Distribution Center Package Consolidation for Space Utilization

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Solution Overview

Problem

Conventional sorting and shipping at distribution centers often result in individual packing of small merchandise items, leading to wasted space in packing cases and increased transportation costs.

Innovation Solution

A method where customer packages are associated with destination information through a management server, allowing multiple packages addressed to the same destination to be packed in different cases, which are then consolidated into a single packing box at the transfer-to distribution center or nearest base.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If small merchandise items are packed individually in packing cases according to customer orders, then sorting accuracy for each destination is improved, but empty space in packing cases increases and transportation cost increases

Engineering Contradiction:

Improvesorting accuracyVSAvoidtransportation cost

Core Design Contradiction:

Measurement precisionVSLoss of energy

Solution Approach 1:

The packing process is divided into two stages: first, merchandise is sorted by size and shape into different packing cases at the transfer-from distribution center; second, packages for the same destination are consolidated into a single packing box at the transfer-to distribution center. This segmentation allows efficient space utilization during transit while maintaining accurate destination sorting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Merchandise is pre-sorted by size and shape into appropriately sized packing cases before transportation, and destination information is associated with each package in advance. This preliminary organization enables efficient consolidation at the transfer-to center without requiring individual packing for each customer order, reducing empty space while maintaining sorting accuracy.

Inventive Principle:

Principle #10Preliminary action

2Loss of energy

If multiple packages addressed to the same destination are consolidated into a single packing box, then transportation cost is reduced, but sorting complexity increases

Engineering Contradiction:

Improvetransportation costVSAvoidsorting complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

A management server acts as an intermediary to associate destination information with each package and coordinate the consolidation process. The server manages the information flow between transfer-from and transfer-to distribution centers, enabling automated consolidation decisions without increasing on-site sorting complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual sorting and consolidation process is replaced with an automated information management system that tracks package destinations and coordinates consolidation. This substitution of mechanical sorting with information-based management reduces the complexity of physical sorting operations while enabling efficient package consolidation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Volume of moving object

If merchandise is sorted by size and shape into different packing cases, then space utilization during transportation is improved, but packing process complexity increases

Engineering Contradiction:

Improvespace utilizationVSAvoidpacking process complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The sorting criteria are changed from destination-based to size and shape-based parameters. This parameter change simplifies the initial packing process by using physical characteristics that are easier to measure and categorize, while still achieving efficient space utilization. The destination information is managed separately through information association rather than physical sorting.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20220147909A1Methods for merchandise sorting and packing management

Publication Date: 2022.05.12 FUJISAWA KAZUNORI

AI summary

An object is to reduce cost and the like during transportation or transfer of merchandise/packages. A method for packing a customer's package, in a distribution system comprising a management server and involving transfer of the customer's package from a transfer-from distribution center to a transfer-to distribution center and delivery of the customer's package from the transfer-to distribution center to a destination or from the transfer-to distribution center to the destination via a nearest base from the destination, wherein the customer's package is associated with information on the destination at the transfer-from distribution center through the management server, for each customer related to the destination, and when the customer's package comprises a plurality of customer's packages addressed to the destination, during the transfer from a transfer-from distribution center to a transfer-to distribution center, the plurality of customer's packages addressed to the destination are packed in different packing materials according to at least shape or size.