Workstation Order Scheduling With Virtual Capacity Pre-Storage
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Solution Overview
Problem
Existing order processing methods are inefficient when dealing with a large quantity of orders.
Innovation Solution
An order processing method that determines to-be-processed orders based on a workstation's free slot capacity and virtual capacity, dividing orders into currently processed and delayed processed orders, and generating outbound instructions to optimize the transfer of goods using a transfer device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the traditional order processing method is used where the scheduling system assigns orders sequentially to workstations, then the system is simple to operate, but the outbound efficiency is low when dealing with large quantities of orders
Solution Approach 1:
The patent introduces a virtual capacity concept that allows workstations to be pre-assigned orders beyond their immediate physical slot capacity. The server pre-calculates and assigns to-be-processed orders including both currently processable orders and delayed processed orders, preparing the workflow in advance. This preliminary action enables the system to handle larger order volumes without proportionally increasing physical resources, thereby improving outbound efficiency while maintaining manageable system complexity
Solution Approach 2:
The patent segments the order processing into distinct phases: currently processed orders (handled immediately within free slot capacity) and delayed processed orders (scheduled for future processing). This segmentation allows the system to manage complex order volumes by breaking them into manageable batches, improving overall throughput without overwhelming individual workstations, thus resolving the contradiction between productivity and system complexity
2Productivity
If more orders are assigned to workstations simultaneously, then the outbound efficiency improves, but the workstation slot capacity is exceeded causing processing delays
Solution Approach 1:
The server performs preliminary calculation to determine the optimal mix of currently processed orders and delayed processed orders for each workstation. By pre-assigning delayed processed orders that will be processed after current orders complete, the system maximizes workstation utilization without causing actual processing delays. This preliminary planning allows higher throughput while maintaining timely order fulfillment
Solution Approach 2:
The patent ensures continuous utilization of workstation capacity by seamlessly transitioning from currently processed orders to delayed processed orders. When free slots become available, delayed processed orders are automatically activated for processing. This continuity eliminates idle time and maintains high throughput without creating bottlenecks or delays, resolving the contradiction between processing volume and waiting time
3Productivity
If the transfer device only moves goods for currently processed orders, then the transfer device operation is simple, but the transfer device capacity is underutilized
Solution Approach 1:
The transfer device is designed to handle multiple types of orders simultaneously - both currently processed orders and delayed processed orders. The device receives comprehensive outbound instructions from the server that include routing information for different order types. This multi-functionality allows the transfer device to fully utilize its capacity by moving goods for various orders in sequence, improving productivity while the centralized server management keeps control complexity manageable
Solution Approach 2:
The system implements feedback mechanisms where the server monitors workstation status (free slot capacity, processing progress) and dynamically adjusts transfer device assignments. The server receives feedback about order processing status and uses this information to optimize transfer device utilization by assigning appropriate delayed processed orders. This feedback loop enables higher transfer device utilization while maintaining simple operational control through centralized management
Data Source
AI summary
An order processing method includes obtaining a free slot capacity and a preset virtual capacity of a workstation; determining a to-be-processed order according to the free slot capacity and the virtual capacity, the to-be-processed order includes a currently processed order and a delayed processed order, a quantity of the currently processed order is the free slot capacity, and a quantity of the delayed processed order is the virtual capacity; generating a first outbound instruction according to the currently processed order; generating a second outbound instruction according to the delayed processed order; sending the first outbound instruction to a first transfer device to cause the first transfer device to move goods in the currently processed order to the workstation; and sending the second outbound instruction to a second transfer device to cause the second transfer device to move goods in the delayed processed order to a pre-storage area.