JP2009298555A - Sorting method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To efficiently sort a large number of goods of a plurality of kinds greatly different in the total number of each of the kinds or in the number of containers thereof to each of shipping destinations. <P>SOLUTION: Picking shelves P, P' facing each other with a first conveyor 1a between them are arranged and picking shelves Q, Q' are arranged downstream of them, the tally total of the goods of a kind is calculated for each of the sorting kinds, the kinds the tally total of which is 1,000 or more are stored in the roughly same number of about 1/4 in the four picking shelves P, P', Q, Q', respectively, as a G4 family group, and thereafter, the kinds the tally total of which is 300 to 999 are stored roughly in the same number of about 1/2 in the two picking shelves P, P' or Q, Q' as a G2 family group, the kinds the tally total of which is smaller than the above are stored in total only in one picking shelf P as a G1 family group, and roughly the same number of goods are simultaneously inputted to one tiered box for shipment from the picking shelves facing each other. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention provides a large number of a plurality of varieties so that only the same varieties of products are accommodated in the same container (the vendor's delivery weight) from a plurality of vendors such as a product manufacturing factory, distribution center, distribution terminal, or product wholesaler. Refill the necessary number of products in different shipping weights for each shipping destination such as a store, company, or other factory where products are sent in multiple containers. The present invention relates to a product sorting method for assorting goods. This technology is useful for sorting a large number of different types of products by destination, mainly in joint distribution centers, distribution centers, and factories that manufacture various types of products.

  Conventionally, a joint distribution center is divided into two A and B types according to its work contents. In the A type, each vendor delivers the product items (also referred to as varieties) ordered to the final shipping destination as many as they are ordered and delivered in units of shipping destinations, and the joint distribution center already stocks the items. The work is simply loaded into the delivery car and delivered to the shipping destination.

In the B type, each vendor is unaware of the final shipping destination, delivers the total number of products to the joint distribution center for each item, and sorts and sorts the goods in units of the shipping destination within the joint distribution center. Each vendor's ordered items are loaded together in a delivery vehicle and delivered to the shipping destination.
As a work method for sorting and assorting shipments in units of shipping destinations within the B type distribution center, picking or sowing using a list display for each shipping destination and a digital display device corresponding to one item per shelf The method of doing is generally known. An example of picking using this digital display device is disclosed in Japanese Patent Laid-Open No. 5-242122.

In the type A of the above-mentioned joint delivery center, the delivery cost is reduced because one delivery vehicle is delivered to one shipping destination. However, for sorting assortment, each vendor sorts assortment for each final shipping destination. However, since each vendor distributes and sorts and sorts goods, it is not possible to introduce efficient equipment, and the cost of sorting and sorting is high and the total logistics cost is high.
Next, in the B type, the purpose of lowering the total logistics cost could be achieved to some extent by collecting and assorting the goods from each vendor at the joint distribution center. The sorting and assortment according to the list of the B type former is human sea tactical and inefficient. In addition, the method of picking or seeding using the digital display device corresponding to the one item per shelf of the B type is effective to some extent when the number of items is small, but as the number of items increases, it requires more space and becomes wider. The number of people picking has increased, and there has been a problem that the logistics cost has not decreased much.

Furthermore, in this type B type joint distribution center sorting method, if one type of product is made to correspond to the outlet of one picking shelf, the number of containers and types of products delivered will increase. As a result, the picking shelf becomes large, which places a heavy burden on the sorting operator and slows the sorting speed. In order to solve this problem, it is possible to divide the picking shelves along the conveyor and place them at multiple locations, and assign a workplace / sorter to those locations. Sorting work on a specific picking shelf that is divided into storage bins that store containers takes time, and the sorting work on this divided picking shelf dominates the overall sorting time, and is simply picking. There is a problem that efficient sorting work cannot be performed simply by dividing the shelves and the workplace / sorting workers into a plurality. In particular, when the shipping numbers of the same shipping destination are continuously sent to the sorting line conveyor for sorting, the problem becomes large.
JP-A-5-242122

  The problem to be solved by the present invention is to solve these conventional problems, and to provide a large number of a plurality of varieties in which the total number of varieties of products delivered in a plurality of varieties or the number of storage containers varies greatly depending on the varieties. The object is to provide a method for efficiently sorting individual products by destination.

The configuration of the present invention that solves this problem is as follows.
1) A large number of products of multiple varieties to be sorted are stored in picking shelves divided into a large number of delivery containers so that only the same varieties of products can be stored in the same container, and provided near the outlet of the picking shelves. In a sorting method in which a required number of products of the type sorted to the shipping destination is taken out from the front of the picking shelf at the sorting work place in front of the picking shelf for the shipping weight transported by the conveyor, and a plurality of items are introduced along the conveyor. In addition to setting up picking shelves and sorting workshops, find the total number of products of each type or the total number of containers that contain them, and divide them into multiple groups based on the total size. Sorting method characterized in that storage racks for the group's varieties are secured on the picking shelf 2) The picking shelf is sandwiched between the conveyors A single shipping number that is stored in a pair at each of the opposing positions and stored in the opposing picking shelves so that the number of products of the group with a large total number is approximately the same, and stopped on the conveyor in front of the opposing picking shelves The sorting method described in 1) above, in which products of the same product type are introduced from each of the picking shelves opposed to the weight, and approximately half of the number of the number of the weights placed. 3) Empty items assigned to the same shipping destination The shipping weight is continuously sent to the conveyor, stopped at the sorting workshop of multiple picking shelves, and the products are put into the same shipping destination at the sorting workshop in parallel, omitting the same shipping destination. The sorting method as described in 1) above, in which the sorted shipping weights are flown downstream at the same time so that they can be stacked and shipped in the same shipping destination unit. 4) Product types on each shelf of the picking shelf The product types to be stored are ranked in the order of storage, one batch is formed with the same rank product type, and empty shipping weights are sent so that the same ship-to party continues in one batch, After completing the input of all the products of one batch, the sorting method according to any one of 1) to 3) described above is to be transferred to the picking shelf or its sorting work place. Provided with a display or a collective display panel attached to each frontage that displays instructions for picking shelves and stores the number of products to be picked up and stores the products to be put into the shipping weight The sorting method according to any one of 1) to 4), wherein the sorting operation is performed according to the display on the display panel.

  In the present invention, a plurality of picking shelves and sorting workplaces are arranged along the conveyor, and the varieties are divided into a plurality of groups according to the total number of products to be sorted by type or the number of containers of the storage containers for storing them. By setting the number of shelves to be stored in more picking shelves for groups with more types of containers, it becomes possible to sort products of the same type with the same number of sorts at the same shipping destination in parallel, and each picking shelf Therefore, it is possible to efficiently sort a large number of products having a large difference in the total number of sorts depending on the kind.

A roller conveyor is generally used as the conveyor. Further, it is common to temporarily stop shipping weights at each work place of the conveyor and to put in the goods. A typical method for temporarily stopping the shipping weight is a method of temporarily stopping the shipping weight by installing a shipping weight stopper on the conveyor in front of the work place. After the product has been introduced, the stopper is retracted electrically or mechanically so that the shipping weight can be sent by the conveyor.
As in the embodiment, the shipping weight may be stacked with the same size and shape.

The number of groups to be divided according to the total number of containers is usually the number of picking shelves installed, and the container storage shelves for the product group of the maximum number of products or the total number of containers are secured in each picking shelf, and there are many less than that It is preferable that the total number of products or the total number of containers can be stored in a large number of picking shelves according to the total number.
The picking shelf can be installed at a position facing the conveyor, or separately on the upstream and downstream sides. In the picking shelf at the opposite position, approximately the same number is loaded from the opposite picking shelf for one stopped shipping weight. Therefore, it takes about half of the loading time.

  Grouping may be performed by using the total number of products for each product type or the total number of containers containing the products, and the number of stored items / containers for each of a plurality of picking shelves that store the products. The number is preferably a substantially equal number (substantially the same number) divided by the number of picking shelves storing the total number. The approximately the same number is used because the total number of products or the total number of containers may not be divisible by the number of picking shelves. In addition, the substantially same number on the opposite shelf is set to be approximately the same because it cannot be made the same when the total number of inputs is odd.

Further, in the first sorting line, products of the same product type are stored so as to be continuously back-packed on a shelf at a predetermined address of the picking shelf, and the products stored in the shelf are stored in the order of the product type. 2nd, 3rd, etc., and the combination of products of the same order on the picking shelf is taken as one batch, and after all products of one batch of product are taken out from the shelf front and completed, In the invention of the method of starting the input of batch products, and continuously sending empty shipping weights of the same shipping destination in the processing of the same batch, and stacking in units of the same shipping destination downstream, In addition, the same shipping destination can be sorted continuously, the same shipping destination can be efficiently stacked, and the sorting speed is further increased. In addition, it is useful to respond to the product of the product whose delivery is delayed because it can be put into the sorting operation without waiting.
In particular, in the first sorting line, picking shelves are arranged opposite to the conveyor, and approximately half of the standard number of products of the same number from the opposite picking shelves are put into one common shipping number, and the shipping number In the method of introducing the total standard number, the input work time is substantially halved and the sorting speed of the first sorting line is further increased.

  In addition, in the sorting method in which only products of the same category even for products of the same shipping destination are input to the same shipping weight, and the sorting method in which the weights of products of the same category are continuously input Because the products of the same category are accommodated in the same weight or in the nearest position, the work of taking the goods from the weight delivered to the shipping destination and placing them on the display shelf / storage shelf is Work can be done quickly because the product display and storage shelves are the same or close.

  Embodiment 1 of the present invention will be described below with reference to the drawings. The present invention is applied to the picking shelves P, P ′, Q, and Q ′ of the first sorting line of the first embodiment.

In the first embodiment, there are 30 varieties (hereinafter also referred to as items), and a total of 32,560 confectionery and bread products are manufactured by five manufacturers (deliverers: hereinafter referred to as vendors), i, ro, ha, ni, and ho. Is delivered to the sorting facility of the joint distribution center with the vendor's delivery number (container), and the sorting facility of the joint distribution center makes the shipping weight that can be stacked in a unified manner for each shipping destination of 50 stores This is a sorting method for a joint distribution center that repacks and assorts goods.
The delivery to the sorting equipment and the sorting work are performed once or a plurality of times a day. The above numerical values are examples of one delivery / sorting operation.
In this sorting equipment, the same number of products (also referred to as the standard number or the number of stitches) determined for each product type is put into an empty shipping weight, and the input weight (referred to as the normal weight) The first sorting line 1 that stacks and unloads in the same shipping destination unit, and the number of products in one shipping number is mixed with the number of products in the same number at the same shipping destination. The entered weight (called fractional weight) is stored in the automatic warehouse, and when a specified number of fractional weights of products of the same category are stored at the same shipping destination, they are unloaded from the automatic warehouse and stacked and carried out. There is a second sorting line 2. This is an example in which the stacking columns of normal weight and fractional weight of each line are joined at a temporary delivery place to a truck and delivered at a predetermined time.
Further, in the first sorting line of the first embodiment, after sorting one batch of products in the same order in the order of storage in the shelves at the front of each of the picking shelves, the next batch operation is started. Adopting batch type. In addition, in the same batch, shipping weights of the same category can be continuously sent to the same shipping destination, and sorting, stacking, and shipping destination shelf arrangement are made efficient. In addition, the picking shelves in the first sorting line are arranged in an opposing manner, so that about half of each empty shipping weight is placed from the opposing picking shelf, and a standard number is placed in the shipping weight. I have to. The sorting method in the first and second sorting lines of the present embodiment is performed with the priority of batch type, continuous loading at the same shipping destination, loading of the same category, and securing of filling rate 70 to 90%.

  In the first sorting line of the first embodiment, the products are grouped according to the number of the sorted products for each product type, and the products with many picking shelves P, P ′, Q, Q ′ are grouped in the large number of products. The storage shelf was secured.

The drawings and symbols of the first embodiment will be described.
FIG. 1 is a plan view showing a sorting facility of a joint distribution center which is an implementation facility of the first embodiment.
FIG. 2 is an enlarged explanatory view showing a first sorting line of the sorting facility of the joint distribution center.
FIG. 3 is an enlarged explanatory view showing a second sorting line of the sorting facility of the joint distribution center.
FIG. 4 is a front view showing the front end side of the picking shelf of the first sorting line.
FIG. 5 is a rear view showing the replenishment side of the picking shelf of the first sorting line.
FIG. 6 is a front view showing the front edge side of the picking shelf of the second sorting line.
FIG. 7 is a rear view showing the replenishment side of the picking shelf of the second sorting line.
FIG. 8 is an explanatory diagram illustrating a work flow of primary sorting and sorting by the first and second sorting lines according to the first embodiment.
FIG. 9 is an explanatory diagram of the order of batches according to the first embodiment.
FIG. 10 is an explanatory diagram showing the flow of products and information in a store, a vendor, a joint distribution center, and an ordering management information center.

  In the figure, SS is a sorting facility of the joint distribution center implementing the present invention, 1 is a first sorting line, 1a is a first conveyor using a roller conveyor, 1b is an empty shipping number supply device, and 1c is a shipping number. A free-falling stopper that temporarily stops the weight, 1d is an auto-labeler that attaches a bar code label that prints information on the shipping destination and the type and quantity of the product that has been placed on the shipping weight that the product has been placed on, and 1e that is shipped An image pickup device that captures and stores a state in which products are stored in the work weight, 1f is a stacking device that stacks shipping weights of the same shipping destination, and 1g is a sorting workshop p, p ′, q, q. The loading completion button 1h is operated to sink the stopper 1c provided on each of the conveyor paths before 'and retreat it so that the shipping weight can be sent by the conveyor 1a, 1h is the shipping destination name and the shelf front to be taken out Collective display panel that displays the number of products collectively, 1i is an empty container storage place, 1j is a stopper that stops the weight with an auto labeler device, H is a display provided for each shelf front of the picking shelf, Y is a container ( (Delivery weight), Z is a shipping weight, W is a product, and J is an order management information center.

In the figure, 2 is a second sorting line, 2a is a second conveyor using a roller conveyor, 2b is an empty shipping number feeder, 2c is a retractable stopper provided on the second conveyor 2a, 2d is An auto-labeler device that attaches a bar code label that prints information about the name of the shipper, the type and number of products that have been added to the shipping weight, and 2e photographs the state in which the goods are stored in the shipping weight 2f is an automatic warehouse for temporarily storing the shipping weight loaded with the product, 2g is a stacking device for stacking the shipping weight of the same shipping destination, 2h is in front of the sorting workshops r and n A loading completion button 2i that allows the stopper 2c provided on each conveyor path to be retracted and retreated so that shipping weight can be sent, and 2i collectively displays the shipping destination name, the shelf opening to be taken out, and the number of products to be taken out. Collection Display board, 2j is a stopper to stop the turn heavy in Otorabera apparatus 2d.
In the figure, reference numeral 3 denotes a management computer.

In the first sorting line 1, two picking shelves P and P ′ having substantially the same shape and size are arranged facing each other across the first conveyor 1 a on the upstream side of the first conveyor 1 a that conveys the shipping weight. On the downstream side, two picking shelves Q and Q ′ having substantially the same shape and size are arranged opposite to each other with the first conveyor 1a interposed therebetween. Each picking shelf P, P ′, Q, Q ′ has a pick-up instruction and a display H for displaying the number of pick-ups and a reset button H ₁ for turning off the pick-up shelf. Between the P, P ', Q, Q' and the first conveyor 1a, a work display p, p ', q, q' and a collective display panel 1h that collects the instructions of the outlets and the number of outlets for all the outlets. And a loading completion button 1g for lowering (releasing) the stopper 1c for stopping the shipping weight in front of each work place of the first conveyor 1a.

  4 and FIG. 5, P, P ', Q, and Q' are picking shelves arranged opposite to each other along both sides of the first conveyor 1a of the first sorting line 1. Each of the picking shelves is composed of free conveyor inclined shelves (fluid shelves) in which the left two of the four rows are inclined to the third shelf and the third shelf to the second shelf. Each shelf on the left two rows can be stacked in two containers, the third shelf can be stacked in five containers, and the rightmost column has one shelf and stacks containers in multiple stages for each cart Store. In one picking shelf P, P ', Q, Q', at least nine kinds of products can be taken out from the take-out slot. However, since the same shelves often store product containers of different varieties in the front and rear, nine or more varieties of products that can be supplied in one picking shelf are possible.

  Further, on the back of the picking shelves P, P ', Q, and Q', a replenishment display button G is displayed for each shelf, indicating that it should be replenished and turning off when the replenishment operation is completed. Y is a container (delivery weight) that contains a vendor's product, Z is a shipping weight that can be stacked with a uniform size and shape, and W is a product.

In the second sorting line 2, the picking shelves R and N are arranged in series on the same side on the upstream side and the downstream side of the second conveyor 2a that transports the shipping weight. Each picking shelves R, each extraction frontage N is provided with indicator H for displaying the number to retrieve the extraction command and the display cancel button H ₁ is the picking shelves R, between the N and the second conveyor 2a Stops the shipping weight in front of the workplaces r, n, the collective display panel 2i that collects the instructions and the number of take-out doors, and the work spaces r, n of the second conveyor 2a. An insertion completion button 2h for lowering (releasing) the stopper 2c, an auto labeler device 2d downstream thereof, a stopper 2j for stopping the numbering, and an automatic warehouse 2f are provided.

In addition, R and N shown in FIGS. 6 and 7 are picking shelves arranged along both sides of the second conveyor 2a of the second sorting line 2, and are inclined shelves (fluid shelves) of four rows and three stages of free conveyors. ). The lower shelf has a higher shelf height. The bottom shelf and the second shelf can be stacked with 4 containers Y (bender's delivery weight) Y. In the third stage, the height between the shelves is low so that two-stage containers Y can be stacked. At least 12 types of products can be taken out from one picking shelf R, N through a pick-up slot. However, since the same inclined shelf often stores product containers of different varieties in the front and rear, there can be more than 12 varieties of products that can be supplied in one picking shelf. Similar to the picking shelves P, P ′, Q, Q ′, each shelf is provided with a display H, a reset button H ₁ , and a replenishment button G.

  Downstream of the two picking shelves R and N are an auto labeler device 2d and an image pickup device 2e having the same function as the first sorting line 1, and further downstream the product shipping weight (fractional weight) Z An automatic warehouse 2f for temporary storage is provided, and further, a stacking device 2g for stacking the shipping weight Z of the same shipping destination is provided downstream thereof.

First conveyor 1a, second conveyor 2a, empty shipment number supply devices 1b, 2b, auto labelers 1d, 2d, imaging devices 1e, 2e, picking shelf display H, automatic warehouse 2f, stacking devices 1f, 2g The number of products delivered by vendor from each vendor, the number of containers, the type of products sorted by destination, the category, the number of sorting, the shelf opening of each picking shelf, and its storage A management computer 3 is provided for storing and managing the product type and the like, assigning the shipping destination of the shipping weight Z, managing the flow of the shipping weight Z, and the like.
In addition, the management computer 3 inputs the number of goods or containers for each product type stored in each of the picking shelves P, P ′, Q, Q ′, R, and N for primary sorting, and the shelf number of the storage shelf. -Storage and display management of the display H at the front end is performed.

  As the shipping weight Z of the first embodiment, one that can be stacked in a uniform size and shape is used. In addition, the number of products of only one product to be packed in the shipping weight Z is determined in advance as the standard number of products (also referred to as the number of positive weights) and stored in the management computer 3. ing. In the following, a standard number of products of one kind of product entered into the shipping weight Z is referred to as a positive weight, and one or more kinds of products are smaller than the standard number of goods in the shipping weight Z. The one with (fractional number) is called fractional weight.

In addition, the product categories in this embodiment are classified into five categories: confectionery bread, Japanese confectionery, Western confectionery, white bread, and side dish bread. Sweet bread categories include ampan I1, melon bread I2, chocolate cream bread I3, Danish bread I4, cupe bread I5, cream bread I6, jam bread I7, butter roll I8, stick bread I9, cream cornet I10, raisin bread I11, sugar roll I12 Varieties of products are included. The category of Japanese confectionery includes products of varieties of Dango I13, Steamed cake I14, Daifuku I15, Yokan I16, Manju I17, and Dorayaki I18. The confectionery category includes cheesecake I19, pie shoe I20, chocolate cake I21, stick roll I24, roll cake I22, and custard cake I23. In addition, the bread category includes merchandise of varieties such as single bread I25, brown rice bread I26, wheat bread I27, and raisin bread I28. The side dish bread category includes croquette bread I29 and yakisoba bread I30 varieties.
In both cases, the shipping weight Z is configured to accommodate only products of the same category as the first and second sorting lines. In addition, products are introduced in the same category order at the same shipping destination.

  In the first embodiment, the number of product types delivered to the joint distribution center from the five vendors i, b, ha, ni, and ho is 30 types, and the total number of products delivered for all types. There are 32,560. Of these, 29,908 products are sent to the first sorting line 1 with the standard number (the number of normal number of double stitches) input by the primary sorting operation described below, and the second sorting line 2 with the fractional number input is sent to the second sorting line 2 The remaining 2,652 pieces are separated and sent, and each line is sorted in parallel into 50 store shipping destinations E01 to E50, sorted on the first and second sorting lines 1 and 2, and stacked. This is an example of being delivered.

  In addition, in the first sorting line 1, the standard number is abbreviated from the picking shelves P to Q ′ in which the picking shelves P, P ′ or Q, Q ′ are opposed to each other in the G4 or G2 genus where the number of products is large. Half is thrown into the empty shipping weight stopped by the first conveyor 1a to reach the total standard number, thereby improving the work efficiency.

  Further, in the first sorting line of the first embodiment, the products with the largest number of inputs are divided into groups G4, G2, and G1 in the descending order, and the four picking shelves are grouped into the G4 category. Many G2 genus products have two picking shelves. The picking shelf allocation of the grouping is illustrated in Table 1.

  In addition, in the first embodiment, the types of products stored in each of the picking shelves are ordered in the order of storage, one batch is formed with the same-ranked products, and all the products of one batch of products are charged. As the next batch of batches is started, empty shipping weights are sent out from the shipping number supply device so that the same ship-to party continues in one batch unit. Therefore, the same shipping weight (positive weight) is surely sent to the same shipping destination and the stacking efficiency is increased without the same shipping weight being sent later in sorting in one batch.

The method of determining the batch is that the products to be stored (supplemented) so as to be back-packed from the back of the shelf into the shelf number of each foremost front of the picking shelf are the first, second, and third according to the order of storage. ,..., And a batch is formed with varieties of the same order (for example, the same order of No. 1, No. 2, No. 3, etc.) on the picking shelf. A first batch is formed with a variety group of rank “1”, a second batch is formed with a variety group of rank “2”, and a third batch is formed with a variety group of rank “3”.
FIG. 9 illustrates an example of batch formation. In the example of FIG. 9, the varieties (a) to (h) are in the storage order 1 in each shelf front, and these form a first batch, and then the varieties (i) to (p) are stored. Rank 2 is used to form a second batch, and varieties (q) to (x) are stored in rank 3, which forms a third batch.

  After the total amount of products of each type forming this batch is put into the shipping weight Z, the loading of the next batch of products is started. Even if the delivery weight of the product of the next batch type is stored in a part of the shelf front, the product is not taken out from this shelf front during the current batch, and the input of the current batch is completed and the next batch After the above process is started, the takeout of the product is started.

  Furthermore, in the first embodiment, as described above, the products of all varieties are divided into five categories of confectionery bread, Japanese confectionery, Western confectionery, bread bakery, and side dish bread, and the same shipping weight is assigned to the first and second sorting lines. Only stores products of the same category, and also introduces products of the same category even at the same shipping destination, and sorts them in order of category.

Furthermore, the types of products to be introduced in a mixed manner are selected so that the input filling rate is about 70 to 90% which is 100% or less even in the same category.
The filling rate (area occupancy) of one product of each type is calculated by filling rate (area occupancy) per piece = 100 / standard number (number of stitches) (%). The filling rate (input filling rate) of one weight for introducing products of the same category is calculated by the following equation. Table 1 shows the area occupancy of each type (item).
Input filling rate = Σ (filling rate per product) * (number of products of that product type)
In the second sorting line of the embodiment, the products of the same category are mixed in such a manner that the filling rate is in the range of 70% to 90% as much as possible.
Incidentally, the charging rate of the first sorting line in which only the standard number of products of one kind of the first embodiment is charged is always 100%.

The numerical values of the specifications of Example 1 are as follows.
1. Number of vendors / I, B, C, D, E ... 5 companies 2. Number of varieties (items) / I1-I30 ... 30 varieties Store (shipping destination) / E01-E50 ... 50 stores 4. Total number of products: 32,560 Number of first sorting line processed products: 29,908 6. 6. Number of second sorting line processed products: 2,652 Standard number (number of stitches) by product type ... See Table 1 8. Category: 5 categories 9. Input filling rate: 70 to 90%
10. 10. Number of picking shelves in first sorting line: 4 shelves (Picking shelves P, P ′, Q, Q ′) Opposite positions Number of picking shelves in the second sorting line: 2 shelves (Picking shelves R, N) Series position

Before describing the sorting operation of the first embodiment in detail, the flow of goods and the flow of information among the joint distribution center, the store, and the vendor will be described first. FIG. 10 illustrates the flow.
Product orders (product type, number of products, delivery date / time) from each of the stores E1 to E50 are sent to the order management information center J provided in the middle. The order management information center J collects the products ordered from each store by type (also referred to as items) at the required time, sets the delivery date and time, and stores the products of that type by the total number. Place an order with the vendor (I, B, C, D).
In addition, the ordering / ordering management information center J sends the information of each store (shipping destination), the type and number of ordered products from the store, and the delivery date / time to the joint delivery center SS, and inputs the information to the management computer 3.

Information on the product type, total number, delivery date and time, delivery date and delivery date of each product delivered from each vendor to the joint delivery center SS is jointly delivered from the order management information center J. The information is sent to the center SS, and the management computer 3 inputs this information before the product arrives at each vendor.
The management computer 3 not only calculates the total number of fractions of each product sent by the second sorting line 2 and prints the primary sorting list, but also the total number of delivered products, delivery date and time, etc. Grouping by the total number of products for each product type to be described, calculating the distribution of a large number of products on multiple picking shelves, etc. The order (rank) to be stored in the shelf address for each product type is determined.

  Each vendor manufactures (or stocks) the total number of ordered products (or the total number of orders) and delivers it to the joint distribution center SS. The joint distribution center SS sorts a large number of delivered products according to the stores (shipping destinations) from which they have been ordered, and stores the products of the ordered types in the shipping destination number Z to each store (shipping destination). ). The sorting method according to the first embodiment of the present invention starts when goods are delivered from a vendor to the joint distribution center SS.

  When the delivery weight Y from each vendor reaches the joint delivery center SS, the worker of the joint delivery center SS first reads the barcode printed on the wrapping paper of the product in the delivery weight Y. The data is read by an apparatus (not shown), the product type is displayed, and the total number of totals of the product type is confirmed from a printed list or a display (not shown) connected to the management computer 3 in the storage work place. Extract the total number from the delivery weight Y. When there is a large number, the delivery weight Y is separated, or when the number is small, a small number is pulled out from the number and accommodated in another number and separated. This is called primary sorting work. The separated products (numbers) are sent to the second sorting line 2 and stored in the picking shelves R and N. A number of remaining weights that have not been separated are sent to the first sorting line 1 and stored in the picking shelves P, P ', Q, Q'.

  The delivery weights delivered from each vendor and primarily sorted are picking shelves P, P ′, Q, Q ′ or picking shelves in the first and second sorting lines 1 and 2 as described below. Stored at a predetermined shelf number from the back of R and N with a delivery number Y.

  After moving the delivery weight Y after the primary sorting to the back of the picking shelves P, P ′, Q, Q ′ or R, N, the worker is on the wrapping paper of the goods in the delivery weight Y When the bar code is read by the bar code reading device, the management computer 3 inputs the bar code, blinks the display H on the back of the picking shelf of the picking shelf number to be stored, and the worker blinks. The delivery weight Y is stored in the shelf address where the display H is located. When the replenishment button G for the shelf address is pressed after the storage, information stored in the designated shelf address is input to the management computer 3. In this way, the operator reads the barcode of the wrapping paper of the delivered number of goods and stores the number in the shelf number where the display H on the back of the shelf flashes. By such work, the number is stored in each picking shelf P, P ', Q, Q' or R, N. The management computer 3 also calculates and stores attributes such as the number stored in the shelf number of each picking shelf, the type of the product, the genus of the group described below, the rank of the batch, the category, and the like.

  The products sent from the vendor in this way are a large number of products sent to the picking shelves P, P ′, Q, and Q ′ of the first sorting line 1 and the picking shelves R and N of the second sorting line 2 for each type. The product is divided into a small number of fractional products sent to the container and stored in the containers (delivery weight) Y in the picking shelves P to N of each line.

  The products sent from the vendor toward the first sorting line 1 and the second sorting line 2 are first sorted as described above. The division method will be described in detail. Divide the total number of products to be sorted for each product type by shipment destination by the standard number of products (the number of normal number of double stitches) to find the quotient and fraction. Next, the product number of the product obtained by multiplying the quotient by the standard number is totaled for each shipping destination, and the total number of products of the product type is counted as four picking shelves P of the first sorting line 1 (normal number heavy sorting line). The containers (delivery number) Y are stored in the required storage shelves of P ′, Q, and Q ′. Alternatively, since the number remaining after separating the following total number of fractions from the total number of the following types is the total number stored in the first sorting line, the number remaining after separation may be used.

  The fractions divided by the standard number (positive number of double stitches) are totaled for each shipping destination, and the total number of fractions is calculated for the two picking shelves R and N of the second sorting line 2 (fractional number sorting line). Store in the storage shelf. The total number of products of the product type is the sum of the total number and the total number of fractions. These calculations are performed by the management computer 3 based on information such as the type of product delivered from the vendor (ordering management information center J), the number of products and the shipping destination, and information such as product type, product number, picking shelf, and shelf address is The management computer 3 stores and manages it. The management computer 3 also creates a list of primary sorting operations by printing.

  Tables 4 to 7 show the sorting table. The total number of products of all varieties is 32,560, 29,908 of them are sent to the first sorting line 1, and the second sorting line 2 is sent to them. 2,652 are sent. The ratio of the number of products sent to the first and second sorting lines is about 10: 1.

The allocation of the storage of the product of the kind to the picking shelves P, P ′, Q, Q ′ in the first sorting line 1 will be described.
As described above, the total number of products (total number of normal items) is calculated for each product type. In the first embodiment, the total number (total number of normal weight items) of each type sorted in the first sorting line 1 is divided into three groups of G1, G2, and G4 as follows in accordance with the size of the number. .
・ G4 genus group: Total count (total number of normal weight items) exceeded 1,000 ・ G2 genus group: Total count (total number of normal weight items) 300-999 ・ G1 genus group ... Total count (total number of regular items) is less than 300

  The storage allocation of the goods (containers) of each group to the picking shelves P, P ′, Q, Q ′ is determined as shown in Table 2 below.

  In the first embodiment, grouping and allocation to the picking shelves P, P ′, Q, and Q ′ and an example of the number of stored products are as follows.

Goods delivered in containers (delivery weight) Y from each vendor are divided into three groups of G1, G2, and G4 genus according to the total number (total number of normal weight items) of each product type. . The G4 genus with a large total count is divided into four total counts and stored in containers Y in four picking shelves P, P ′, Q, Q ′. The products of the G2 genus are divided into two picking shelves P, P ′ or (Q, Q ′) and stored, and all the products of the G1 genus having a small number are stored in the picking shelves P.
The product type, the number of products, the number of containers, the standard number of each product type (number of normal number of double stitches), etc. are input and stored in the management computer 3, and the total number (total number of positive number items) and total number of fractions (Total number of fractional items) is calculated by the management computer 3, which stores and manages the storage shelf addresses, types, and numbers of the picking shelves P, P ', Q, and Q' of the container Y of the product. ing. In addition, the storage shelf address (frontage position) of the storage picking shelf, the number of products and the product type are printed, and the primary sorting is facilitated by the printed paper by the operator. The products of the total number of fractions of each kind of the primary sorting are sent to the second sorting line 2 and stored in the picking shelves R and N. The management computer 3 manages the type, number and storage shelf address stored in each picking shelf P, P ′, Q, Q ′.

  Tables 4-7 show the total number (total number of regular items) and the total number of fractions (fractional items) that are sorted by the first and second sorting lines after all products delivered from the vendor are sorted first. Total number), the number of products for each type stored in the picking shelves P, P ′, Q, and Q ′ for storing them, and the total number of items input for each type for each shipping destination (store) E1 to E50 (total number of items) Tables 4 to 7 show the total number (total number of regular weight items) input to the normal weight and the total total number of fractions (total number of fraction number items) input to the fraction weight.

  As described above, when the primary sorting is performed and the goods are stored in the respective picking shelves P to N, the management computer 3 determines whether the picking shelves P, P ′ or Q, Q ′ in the first sorting line 1 The order of the kinds stored on the shelf is given, one batch is formed with the same kind of kind, and sequential processing is performed for each batch. Thus, the empty shipping weight supply device 1b is operated so that the shipping weights Z assigned to the same shipping destination are continuous, and the empty shipping weights Z are assigned to the picking shelves P, P ′, Q, Send in front of Q '. The empty shipping weight Z from the empty shipping weight supply device 1b is stopped by a stopper 1c in front of each sorting work site p, p ', q, q'. In the first sorting line 1, two empty shipping weights Z are temporarily stopped. Here, at the left and right workplaces p, p ′ or q, q ′, approximately half of the standard number is loaded from the opposed picking shelves P, P ′, Q, Q ′, and the standard number is loaded into one shipping weight. To do. The first display 1h displays approximately half of the standard number.

  On the other hand, in the second sorting line 2 as well, an empty shipping number Z to which a shipping destination is assigned is sent from the empty shipping number supply device 2b as judged from the product type of the picking shelves R and N. The stopper 2c is stopped in front of the sorting work places r and n of the picking shelves R and N (see FIGS. 1 and 2).

  Both the first conveyor 1a and the second conveyor 2a can transport the shipping weight Z only serially (one row, one piece forward). Therefore, the stopper 1c is controlled so that the empty shipping weight Z is stopped before the work places p, p ', q, q' as much as possible, so that sorting of the same shipping destination can be performed almost simultaneously.

When an empty shipping weight Z stops before each sorting work place p, p ′, q, q ′ on the first sorting line 1, sorting work is started almost simultaneously on each line.
The operator looks at each display H on the front surface of the picking shelves P, P ′, Q, Q ′ or looks at the collective display boards 1h, 2i to confirm the position of the frontage to be taken out and the number of products to be taken out. the retrieval request number of products from its frontage, press the reset button H ₁ When you take out, to clear the display. Thereafter, the taken-out merchandise is put into the stopped shipping weight Z.

  In the first sorting line 1, the number of products to be taken out is picked up from the picking shelves P, P 'or picking shelves Q, Q' by the standard number (the number of regular number of double stitches) determined by the product type. Half of the standard number is taken out from each of the opposing picking shelves P, P '(Q, Q') and put into one common shipping weight Z. Accordingly, the display unit H displays an integer value that is approximately ½ of the standard number.

  The product input operation at each sorting work site p, p ′, q, q ′ of the first sorting line 1 is a standard number (the number of normal number of double stitches) or about half of the products of one kind from the storage shelf. Since it is a sorting operation that is simply taken out and put in an empty shipping weight Z, it can be performed quickly and easily. In the G4 genus group with many products to be sorted, the four picking shelves P, P ', Q, and Q' have two sets of opposing picking shelves, and two sets of half of the standard number are processed in parallel. Can efficiently introduce products.

  In addition, since the sorting work at the sorting work place p, p ′ or (q, q ′) of each picking shelf is the same standard number (the number of the normal number of double stitches) input at the same shipping destination, the sorting is substantially the same. Since it will be working time, sorting will be completed at the same time (loading completed) and the positive weight will be able to flow downstream. While flowing downstream, an empty shipping weight Z for the next sorting is sent from the upstream.

  Furthermore, in the first sorting line 1, the order is assigned in order to the types stored in the picking shelf, one batch is formed with the same-ranked types, and the batch method of sorting for each batch is completed. The shipped shipping weight Z is reliably and continuously transported from the same shipping destination, and the label of the shipping destination, product type and number of products is pasted on the shipping weight Z by the auto labeler 1d, and the imaging device At 1e, the state of the introduced product is photographed from above for each shipping weight, and the image is stored together with the shipping destination, product type, number of products, and weight ID. When this shipping weight Z collapses or falls over the subsequent stack, it can be immediately recovered manually.

In addition, while the sorting of the same shipping destination in the same batch is continued, the products are input so that the number of products of the same category in the same category are continuously loaded. In Table 4-7, items standard number of same type in the same category with respect to the store E _n identical shipping destination included in the same batch in the row direction of the table (Ireme number) by picking shelves P, P ', Q, We are going to put it into the shipping weight from Q '. The charging rate of products in the first sorting line is always 100%.

  In addition, when the introduction of the product of the same category at the same shipping destination is completed in the batch, the standard number of products of the product of the next category is introduced. When the introduction of products of all categories of the same shipping destination is completed, the same sorting is performed for the next shipping destination. The computer 3 displays the information on the display H and the collective display panels 1h and 2i so as to make such sorting.

  On the other hand, in the second sorting line 2, the empty shipping weight Z sent from the empty shipping weight supply device 2b is temporarily stopped by the stopper 2c in front of the work place r of the picking rack R. The worker knows the type (frontage) to be taken out and the number of pieces to be taken out from the plurality of indicators H or the collective display panel 2i of the picking shelf R, and the shipping number in which the products of the plurality of types are temporarily stopped for the number of displays. Throw in heavy Z. When the loading completion button 2h is pushed after the loading is completed, the shipping weight Z loaded with the product is sent and stopped at the stopper 2c in front of the work place n of the next picking shelf N. The empty shipping guard stops at the work place r. At the work place n, the worker takes out the required number of products from the frontage according to the display on the display H of the picking shelf N or the collective display panel 2i, and puts it into the shipping weight Z that is stopped. The When all are loaded, the loading completion button 2h is pushed to send the shipping weight Z completed loading downstream.

  The sorting operation in the second sorting line 2 is performed by picking up a plurality of products of the same category from the picking shelves R and N to the shipping weight Z and extracting a plurality of products of the same category to the shipping weight Z. In many cases, products with different varieties are taken out from each of the two picking shelves R and N and loaded, so the time required for sorting one shipping load is generally long. It will be. In addition, when it is not possible to load fractional products from the same shipping destination with only one shipping weight Z, a plurality of empty shipping weights Z are sent so that all fractional products are sorted. At that time, the management computer 3 manages the types and the number of products to be put into each shipping weight Z, and displays them on the display H and the collective display panel 2i so that the work can be smoothly performed.

  On the other hand, even in the second sorting line, fractional products are stored in the picking shelves R and N. The order is stored in the order of storage in the shelf addresses of the shelf fronts of the picking shelves R and N, one batch is formed in the same order, and the same shipping destination is continuous within the same batch, and is the same at the same shipping destination. The loading rate when the products of the category of the product are introduced into the same weight at the same shipping destination so that the product weight of the product of the category is continuous is as high as 70 to 90%. As shown, the computer 3 calculates the type and number of products to be input and displays them on the display H and the collective display panel 2i.

Batch in the second sorting line (1, 2), category (sweet roll, sweets, confectionery), picking shelves R, shelf frontage of N, Table 8 varieties and number examples should put the item ID and (variety) for the store _{E n} It shows.

  In the example of Table 8, an example in which a product is input in the same batch so that the input filling rate in the same shipping destination and the same category (confectionery bread classification) is as high as 70 to 90% is as follows.

In the same store E1 of the second sorting line, fractional products are displayed and introduced into the 12 varieties of “confectionery bread” of the same category in the first batch in consideration of the filling rate as follows.
For the first empty shipping weight, 4 items (product type) I1 products and 3 item (product type) I4 products are placed. Then, the charging rate becomes 40% + 38% = 78%. Next, six items (product type) I7 are put into the second empty shipping weight. The charging rate at this time is 60%, and when the next item (product type) I9, I11 in the next shelf front is input, it exceeds 100%. The charging is completed at 60%, and it flows downstream.
For the third empty shipping weight, if 6 items (product types) I9 and I11 are introduced, three, the filling rate is 50% + 25% = 75%. As described above, the computer 3 selects the products to be input from the shelf front as close as possible so that the input filling rate is 70 to 90% even for the products of the same category, and inputs them to the display H and the collective display panel 2i. Display the varieties and quantity.

  The shipping weight Z for which the product has been loaded in the two picking shelves R and N is sent downstream by the second conveyor 2a, and the label is changed to the shipping weight Z by the auto labeler 2d as in the first sorting line 1. At the same time, a product having a shipping weight Z is photographed by the imaging device 2e, and the image is stored together with information on the shipping weight number, the shipping destination, the product type, and the number.

  Thereafter, the shipping weight Z into which the merchandise is input is stored in the automatic warehouse 2f. Multiple shipment weights Z are received, and multiple shipment weights Z containing products of the same category at the same shipment destination are delivered at an appropriate time, and the same shipment destination is provided by the downstream stacking device 2g. Shipping weights Z of the same category or near categories are stacked in about 20 steps and moved to a temporary place for delivery. At this time, together with the shipping weight Z of the same shipping destination stacked in about 20 stages from the first sorting line 1, they are transported together by a truck or the like. The shipping weights Z are stacked in preparation for the storage of the joint distribution center to be narrow and preparation for loading trucks and the like.

  As described above, in this embodiment, the products delivered to the joint distribution center from a plurality of vendors are the first sorting line 1 in which a large number of products are put into the shipping weight Z and the same number of the same product type, and a small number of fractions. By dividing and processing in parallel with the second sorting line 2 that sorts the numbers so that many types are mixed, the burden of sorting work can be reduced and the sorting work time can be shortened.

Further, as in the first sorting line 1 of the first embodiment, varieties having a large number of sorting (total number of totals) are grouped by the number of the number, and the types are stored in a picking shelf having a large number of groups. By securing the shelves, it is possible to perform almost simultaneous loading in a plurality of picking shelves, and the sorting speed can be increased. In particular, in batch processing that processes the same order of the products to be stored in the same order as one batch, the shipping weight Z for the same shipping destination can be surely continuously flowed, and the stacking must be temporarily stored. It can be done directly and sorting work is effective.
Furthermore, when the numbers of the products of the same category are stacked or arranged in series or close to each other, the work of displaying and storing the goods after being delivered to the shipping destination becomes easy.
In addition, when the charging rate is set high to 70 to 90%, the number of used weights can be reduced.

  The present invention is not limited to a configuration in which a plurality of picking shelves are necessarily arranged in an opposing manner as in the first sorting line of the first embodiment. The present invention can be used even when each kind of product is produced in each department of the same factory and shipped to an order destination.

It is a top view which shows the sorting equipment of the joint delivery center which is the implementation equipment of Example 1. FIG. It is an expansion explanatory view showing the 1st sorting line of the sorting equipment of a joint distribution center. It is an expansion explanatory view showing the 2nd sort line of the sort equipment of a joint distribution center. It is a front view which shows the take-out front side of the picking shelf of a 1st sorting line. It is a rear view which shows the replenishment side of the picking shelf of a 1st sorting line. It is a front view which shows the take-out front side of the picking shelf of a 2nd sorting line. It is a rear view which shows the replenishment side of the picking shelf of a 2nd sorting line. It is explanatory drawing which shows the work flow of the primary sorting of Example 1, and the sorting by the 1st, 2nd sorting line. It is explanatory drawing of the order | rank of the batch of Example 1. FIG. It is explanatory drawing which shows the flow of the goods and information of a store, a vendor, a joint delivery center, and an order placement management information center.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 1st sorting line 1a 1st conveyor 1b Empty weight supply device 1c Stopper 1d Auto traveler device 1e Imaging device 1f Stacking device 1g Loading completion button 1h Collecting display board 1i Empty container place 1j Stopper 2 2nd sorting line 2a 1st 2 Conveyor 2b Empty shipment number supply device 2c Stopper 2d Auto-traveller device 2e Imaging device 2f Automatic warehouse 2g Stacking device 2h Loading complete button 2i Collective display panel 2j Stopper P, P ', Q, Q' Picking shelf H Display H ₁ Reset button G Refill button Y Container (delivery weight)
Z Shipping weight W Commodity J Order management information center SS Sorting facility of joint distribution center p, p ', q, q' Sorting workshop R, N Picking shelf r, n Sorting workshop 3 Management computer

Claims (5)

  Conveyors that are installed near picking shelves of a large number of products to be sorted, divided into a number of delivery containers so that only the same type of products can be stored in the same container, and stored in picking shelves In the sorting method in which the required number of products of the kind sorted to the shipping destination is picked up from the opening of the picking shelf at the sorting work place in front of the picking shelf with respect to the shipping weight being transported in the picking shelf, a plurality of picking shelves along the conveyor In addition, the total number of commodities of the product type or the total number of containers containing the product is obtained for each product type, and the total size is divided into a plurality of groups. A sorting method characterized by securing storage shelves for the varieties of the group.   A pair of picking shelves are provided at each of the opposing positions so that the conveyor is sandwiched between them, and the opposing picking shelves are stored so that the number of products of the group with a large total number is approximately the same, and stored in the conveyor in front of the opposing picking shelves. 2. The sorting method according to claim 1, wherein a product of the same product type is input from each of the picking shelves opposed to one shipping weight, which is about half of the number of the weights that are input.   Empty shipping weights assigned to the same ship-to party are continuously sent to the conveyor, stopped at the sorting workshop of each of the multiple picking shelves, and products are sent to the shipping weight of the same ship-to party in parallel at each sorting shop. The sorting method according to claim 1, wherein the same shipping destination is sorted at substantially the same time, and the sorted shipping weight is flowed downstream so that the same shipping destination can be stacked and shipped.   The product types stored on each shelf of the picking shelf are ranked in the order of storage, so that one batch is formed with the same rank product type, and the same ship-to party continues in one batch. The sorting method according to any one of claims 1 to 3, wherein an empty shipping weight is sent out, and after the completion of the introduction of all the products of one batch type, the operation moves to the next batch of input work.   Indicators or sets attached to each picking shelf or the sorting work area for displaying instructions for picking shelves and storing the number of products to be picked up. The sorting method according to any one of claims 1 to 4, further comprising a display panel, wherein the sorting operation is performed according to the display on the display or the collective display panel.

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