Temporary Storage Management System for Warehouse Congestion
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Solution Overview
Problem
Warehouses face inefficiencies in managing temporary storage due to congestion scenarios, particularly with inbound shipments where low-priority loads block high-priority ones, and outbound shipments where building mixed pallets is labor-intensive and space-constrained, leading to delays and financial penalties.
Innovation Solution
Implementing a temporary storage management system that uses an electronic locationing system to redirect asset tag location information from a warehouse management system to a temporary storage management system, allowing items to be opportunistically stored and retrieved, thereby bypassing predetermined storage locations and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If items are stored in predetermined storage locations according to WMS planning, then storage organization is maintained, but congestion occurs when low-priority loads block high-priority loads and dedicated staging space is insufficient
Solution Approach 1:
The system dynamically determines storage locations based on priority and availability. Instead of fixed predetermined locations, the temporary storage management system allows items to be placed in any available location within the warehouse, with locations being dynamically allocated and tracked through electronic locationing systems and asset tags
Solution Approach 2:
The patent introduces a new dimension of temporary storage management by implementing a separate temporary storage management system that operates alongside the traditional WMS. This creates an additional layer of storage organization that allows items to be stored in temporary locations without disrupting the predetermined storage structure, effectively adding a new spatial dimension for congestion management
2Ease of operation
If dedicated staging areas are established for outbound loads, then load preparation is facilitated, but warehouse space is consumed and throughput is reduced
Solution Approach 1:
The temporary storage locations serve multiple functions: they act as staging areas for outbound loads, temporary holding areas for inbound items, and flexible space that can be allocated based on current operational needs. The same physical space can be used for different purposes at different times, eliminating the need for dedicated single-purpose staging areas
Solution Approach 2:
The system enables preliminary load preparation by allowing items to be staged in temporary locations in advance of actual shipping needs. Items can be pre-positioned, pre-assembled, or pre-packaged in temporary storage areas, and then quickly moved to final destinations when ready, reducing last-minute preparation time and improving overall throughput
3Productivity
If low-priority shipments are unloaded first to clear docks, then high-priority shipments can be processed, but unloading time and labor resources are increased
Solution Approach 1:
Items from low-priority shipments are quickly placed in temporary storage locations without requiring full processing or sorting at the time of unloading. This preliminary action clears the dock rapidly while the items remain in temporary holding, allowing high-priority shipments to be processed immediately without the time penalty of complete unloading and sorting of low-priority items
Data Source
AI summary
Methods and systems for managing temporary storage in warehouses are disclosed herein. An example method includes receiving a first electronic notification that items of a shipment are to be stored in temporary locations in a warehouse; in response to the first notification, automatically redirecting location information determined electronically based on asset tags affixed to the items from a warehouse management system to a temporary storage management system as the items are stored in the temporary locations; receiving a second electronic notification that the items are to be moved from the temporary locations to final locations; and in response to the second notification, automatically communicating the redirected location information to enable the warehouse worker to locate the items at the temporary locations based on the redirected location information and store them at the final locations, the final locations identified for the warehouse worker by the warehouse management system.