Order Picking Conveyor Segmentation for Warehouse Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current order picking systems face inefficiencies due to jams in storage container conveyance, high manipulation effort, and uneven utilization of picking personnel, particularly with a high percentage of slow-moving items requiring numerous flow channels and frequent provisioning, which affects the service life and performance of the system.
Innovation Solution
The system integrates two picking areas within the container warehouse and outside it, with coordinated distribution of storage containers based on turnover rates, allowing continuous conveyance without interruptions and optimizing the use of picking personnel by dynamically assigning storage containers to available staging areas, reducing unnecessary returns, and using a computerized disposition check to manage conveyor paths and staging areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If storage containers are conveyed through a single conveyor system to multiple picking workstations, then the system structure is simplified, but traffic jams occur reducing productivity
Solution Approach 1:
The conveyor system is segmented into multiple independent conveyor paths (first conveying path for integrated picking area, second conveying path for non-integrated picking area) that operate in parallel. This segmentation eliminates traffic jams by providing multiple routes for storage container conveyance, thereby maintaining high productivity while keeping each individual conveyor path relatively simple.
Solution Approach 2:
The system transitions from a single-dimension conveyor arrangement to a multi-dimensional layout by integrating one picking area within the container warehouse and positioning another outside it. This spatial dimensionality change creates independent conveying paths that avoid interference and jams, resolving the contradiction between system simplicity and productivity.
2Productivity
If storage containers are frequently returned to warehouse after picking, then picking personnel can process orders efficiently, but manipulation effort increases reducing ease of operation
Solution Approach 1:
The system performs preliminary actions by distributing storage containers to multiple picking workstations in advance based on order forecasts and turnover rates. This allows picking personnel to process orders efficiently without frequent returns, as containers are strategically positioned at appropriate picking areas before needed, reducing manipulation effort while maintaining productivity.
Solution Approach 2:
The system enables self-service by allowing storage containers to be automatically conveyed and distributed to picking workstations without manual intervention. Containers are returned to the warehouse automatically after picking operations, reducing manual manipulation effort while maintaining efficient order processing through automated conveyor systems.
3Productivity
If picking areas are integrated within the container warehouse, then conveying path is shortened improving productivity, but the warehouse space requirements increase
Solution Approach 1:
The system applies local quality by integrating one picking area within the container warehouse to achieve short conveying paths and high productivity for specific high-turnover items, while positioning another picking area outside the warehouse for items requiring longer conveyance. This localized optimization allows the system to benefit from both integrated and non-integrated arrangements without requiring the entire system to compromise on either space or efficiency.
4Adaptability or versatility
If numerous flow channels are provided for slow-moving items, then all items can be accommodated, but device complexity increases
Solution Approach 1:
The system changes the parameter of container distribution by using a computerized disposition check that dynamically allocates storage containers to picking workstations based on turnover rates and order forecasts. This parameter change eliminates the need for numerous dedicated flow channels for slow-moving items, as containers are flexibly assigned to appropriate picking areas based on real-time needs, reducing device complexity while maintaining full item accommodation capacity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a process and an installation (1) for the order-picking of articles with different handling frequencies from storage containers (2) into order containers (3), in the case of which the storage containers are conveyed by a first conveyer (7) from a container store (4) to order-picking workstations (29, 41) in different order-picking regions, at which a respective order-picker, to make up an order, removes an article from at least one storage container and sets it down in an order container supplied by a second conveyer (8). By means of a warehouse-management system, in a forecast relating to the number or orders, the order positions for a respective article are determined and, in a planning check, the order containers are assigned to an order-picking workstation (41) in the first order-picking region (5), this workstation being integrated in the container store, and/or to an order-picking workstation (29) in the second order-picking region (6), this workstation being arranged separately from the container store. Accordingly, the storage containers are transported over different, automated conveying routes (65, 80) either to an order-picking workstation (41) in the first order-picking region or to an order-picking workstation in the second order-picking region (6).