Order-Picking Sequencing with Capacity-Matched Product Groups
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Solution Overview
Problem
Existing order picking systems require expensive equipment that operates inefficiently due to being designed for the largest possible order, leading to underutilization of sorting devices.
Innovation Solution
A method that segments the overall product sequence into product groups, each containing a number of items regardless of order limits, allowing the second sorting device to operate at maximum capacity, and decouples order boundaries for optimized operation of both sorting devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If equipment is designed for the largest possible order, then the sorting device can handle maximum capacity, but the equipment operates inefficiently due to underutilization
Solution Approach 1:
The patent segments the overall product sequence into multiple product groups, where each group contains a number of items that corresponds to the sorting capacity of the second sorting device. This segmentation allows the sorting device to operate at full capacity for each batch rather than being underutilized, thereby resolving the contradiction between having sufficient capacity for large orders and maintaining operational efficiency for actual workloads.
2Adaptability or versatility
If the second sorting device is designed for maximum capacity, then it can handle the largest orders, but it operates inefficiently when handling smaller orders
Solution Approach 1:
By dividing the total product sequence into product groups where each group's size matches the sorting device's capacity, the system ensures that the second sorting device operates at full efficiency for each batch. This prevents the device from being underutilized on smaller orders, thereby reducing unnecessary sorting time while maintaining the ability to handle large orders through multiple batches.
Solution Approach 2:
The control computer creates the product groups and determines the retrieval sequence before the actual sorting process begins. This preliminary organization of products into capacity-matched groups allows the sorting device to immediately operate at optimal capacity when the sorting process starts, eliminating time losses that would occur with ad-hoc sorting of smaller quantities.
3Reliability
If order boundaries are maintained in the sorting sequence, then order integrity is preserved, but the sorting devices cannot operate at optimized capacity
Solution Approach 1:
The patent segments the product sequence into product groups that may span across multiple order boundaries. The control computer tracks which products belong to which orders and ensures that products for the same order are sorted together in the appropriate batches. This allows the sorting devices to operate at full capacity by grouping products efficiently while maintaining order integrity through controlled sequencing.
Solution Approach 2:
The control computer receives information about order requirements and uses this feedback to determine the optimal product groupings and retrieval sequence. By continuously monitoring order status and adjusting the product group assignments, the system ensures that sorting operations maintain order integrity while maximizing sorting device capacity utilization through intelligent sequencing.
Data Source
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AI summary
The invention relates to a multi-stage method for sequencing goods (A1.. 15) in an order-picking system (1a.. 1e) comprising a first sorting device (6a.. 6c) with a plurality of buffer conveyor lines (7, PL1.. PL4) arranged parallel to one another with respect to the conveying process and a second sorting device (11) arranged downstream thereof. Detected orders (AT1.. AT10) are connected together in a control computer (21) of the order-picking system (1a.. 1e) and subsequently segmented into groups (WG1..WG7) of goods regardless of order limits (ATG), each group having a respective specifiable number of goods (A1.. 15). Groups (WG1.. WG7) of goods are selectively transferred into the buffer conveyor lines (7, PL1.. PL4) for the sorting process and subsequently conveyed to the second sorting device (11), where the groups are sorted, group (WG1.. WG7) by group (WG1.. WG7), according to the order sequence. The invention additionally relates to an order-picking system (1a.. 1e) in which the aforementioned method can be carried out.