Order Picking Control with Recirculating Shipping Load Sequencing
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Solution Overview
Problem
Current order picking systems require operators to constantly check and manage multiple source and shipping loads, leading to increased errors and mental workload, and inefficient equipment management, with limited optimal management of exit movements due to the fixed number of insertion positions.
Innovation Solution
A method and system that processes orders by selecting a dominant reference, grouping commands, constructing a specific list to control a '1 to 1' type preparation station with recirculation, reducing the need for multiple picking and insertion positions, and optimizing the movement of shipping loads through a recirculation loop, allowing for increased efficiency and error reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple picking and insertion positions are used, then more orders can be processed simultaneously, but operator mental workload and error rate increase
Solution Approach 1:
The system segments the order processing into multiple independent command lines, each representing a discrete picking and insertion task. The control system processes these command lines sequentially in optimized groups, allowing the operator to focus on one task at a time while the system manages the overall workflow, thus maintaining productivity without increasing mental workload
Solution Approach 2:
The control system performs preliminary actions by pre-processing the command list, identifying optimal groupings of command lines, and determining the most efficient processing sequence before presenting tasks to the operator. This includes analyzing reference patterns and preparing the task sequence in advance, so the operator receives ready-optimized instructions rather than having to manage multiple positions simultaneously
2Productivity
If multiple insertion positions are provided, then shipping loads can be distributed more efficiently, but equipment management complexity increases
Solution Approach 1:
The system uses a single insertion position that performs multiple functions by processing different command lines in sequence. The same insertion position handles various shipping loads for different orders over time, eliminating the need for multiple dedicated insertion positions while maintaining distribution efficiency through intelligent task sequencing
Solution Approach 2:
The system dynamically assigns different shipping loads to the single insertion position based on the current command line being processed. The insertion position's function changes over time to handle different orders and references, allowing flexible adaptation to varying order requirements without requiring multiple fixed positions
3Device complexity
If commands are processed in fixed groups, then system control is simplified, but flexibility in handling priority variations is reduced
Solution Approach 1:
The control system performs preliminary analysis of all command lines to identify priority levels and reference patterns before creating processing groups. This pre-processing allows the system to establish simple grouping rules in advance while still accommodating priority variations, as the high-priority commands are identified and positioned appropriately in the sequence during the preliminary phase
Solution Approach 2:
The system changes the grouping parameters dynamically based on command characteristics. While the basic grouping mechanism remains simple, the criteria for grouping (such as reference patterns, priority levels, and command line characteristics) are adjusted to accommodate different scenarios, allowing flexibility in priority handling without complicating the core control logic
Data Source
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AI summary
A method is proposed for processing an order list in an order preparation system comprising a control system and at least one preparation station (including a picking position, an insertion position and local recirculation means). The control system performs the following steps: selection (21) of a reference present in the largest number of order lines from among all the order lines in the order list; determination (22) of a set E of all the NE orders, each containing an order line containing the selected reference; creation (23) of a group G of N orders which are either the NE orders, if NE≤Nmax with Nmax a predetermined threshold, or the first Nmax orders resulting from a sorting of the NE orders according to a descending order of priority level, if NE>Nmax;construction (24) of an LC list of all the K order lines contained in the N orders of group G, respecting a set of rules; and control (26) of the order preparation system to bring source loads to the picking position and shipping loads to the insertion position, and to recirculate shipping loads to the insertion position, according to the LC list.;