Picker Wall Slot Reservation to Reduce Container Re-Retrieval
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Solution Overview
Problem
Existing order fulfillment systems inefficiently assign tasks and control agents, leading to suboptimal retrieval and re-retrieval of objects, which decreases productivity and efficiency by requiring multiple retrievals to fulfill different orders.
Innovation Solution
Implementing a controller that optimizes the use of a picker wall by reserving slots, delaying container removal decisions, and generating an order fulfillment plan based on order priorities and container types to minimize retrievals and ejections, thereby maximizing order fulfillment throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the order fulfillment system directs retrieval of an object to a picking site, picking of items, returning the object to storage, and subsequent re-retrieval to fulfill different orders, then individual orders can be fulfilled, but the same object is retrieved multiple times unnecessarily, decreasing productivity and efficiency
Solution Approach 1:
The system performs preliminary actions by retrieving containers to the picker wall in advance and holding them there, so that multiple orders can be fulfilled without repeated retrievals. The controller anticipates future picking needs and prepares containers beforehand, eliminating the need for agents to travel back to storage locations.
Solution Approach 2:
The picker wall serves as an intermediary buffer between storage containers and picking locations. Containers are transferred to the picker wall once and held there, allowing multiple picking operations to occur without returning to storage. This intermediary structure decouples the retrieval operation from the picking operation.
2Adaptability or versatility
If containers are frequently placed and removed from the picker wall to fulfill different orders, then order flexibility is maintained, but the total number of container movements increases, reducing efficiency
Solution Approach 1:
The controller performs preliminary planning to determine which containers to place on the picker wall and for how long. By anticipating future order requirements, the system prepares containers in advance and holds them on the picker wall, reducing the need for frequent movements while maintaining flexibility to fulfill different order combinations.
Solution Approach 2:
The controller continuously monitors the state of the picker wall and incoming orders, using feedback to dynamically adjust container placement and removal decisions. This real-time optimization ensures that containers remain on the picker wall as long as they are needed, minimizing movements while adapting to changing order requirements.
3Adaptability or versatility
If the picker wall capacity is fully utilized by placing multiple containers, then order fulfillment options increase, but the decision complexity for determining which container to eject increases
Solution Approach 1:
The controller uses feedback from the order management system to prioritize orders and determine which containers should be retained on the picker wall. By continuously receiving information about incoming orders and their requirements, the controller can make informed decisions about which containers to eject and which to retain, simplifying the decision-making process through systematic evaluation criteria.
Solution Approach 2:
The system changes the parameter of container retention time based on order priority and predicted future needs. High-priority orders result in containers being retained longer, while low-priority containers are ejected sooner. This dynamic parameter adjustment simplifies decision complexity by providing clear retention criteria based on order characteristics.
Data Source
AI summary
Disclosed is a system and associated methods for optimizing order fulfillment. The system determines the containers in a site with items for a set of received orders, and reserves different slot types of an item cache for each container based on the properties of the contained items or container. The system transfers a set of containers to the item cache by placing each of the set of containers into a slot that is associated with a slot type that matches a slot type reserved for that container. The system replaces a first container from the set of containers upon delivering a second container to the item cache and other containers from the set of containers in the slot type reserved for the second container having items for unfulfilled orders and the first container not having items for unfulfilled orders once the second container is brought to the item cache.