Warehouse Order Processing With Virtual Capacity for Faster Dispatch
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Solution Overview
Problem
Existing order processing methods are inefficient when dealing with a large quantity of orders, leading to suboptimal utilization of workstation capacity and increased time in transferring goods from storage to workstations.
Innovation Solution
A method that assigns orders to workstations based on a virtual capacity and free slot capacity, distinguishing between currently processed and delayed orders, and utilizing a transfer device to move goods accordingly, with real-time monitoring of workstation status to optimize movement paths and reduce unnecessary transfers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the scheduling system assigns orders one batch at a time according to workstation capacity, then the workstation can process orders sequentially, but the outbound efficiency is low when the quantity of orders is large
Solution Approach 1:
The patent applies preliminary action by pre-transferring cases to the workstation before the actual picking operation begins. The scheduling system identifies cases containing goods needed for multiple orders and transfers them in advance, so that when orders are assigned to workstations, the cases are already available. This eliminates the need for repeated transfers between warehouse and workstation, significantly improving outbound efficiency and reducing time loss.
Solution Approach 2:
The patent implements continuity of useful action by maintaining a continuous flow of case transfers and order processing. The system continuously monitors workstation capacity, case availability, and order requirements, dynamically adjusting the scheduling to ensure that cases are transferred to workstations continuously rather than in discrete batches. This continuous operation maximizes workstation utilization and eliminates idle time, thereby improving productivity.
2Productivity
If the transfer device moves cases back and forth between warehouse and workstation for each order batch, then orders can be processed, but the transfer device utilization is low and time is wasted
Solution Approach 1:
The scheduling system performs preliminary identification of cases that will be needed for upcoming orders and transfers them to the workstation in advance. This preliminary action allows the transfer device to complete transfers before orders are assigned, eliminating the need for repeated back-and-forth movements. The transfer device operates more efficiently by transferring cases in larger batches rather than making multiple short trips.
Solution Approach 2:
The patent merges multiple case transfer operations into a single continuous transfer process. Instead of transferring cases for each order separately, the system combines transfers of multiple cases that are needed for different orders into one unified transfer operation. This merging reduces the total number of trips the transfer device must make, improving its utilization and reducing overall transfer time.
3Reliability
If the system waits for workstation slots to be free before assigning new orders, then workstation capacity is respected, but the response time for order processing is increased
Solution Approach 1:
The system performs preliminary assessment of case availability and workstation capacity before order assignment. By identifying cases that can be pre-transferred and evaluating workstation status in advance, the system can prepare the workflow ahead of time. This allows orders to be assigned more quickly once workstation slots become available, as the cases are already in position and ready for picking.
Solution Approach 2:
The scheduling system implements continuous feedback monitoring of workstation slot availability, case transfer status, and order queue conditions. This real-time feedback allows the system to dynamically adjust the timing of order assignments and case transfers, optimizing the utilization of workstation capacity while minimizing delays. When slots become free, the system immediately responds by assigning new orders and initiating case transfers without unnecessary waiting.
Data Source
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AI summary
The present disclosure provides an order processing method, an outbound method, a device, a system, and a storage medium. A server obtains a slot capacity of each workstation and a preset virtual capacity, determines a to-be-processed order of each workstation according to the slot capacity and the virtual capacity, and generates an outbound instruction according to the to-be-processed order. A transfer device transfers goods in the to-be-processed order from the warehouse according to the outbound instruction. According to this solution, more orders can be assigned at a time, and thus more goods can be carried from the warehouse at a time, improving the outbound efficiency.