Order Fulfillment System with Return Tour Optimization

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional item picking and packaging systems are inefficient and require significant capital investment, failing to optimize the picking and packaging process, and lack adaptability in handling customer orders and returns.

Innovation Solution

An order fulfillment system that determines whether customer orders warrant bulk picking or pick tours, generates pick and return tours, and optimizes the route for pick agents using a value sorted tree map to efficiently select and return items within a warehouse, incorporating a return order generating unit for processing customer returns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional manual picking and packaging techniques are used, then capital investment is reduced, but productivity and efficiency deteriorate

Engineering Contradiction:

Improvepicking and packaging efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system enables pickers to independently access optimized pick tours and routing information through mobile devices, allowing them to self-navigate the warehouse and perform picking tasks without constant supervisor intervention or complex centralized control mechanisms

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system dynamically changes picking parameters by generating optimized pick tours based on real-time order data, warehouse layout, and picker location, transforming static manual processes into adaptive, data-driven operations that improve efficiency without requiring full automation infrastructure

Inventive Principle:

Principle #35Parameter changes

2Productivity

If automated picking stations and packing machines are introduced, then productivity is improved, but capital investment increases

Engineering Contradiction:

Improvepicking and packaging efficiencyVSAvoidcapital investment

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The system replaces physical automation machinery with software-based optimization algorithms and mobile computing devices, substituting expensive mechanical automated picking stations with digital tour generation and mobile device guidance systems that achieve similar efficiency improvements at lower cost

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses digital copies and representations of warehouse layouts, order data, and picker locations to generate virtual pick tours that guide physical pickers, replacing the need for physical automation equipment with information-based virtual models of the picking process

Inventive Principle:

Principle #26Copying

3Adaptability or versatility

If conventional item picking systems are used, then device complexity is reduced, but adaptability in handling customer orders and returns deteriorates

Engineering Contradiction:

Improvehandling customer orders and returnsVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system performs multiple functions including generating pick tours for order fulfillment, creating return tours for processed returns, optimizing picker routing, and providing real-time guidance through mobile devices, consolidating these diverse capabilities into a single software platform that adapts to different operational needs without requiring separate specialized systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system dynamically adapts to changing conditions by generating new pick tours based on real-time order data, updating picker routing information as locations change, and adjusting return tour generation based on processed return status, enabling the system to respond flexibly to varying operational requirements without complex reconfiguration

Inventive Principle:

Principle #15Dynamics

4Loss of time

If conventional picking processes are used, then ease of operation is maintained, but loss of time in picking and packaging increases

Engineering Contradiction:

Improvepicking and packaging timeVSAvoidpicker operation simplicity

Core Design Contradiction:

Loss of timeVSEase of operation

Solution Approach 1:

The system performs preliminary actions by pre-generating optimized pick tours that calculate the most efficient routing paths before pickers begin their tasks, pre-organizing pick sequences and locations based on warehouse layout and order requirements, so that pickers simply need to follow the pre-computed optimized routes without performing complex real-time optimization themselves

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12077381B2Return ordering system and method

Publication Date: 2024.09.03 AMERICAS COLLECTIBLES NETWORK

AI summary

The customer order fulfillment and return system for returning items from a customer order to specified locations in a warehouse. The returned items are assigned to specific sub-compartments of a tote, and the tote is assigned to a specific mobile return cart. The system then generates a return tour and the returned items are then returned to specific locations in the warehouse.