Put-to-Light Pick Cart Guidance for Multi-Item Order Picking
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Solution Overview
Problem
Traditional voice-controlled picking systems in warehouses are often inefficient and inaccurate, requiring extensive training and failing to handle multiple items in orders effectively.
Innovation Solution
A cloud-based put-to-light picking system utilizing customized software and specialized hardware, including a pick cart with LED lights and a handheld scanner, that guides users through the warehouse to efficiently collect products by illuminating buttons and lights based on order requirements, providing real-time progress and route optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If voice-controlled picking systems are used, then workers can be guided through the picking process, but the system is inefficient and inaccurate for handling multiple items in orders
Solution Approach 1:
The patent replaces voice-controlled guidance with a visual light-based guidance system. Pick carts equipped with LED lights and display buttons provide visual instructions to workers, eliminating the need for voice commands. This substitution improves picking accuracy and efficiency by providing clear, unambiguous visual cues for locating and selecting multiple items in orders.
Solution Approach 2:
The patent introduces a computer system as an intermediary between the warehouse management system and the pick carts. This intermediary processes order information, calculates optimal picking routes, and communicates instructions to the pick carts through lights and displays, coordinating the entire picking operation to improve overall efficiency and accuracy.
2Ease of operation
If extensive training is provided to workers for voice-controlled systems, then workers can operate the system, but the process becomes time-consuming and requires significant resource investment
Solution Approach 1:
The pick-to-light system is designed to be intuitive and self-explanatory through its visual interface. Lights automatically guide workers through the picking process without requiring trained interpretation of voice commands. The system serves itself by providing clear visual instructions that any worker can understand, eliminating the need for extensive training programs and reducing time investment.
3Productivity
If traditional picking schemes are used, then orders can be fulfilled, but the system fails to handle multiple items in each order effectively
Solution Approach 1:
The patent implements dynamic route optimization that adapts to multiple items in orders. The computer system calculates optimal picking routes in real-time based on the number and location of items required. Pick carts receive dynamic instructions through lights and displays, allowing the system to efficiently handle varying order compositions with multiple items rather than following fixed traditional picking paths.
Solution Approach 2:
The pick cart system is designed with universal functionality to handle diverse order requirements. The combination of LED lights, display buttons, and computer system coordination creates a multi-functional platform that can manage single-item or multi-item orders, adapt to different warehouse layouts, and accommodate various picking strategies, making the system versatile for handling multiple items in each order.
Data Source
AI summary
A picking system may provide a fast, flexible pick cart solution that may be deployed in warehouses or distribution centers to enable users to pick multiple items to put into a plurality of order bins (or carts) with high speed and accuracy to create completed orders ready for packing and shipping. Hardware and software may be bundled on the carts which may shorten training times, simplify integration, and allow for adjustment of carts based on product/items needs, all while improving picking efficiency. The picking system may include a cloud-based computer platform that may control light and displays in the lighted pick shelves that direct users to place a specified quantity of items in specific order bins. Users in remote locations may be linked to the cloud-based computer platform that may control lighted pick shelves in the users' locations.