Order Picking Recirculation Layout for Fewer Exit Movements
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Solution Overview
Problem
Current customer-order preparing systems face challenges with high error rates and operator stress due to the need to manage multiple picking and insertion positions, and they do not optimize the storage and removal of source loads, limiting the reduction of exit movements.
Innovation Solution
A method and system that utilize a single picking and insertion position with recirculation capabilities, organizing customer orders to minimize recirculation and optimize the preparation process, allowing for the reduction of source load exit movements and improving order preparation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple picking and insertion positions are used to handle multiple customer orders simultaneously, then the productivity of the system increases, but the error rate increases and operator stress increases
Solution Approach 1:
The system segments the order processing into two distinct phases: a recirculation phase where shipping loads are circulated and prepared in a controlled single-position environment, and a final delivery phase where completed orders are removed. This segmentation allows the system to maintain high throughput by processing multiple orders through recirculation while preserving accuracy through the simplified single-position operation.
Solution Approach 2:
The system performs preliminary actions by circulating shipping loads through the single picking position multiple times before final delivery. During these recirculation passes, all necessary picking operations are completed in advance, allowing the operator to work with a single position at a time and minimize errors. This preliminary preparation enables high productivity without sacrificing accuracy.
2Productivity
If multiple picking and insertion positions are used to handle multiple customer orders, then the productivity increases, but the device complexity increases
Solution Approach 1:
The system merges the functions of multiple picking positions and multiple insertion positions into a single picking position and a single insertion position that operate in sequence through recirculation. Instead of having parallel positions, the same position performs multiple functions across multiple passes, significantly reducing device complexity while maintaining the ability to handle multiple orders simultaneously through the recirculation mechanism.
Solution Approach 2:
The system introduces dynamic recirculation of shipping loads, allowing the single picking and insertion positions to be dynamically reused across multiple passes. This dynamic approach enables the system to handle multiple orders with minimal infrastructure, as the same physical positions are repeatedly utilized in different contexts throughout the recirculation process.
3Productivity
If the number of insertion positions is increased to handle more orders, then the productivity increases, but the number of source load exit movements increases
Solution Approach 1:
The system maintains continuous useful action by recirculating shipping loads that have not yet been completed through the single insertion position. Instead of requiring multiple insertion positions to handle different orders simultaneously, the system keeps the same insertion position continuously active across multiple passes, eliminating idle time and reducing the need for source loads to be repeatedly exited and repositioned.
Data Source
AI summary
Processing a list of customer orders with a control system and a preparing station, which includes a picking position, an insertion position and local recirculation. The control system: selects a reference in the greatest number of order lines of the list; determines a set E of all the NE orders each containing an order line containing the selected reference; creates a group G of N orders that are the NE orders, if NE≤Nmax with Nmax being a predetermined threshold, or the Nmax first orders of the NE orders sorted according to decreasing order of priority, if NE>Nmax; builds a list LC of the K order lines in the N orders of the group G; and controls the system to bring source loads to the picking position and ship loads to the insertion position and to make the shipping loads recirculate to the insertion position, according to the list LC.