Multi-Stock Bin Selection for Fewer ASRS Workstation Moves
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Solution Overview
Problem
Traditional automated storage and retrieval systems in e-commerce and retail face inefficiencies due to the inability to dynamically select and deliver multi-stock bins containing the highest number of SKUs to workstations just in time, leading to increased order processing time and reduced ability to meet customer demands, especially during rush orders.
Innovation Solution
An automated storage and retrieval system that uses a controller to track a stock waitlist and select multi-stock bins containing the highest number of required SKUs, optimizing bin selection and delivery to workstations to maximize items picked per bin presentation, thereby reducing the number of bin moves and enhancing processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional systems fetch bins from warehouse and deliver to workstations, then bins can be delivered to workstations, but the number of bin moves increases and order processing time increases
Solution Approach 1:
The system performs preliminary actions by pre-fetching and staging bins at a buffer location before they are actually needed at workstations. The controller predicts which bins will be needed based on order patterns and prepares them in advance, reducing the time bins need to be fetched during active picking operations.
Solution Approach 2:
The patent introduces an intermediary buffer storage location between the warehouse and workstations. This buffer acts as a mediator that decouples the bin fetching operation from the picking operation, allowing bins to be prepared in advance and delivered to workstations more efficiently without creating bottlenecks.
2Productivity
If multiple bins are fetched to different workstations in parallel, then different SKUs can be picked simultaneously, but the number of bin moves increases
Solution Approach 1:
The system segments the bin fetching and delivery process into distinct phases: identification of required bins, staging at buffer location, and sequential delivery to workstations. This segmentation allows the system to manage multiple bins more efficiently by handling them in organized batches rather than as individual complex operations.
Solution Approach 2:
The buffer location serves as an intermediary that simplifies bin management by consolidating multiple bins before distribution. Instead of directly managing complex one-to-many bin deliveries, the system uses the buffer as a intermediate staging point that reduces the overall complexity of coordinating multiple bin moves.
3Productivity
If bins are stored in warehouse and fetched on demand, then inventory can be maintained, but the system cannot meet rush order demands
Solution Approach 1:
The system performs preliminary actions by anticipating and pre-fetching bins that are likely to be needed for rush orders. The controller monitors order patterns and proactively stages relevant bins at the buffer location before rush orders arrive, enabling faster fulfillment without compromising inventory management.
Solution Approach 2:
The system dynamically adjusts bin fetching and staging operations based on real-time order demands. When rush orders are detected, the controller prioritizes fetching and staging relevant bins at the buffer location, dynamically optimizing the retrieval speed and resource allocation to meet urgent demands while maintaining normal operations for standard orders.
Data Source
AI summary
An automated storage and retrieval system stores multi-stock bins each holding different stock-keeping units (SKUs). Records dynamically track which SKUs are in each bin. A controller tracks a stock waitlist indicating quantities of SKUs still required to be delivered to a workstation in order to fulfil current orders assigned to the workstation. When a robot is available, the controller selects a multi-stock bin that has a highest number of unique ones of the required SKUs indicated on the stock waitlist and commands the robot to fetch and deliver the selected bin to the workstation. For new orders, the controller may determine if direct assignment can be done to a workstation without additional bins being scheduled. For other pending orders, the controller may assume each pending order is assigned to the workstation and then pick the order that would require a lowest number of bins to be delivered to the workstation.