and not easily configurable, leading to inefficient use of space and increased labor costs, especially during peak seasons, as they do not optimize the put face for varying order profiles.
Innovation Solution
A modular and configurable pick/put wall system with attachable light modules and mobile apparatuses that can be repositioned and reconfigured to match changing order requirements, using light bars and a cloud-based configuration application to direct operators efficiently and accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed pick wall structure is used, then the system is simple and stable, but it cannot adapt to varying order profiles and peak season demands
Solution Approach 1:
The pick wall is divided into modular components including horizontal arms that can be independently attached and detached from the vertical support. Each horizontal arm can be positioned at different heights and configurations, allowing the system to be segmented and reconfigured based on order fulfillment needs without redesigning the entire structure.
Solution Approach 2:
The pick wall transitions from a static fixed structure to a dynamic reconfigurable system. The horizontal arms are designed to be movable and adjustable, enabling the system to adapt its configuration dynamically in response to changing order profiles and throughput demands during different operational periods.
2Productivity
If more automated conveyances are installed to handle peak season throughput, then productivity increases, but infrastructure investment increases significantly
Solution Approach 1:
The system uses dynamically reconfigurable horizontal arms that can be adjusted to optimize throughput capacity during peak seasons without requiring additional automated conveyance infrastructure. The same physical structure can be reconfigured to handle varying volumes, eliminating the need for separate infrastructure investments for different operational capacities.
Solution Approach 2:
The modular pick wall structure serves multiple functions across different operational scenarios. The same horizontal arms and support structure used during normal operations can be reconfigured to handle peak season demands, making the infrastructure universally applicable across different throughput requirements and eliminating the need for dedicated peak season equipment.
3Area of stationary object
If the put face is not optimized for varying order profiles, then the system is simple to operate, but space utilization is inefficient and labor costs increase
Solution Approach 1:
The put face is segmented into multiple horizontal arms that can be independently configured. This segmentation allows each arm to be optimized for specific order profiles or product types, maximizing space utilization within the available vertical and horizontal space while maintaining straightforward operation through modular simplicity.
Solution Approach 2:
The system allows changes in the configuration parameters of the horizontal arms (position, orientation, spacing) to optimize space utilization for different order profiles. These parameter adjustments enable the put face to adapt to varying operational requirements without fundamentally changing the system's ease of operation.
Data Source
AI summary
A modular order fullment system uses a number of inexpensive mobile apparatuses such as containers with horizontally accessible bins that are brought to a stationary frame that supports a pick-to-light system to direct a human or robotic operator to pick from or put to receptacles in the mobile apparatus.