Sequencing Tower and ASRS Coordination for Fulfillment Throughput
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Solution Overview
Problem
Existing order fulfillment systems face inefficiencies due to inconsistent demand, operator variability, and resource mismanagement, leading to subsystem starvation, overloading, and material waste, particularly in e-commerce and micro-fulfillment environments.
Innovation Solution
An integrated system and method utilizing a sequencing tower and automated storage and retrieval system (ASRS) to synchronize and optimize the operation of various subsystems, including carton erection, receiving, picking, and packing, by controlling the release of inventory items and containers to maximize productivity and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If systems are oversized to accommodate inefficiencies and operator variability, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The sequencing tower pre-positions containers and performs preliminary sorting operations before items reach the picking face. Donor totes are staged and prepared in advance, and the system anticipates picking requirements by maintaining optimized inventory positions, reducing the need for oversized buffer capacities
Solution Approach 2:
The sequencing tower acts as an intermediary between the ASRS and the picking face, mediating the flow of materials. It receives items from the ASRS, sequences them according to picking priorities, and releases them to the picking face in an optimized sequence, thereby managing variability without requiring system oversizing
2Manufacturing precision
If multiple donor totes are retrieved to fill one order, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The system performs preliminary actions by pre-positioning multiple donor totes containing items that are likely to be picked together at the picking face. The sequencing tower anticipates order requirements and stages the necessary totes in advance, so when an order is placed, the items are already positioned for immediate retrieval without requiring multiple sequential tote retrievals
Solution Approach 2:
The sequencing tower merges the retrieval operations for multiple donor totes into a single coordinated action. Instead of retrieving totes sequentially from the ASRS, the system combines multiple tote preparation operations and stages them simultaneously at the picking face, reducing the total time required to gather all items for an order
3Adaptability or versatility
If operators move between donor totes and multiple order totes, then adaptability is improved, but productivity decreases
Solution Approach 1:
The sequencing tower performs self-service by automatically sequencing and positioning containers according to picking requirements without operator intervention. The system autonomously manages the flow of donor totes and order totes, releasing them in the optimal sequence to the picking face, thereby eliminating operator movement between multiple totes while maintaining adaptability to different order configurations
Solution Approach 2:
The patent replaces the mechanical system of operator movement with an automated sequencing mechanism. The sequencing tower uses automated positioning and release mechanisms to deliver the correct totes to the picking face in the correct sequence, substituting human physical movement with automated mechanical systems that achieve the same adaptive functionality at higher speeds
4Adaptability or versatility
If subsystems operate at different capacities, then adaptability is improved, but productivity decreases due to starvation and overloading
Solution Approach 1:
The sequencing tower incorporates feedback mechanisms that monitor the status of upstream ASRS operations and downstream picking operations. Based on this feedback, the tower dynamically adjusts its sequencing and release rates to balance the capacities of different subsystems, preventing starvation of the picking face and overloading of the ASRS while maintaining operational flexibility
Solution Approach 2:
The system employs dynamic sequencing where the release rate and sequence of containers from the sequencing tower are continuously adjusted based on real-time conditions. The tower can accelerate or decelerate its output rate to match the varying capacities of connected subsystems, creating a dynamic balance that prevents both starvation and overloading while preserving adaptability to changing order patterns
Data Source
AI summary
A system and method is provided for controlling an automated warehouse or order fulfillment facility. The system includes a sequencing tower, which functions as a buffer for inbound items and shipping containers, and various pick/decant workstations which are connected between the sequencing tower and an automated storage and retrieval system (ASRS). The sequencing tower is adapted for receiving, storing, and releasing newly erected shipping containers and inbound vendor cases. The pick/decant workstations function as a hub between the sequencing tower and the ASRS, where operators at the pick/decant workstations pick order items to shipping containers to fulfil orders or pick inbound/vendor items to inventory containers to be stored in the ASRS. The system and methods synchronize the sequencing tower and ASRS to release items to arrive at the workstations simultaneously to optimize efficiency and throughput of the facility.