Multi-Level Goods-to-Operator Workstation for Faster Order Picking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional order picking systems are time-consuming and require additional employees, leading to inefficiencies and errors in high-volume distribution and fulfillment operations.
Innovation Solution
A goods to operator workstation with multiple levels and conveyors that facilitate the delivery of product containers to a picker, allowing for automated retrieval and placement of items into designated containers, reducing the need for manual handling and enabling efficient order fulfillment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional order picking systems are used, then employees can manually pick products, but the process is time-consuming and requires additional employees
Solution Approach 1:
The system enables self-service by having containers automatically delivered to the operator's workstation and automatically removed after picking, eliminating the need for additional employees to bring and collect containers. The operator simply performs the picking action while the system handles container logistics.
Solution Approach 2:
The patent replaces the manual mechanical system of employees walking to storage racks with an automated conveyor system that transports containers to the operator. This substitution of mechanical labor with automated material handling equipment directly improves efficiency and reduces time loss.
2Reliability
If conventional order picking systems are used, then employees can pick products, but errors occur in the picking process
Solution Approach 1:
The system incorporates feedback mechanisms where the control system tracks which containers have been picked and which remain, providing real-time information to the operator through indicators. This feedback loop ensures accurate tracking of picked items and prevents errors in order fulfillment.
Solution Approach 2:
The control system acts as an intermediary between the storage system and the operator, coordinating container delivery, tracking picking status, and managing container removal. This intermediary coordination reduces errors by ensuring systematic and accurate order fulfillment.
3Ease of operation
If a gap is defined between upper and lower levels to allow container placement, then operators can easily place containers, but the structure becomes more complex
Solution Approach 1:
The workstation is segmented into distinct upper and lower levels with a defined gap between them, allowing operators to easily place and retrieve containers at the lower level while the upper level handles different container types. This segmentation simplifies the operation of container placement without requiring the entire structure to be overly complex.
Data Source
AI summary
In various embodiments, a goods to operator workstation is provided. The goods to operator workstation include an upper level. The upper level includes an upper level conveyor and one or more upper level container bays configured to receive and present one of the one or more upper level containers. The goods to operator workstation also includes at least one connector panel extending from the upper level. The goods to operator workstation further includes a lower level coupled to the at least one connector panel. The lower level is configured to receive one or more lower level containers.