Picking System Batch Generation and Placement Body Division
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In a picking system, the diverse types of articles stored in an automatic warehouse with varying needs lead to potential delays in supplying articles to operation areas, resulting in inefficient picking operations due to insufficient placement bodies for high-demand items.
Innovation Solution
A control system that performs batch generation and assignment of picking operations, adjusts the number of placement bodies by increasing the deliverable total number when necessary, and implements a placement body division process to distribute articles across multiple placement bodies, ensuring adequate supply and reducing operation wait times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of placement bodies is increased to meet high-demand articles, then the availability of articles for picking operations is improved, but the storage space requirement and system complexity increase
Solution Approach 1:
The system dynamically adjusts the number of placement bodies based on real-time demand analysis. The control system monitors picking operation requirements and automatically creates or transfers placement bodies from the automatic warehouse to operation areas only when needed, rather than maintaining a fixed large inventory. This dynamic adjustment resolves the contradiction by providing high availability when needed while avoiding unnecessary complexity during low-demand periods.
Solution Approach 2:
The system changes the parameter of placement body quantity from a static configuration to a dynamic variable. By analyzing demand patterns and adjusting the number of placement bodies accordingly, the system optimizes the balance between availability and complexity. The control system modifies placement body creation and transfer parameters based on real-time picking operation requirements.
2Productivity
If batch operations are generated to improve picking efficiency, then the productivity is improved, but the coordination complexity between multiple operation areas increases
Solution Approach 1:
The system segments picking operations into independent batch operations that can be processed separately for each operation area. Each batch operation is generated independently based on local demand, and the control system coordinates these segmented operations through standardized transfer protocols. This segmentation allows improved productivity through batch processing while managing coordination complexity through modular, independent operation units.
Solution Approach 2:
The control system implements feedback mechanisms to monitor the status of batch operations and placement bodies across multiple operation areas. By receiving real-time feedback on operation progress and availability, the system automatically adjusts batch generation and transfer timing to optimize coordination. This feedback loop resolves the contradiction by enabling efficient batch processing while simplifying coordination through automated, data-driven decision-making.
3Loss of time
If placement bodies are transferred quickly to operation areas, then the response time is improved, but the transport frequency and energy consumption increase
Solution Approach 1:
The system performs preliminary actions by pre-positioning placement bodies in the automatic warehouse and pre-generating batch operations based on forecasted demand. This allows operation areas to receive placement bodies with minimal delay when actual picking operations start, improving response time without requiring constant rapid transfers. The preliminary preparation reduces the need for frequent emergency transfers, thereby lowering energy consumption.
Solution Approach 2:
The system implements periodic action by scheduling placement body transfers based on predetermined cycles and demand patterns rather than continuous real-time transfers. The control system analyzes historical data to establish optimal transfer intervals, balancing quick response with energy efficiency. This periodic approach resolves the contradiction by maintaining acceptable response times while significantly reducing unnecessary transport frequency and energy consumption.
Data Source
AI summary
In a picking system, a control system performs a batch generation process of collecting a predetermined number of pieces of the order information and setting picking operations corresponding to the collected pieces of the order information as a single batch operation. In the batch generation process, if the control system is able to set a target batch operation number to less than or equal to a deliverable total number, the control system collects the predetermined number of pieces of order information such that the target batch operation number is less than or equal to the deliverable total number, and if the control system is unable to set the target batch operation number to less than or equal to the deliverable total number, the control system performs a deliverable total number increase process of increasing the deliverable total number.