Automated Sortation Container Inversion for Order Processing Speed

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Solution Overview

Problem

Current order fulfillment processes face inefficiencies, particularly in automated sortation, leading to bottlenecks and delays, which hinder the ability to meet increasingly high customer expectations for rapid delivery and increase labor costs.

Innovation Solution

The implementation of an automated order sortation system that includes an item conveyor system, a barcode scanner, and a container handling system capable of inverting containers to efficiently transfer items onto the conveyor and to the automated sorter, optimizing the pace of material flow and reducing manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated order sortation systems are used to increase fulfillment efficiency, then order processing speed improves, but system complexity and initial costs increase

Engineering Contradiction:

Improveorder processing speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the sortation process into distinct functional modules: container handling system, item conveyor system, barcode scanning system, and automated sorter. Each module performs a specific function and can operate independently, reducing overall system complexity while maintaining high automation levels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The container handling system acts as an intermediary between the storage area and the automated sorter, managing container inversion and item transfer. This intermediary component simplifies the interaction between complex subsystems and enables smoother material flow.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If manual item transfer methods are used, then system complexity is reduced, but labor costs and processing time increase

Engineering Contradiction:

Improvesystem complexityVSAvoidprocessing time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The container handling system automatically inverts containers and transfers items to the conveyor without requiring manual intervention. The system serves itself by using the container's own structure and the handling mechanism to accomplish the transfer, eliminating labor costs while maintaining speed.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If containers are not inverted before transfer, then the transfer process is simpler, but item flow to the conveyor is inefficient and causes downtime

Engineering Contradiction:

Improvetransfer process simplicityVSAvoidmaterial flow efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The container handling system inverts the container before item transfer, flipping it so that items are discharged onto the conveyor in an efficient manner. This inversion enables smooth material flow and prevents bottlenecks, significantly improving productivity despite the additional inversion step.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11648589B2Systems and methods to enhance the utilization of order sortation systems

Publication Date: 2023.05.16 TARGET BRANDS INC

AI summary

Systems and methods can enhance efficiencies of order fulfillment processes. For example, this document describes systems and methods for optimizing the efficiency of automated order sortation processing lines to expedite order processing in a cost-effective manner. In some embodiments, this innovation includes a fast, efficient method for supplying items to order sortation process lines so that they operate at peak efficiently, and the workers are utilized at a high level of efficiency.