Storage Unit Replenishment at Picking Stations
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Solution Overview
Problem
Current methods for order fulfillment and storage unit replenishment in storage facilities are complex, inefficient, and require significant technical work, leading to poor cubic utilization of storage units and increased costs due to the need for separate operations like consolidation and sorting outside of aisles.
Innovation Solution
A method where storage units are replenished and consolidated directly at the picking station by the picker, allowing for increased storage density, reduced technical complexity, and improved throughput by eliminating the need for dedicated replenishment operations and sorting outside the aisles, using cross-conveyance locations within the storage racking system for efficient unit exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If storage units are replenished using separate dedicated replenishment operations, then storage units can be refilled, but cubic utilization becomes poor and system complexity increases
Solution Approach 1:
The patent combines the replenishment operation with the order fulfillment picking operation. Pickers simultaneously pick goods for orders and replenish storage units from the same storage locations, eliminating the need for separate replenishment operations and improving storage unit utilization
Solution Approach 2:
The storage units serve multiple functions: they store goods for order fulfillment and simultaneously serve as replenishment sources. The same storage locations are used for both picking and replenishment activities, increasing their utilization efficiency
2Quantity of substance
If consolidation operations are performed separately during off-peak hours, then storage units can be optimized, but system complexity and operational costs increase
Solution Approach 1:
The patent enables continuous replenishment activity by integrating it into the ongoing picking operations. Instead of performing consolidation during off-peak hours, replenishment occurs continuously whenever pickers access storage locations, maximizing system productivity
3Ease of operation
If sorting and matching operations are performed in the front-zone outside racking, then goods can be organized, but technical work and space requirements increase
Solution Approach 1:
The patent extracts the sorting and matching operations from the front-zone and relocates them to the storage aisles themselves. Storage units are organized and prepared within the racking structure, eliminating the need for separate sorting areas outside the racking
4Productivity
If multiple separate operations (picking, replenishment, consolidation) are performed, then order fulfillment can be achieved, but costs and technical complexity increase
Solution Approach 1:
The patent merges picking, replenishment, and consolidation operations into a single integrated workflow. Pickers perform all three functions by accessing the same storage locations during normal operations, eliminating the need for multiple separate operational systems
Data Source
AI summary
A method of order fulfilling and replenishment of storage units in a storage facility can be provided. The storage units can be stored in a plurality of storage racking units and levels of a storage racking, with at least one storage-entry feeding line and at least one outbound line being provided for each storage module. Additionally, at least one automatic storage and retrieval device can be provided for retrieval of storage units from the multilevel racking or storage into the multilevel racking, and at least one picking station to which storage units are fed can also be provided for picking for fulfilling orders. Thus, fully or partially deplenished or depleted storage units can be replenished or consolidated on the fly directly at the picking station by the picker.