Picking Station Sequence Control for Higher Order Throughput
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Solution Overview
Problem
Existing automated storage and retrieval systems face inefficiencies in optimizing the throughput of product picking operations at picking stations, particularly in determining the sequence and placement of products from storage containers into consolidation containers.
Innovation Solution
A method and system for controlling a picking device at a picking station, utilizing a picking system controller to optimize the sequence of picking products from storage containers based on factors such as travel distance, product availability, and order priority, and rearranging container positions for minimal travel, while using camera vision for precise product identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If products are picked from storage containers in a conventional sequence, then the picking operation can be completed, but the throughput is reduced due to unnecessary travel distance and time
Solution Approach 1:
The system performs preliminary actions by receiving and ranking multiple product orders before establishing picking sequences. The picking system controller pre-processes order information, ranks orders based on priority and other factors, and prepares optimized picking sequences in advance, allowing the picking device to execute operations efficiently without real-time decision delays
Solution Approach 2:
The system dynamically adjusts picking sequences based on multiple variables including order priority, product location, consolidation container availability, and picking device position. The controller continuously evaluates and re-ranks orders, establishing different picking sequences for different timeframes to optimize throughput under changing conditions
2Productivity
If the picking device travels between multiple storage containers and consolidation containers, then products can be picked and consolidated, but the travel distance reduces operational efficiency
Solution Approach 1:
The system implements feedback mechanisms by continuously monitoring the positions of storage containers, consolidation containers, and the picking device. The controller uses this position information along with order rankings to dynamically adjust and re-optimize picking sequences, ensuring the picking device follows the most efficient path while consolidating products
Solution Approach 2:
The system changes operational parameters by establishing different picking sequences for different timeframes based on varying conditions such as order priority levels, product locations in storage containers, availability of consolidation containers, and picking device position. This parameter optimization minimizes travel distance while maintaining productivity
Data Source
AI summary
A method picks products from at least one storage container in a picking zone of a picking station of an automated storage and retrieval system. The picking is controlled by a picking system controller communicating with a warehouse management system, WMS. The picking is performed by a picking device in the picking zone by placing picked products in one or more consolidation containers according to orders. The picking system controller is adapted for controlling the picking device and picking station for executing the method. The method includes a) receiving and ranking product orders in the warehouse management system, b) moving, by means of a transport system, storage containers with ordered products towards the picking zone according to the ranking of product orders, and c) checking which storage containers are available and ready to be picked from in the picking station and which storage containers and consolidation containers will be available within a timeframe, as well as determining a current position of the picking device relative to the positions of the at least one storage container that are ready to be picked from and the consolidation containers that are ready to receive the picked products. The method further includes d) establishing different picking sequences for completing each product order from the ranked product orders. Each picking sequence lists the products to be picked from the storage containers and which consolidation containers to place the products in within the timeframe. Each picking sequence is established by estimating the following: shortest travel distance for moving the picking device for picking from one storage container to picking from another storage container; fastest completion of picking from storage containers in the picking station for enabling new storage containers to enter the picking zone of the picking station; and fastest completion of the consolidation containers for replacing with new consolidation containers. The method further includes e) ranking the picking sequences and selecting the picking sequence providing higher throughput of picked products according to ranked product orders; f) executing picking of products by letting the picking system controller control the picking device to pick products from the storage containers and place them within the consolidation containers according to the selected picking sequence within the timeframe; and g) repeating steps a) to f) above.