Warehouse Picking Station Layout Using Virtual Fulfillment Levels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing warehouse designs face limitations in space utilization, particularly vertical space, due to the constraints of picking station quantity and the need for additional floors or mezzanine constructions, which are not feasible in all regions and consume valuable space.
Innovation Solution
The implementation of virtual order fulfillment levels by arranging picking stations at different heights within the same floor, utilizing raised platforms and vertically stacked connecting conveyor systems to optimize space without additional construction, allowing for efficient use of both vertical and horizontal space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the quantity of picking stations is increased to improve order fulfillment capacity, then productivity increases, but the required floor space and conveyor system complexity increase
Solution Approach 1:
The patent applies vertical stacking of picking stations to utilize the third dimension (height) instead of expanding horizontally. Multiple picking stations are arranged at different vertical levels, allowing increased order fulfillment capacity without proportionally increasing floor space. The conveyor system connects these vertically stacked stations, enabling efficient material flow between levels.
2Productivity
If mezzanine floors are constructed to add more picking levels, then productivity increases, but construction cost and vertical space consumption increase
Solution Approach 1:
The patent segments the warehouse space into multiple vertical levels using raised platforms rather than constructing complete mezzanine floors. This segmentation approach allows picking stations to be distributed across different heights without requiring full-floor constructions, reducing both construction costs and vertical space consumption while maintaining productivity benefits.
3Area of stationary object
If picking stations are arranged at different heights to optimize space utilization, then space utilization improves, but conveyor system complexity increases
Solution Approach 1:
The patent merges multiple conveyor functions into a integrated vertical transport system that serves stacked picking stations. The conveyor system combines horizontal and vertical transport capabilities, using elevators or vertical conveyors to move goods between levels and horizontal conveyors within levels, creating a unified system that manages complexity while achieving efficient space utilization.
Data Source
AI summary
A warehouse for order fulfilment with a product storage and at least one order fulfillment level in which picking stations are arranged and supplied with articles from the product storage for picking into order load carriers according to allocated orders wherein each picking station is supplied with articles from the product storage by a connecting conveyor system on the least one order fulfillment level, where each order fulfillment level has at least one further virtual order fulfillment level in which picking stations are arranged at different height from the at least one order fulfillment level.