Pouch Sorter Buffer Loading Using Forecasted Order Demand
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Solution Overview
Problem
Existing sorting conveyors face inefficiencies in buffer loading and resource utilization due to non-uniform loading based on actual customer orders, leading to high processing volumes during order receipt and low utilization at other times, which results in significant logistical challenges and increased workforce requirements.
Innovation Solution
Implement a system with a system control device that predicts future article demand and proactively transfers items to the buffer, using AI and order forecasting to optimize loading and reduce peak loads, allowing for continuous filling and efficient resource utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are transferred to the buffer only after receipt of customer orders, then the buffer is used only when needed, but the loading is non-uniform causing load peaks and low utilization at other times
Solution Approach 1:
The system performs preliminary actions by forecasting customer orders in advance and transferring corresponding articles to the buffer before the orders are actually received. This proactive approach smoothens the loading profile of the buffer, avoiding load peaks while maintaining high buffer utilization and reducing order throughput times.
2Ease of operation
If customer orders are accumulated in ERP before forwarding to WMS, then order processing is centralized, but processing volume fluctuates significantly between peak and low periods
Solution Approach 1:
The system implements a feedback mechanism where the control device continuously monitors actual customer orders received and compares them with forecasted orders. Based on this feedback, the system dynamically adjusts the transfer of articles to the buffer, ensuring that the buffer is proactively loaded with forecasted items while also receiving actual orders, thereby smoothing logistics utilization.
Solution Approach 2:
The system changes the timing parameter of article transfers by shifting from reactive transfer (after order receipt) to proactive transfer (before order receipt based on forecasts). This parameter change in transfer timing smoothens the logistics workflow and eliminates significant fluctuations in processing volume.
3Quantity of substance
If the buffer is loaded reactively based on actual orders, then storage space is used only when needed, but workforce requirements increase to handle load peaks
Solution Approach 1:
By performing preliminary transfer of forecasted articles to the buffer before customer orders are received, the system proactively utilizes buffer storage space. This eliminates the need for reactive workforce coordination during load peaks, as the buffer is continuously supplied with articles in advance, thereby reducing workforce requirements and coordination complexity.
Data Source
AI summary
The present invention relates to a system for the optimized use of a sorting conveyor, in particular of a pouch sorter, having a sorting conveyor which is set up to assemble items to form packing orders corresponding to customer orders, wherein the sorting conveyor has a buffer for the intermediate storage of items, and wherein the buffer can be connected in terms of conveying technology to a goods store; and a system control device.