JP2010260697A - Picking system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a multi-order type picking system superior in working efficiency. <P>SOLUTION: This picking system includes an article collecting conveyor for carrying an article collecting box, a storage shelf arranged in a plurality of respective zones set along the article collecting conveyor, an order display arranged in the respective zones, an article connecting box supply means for supplying one or more of article collecting boxes storable in one zone to the article collecting conveyor as one group, and a control means for controlling the whole system. This control means recognizes a picking frequency in the respective zones based on inputted order data, and determines the number of article collecting boxes storable in one zone with every duct based on the picking frequency, and is constituted so that the article collecting boxes of its number are sent out to the article collecting conveyor from the article collecting box supply means. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a picking system for picking a specified product out of products on a rack and putting it into a collection box conveyed by a collection conveyor, and in particular, can pick a plurality of orders at the same time. The present invention relates to a so-called multi-order picking system.

  In general, a line-type digital display picking system is used for assembling a wide variety of products in order (order) units. This kind of picking system includes a collection conveyor that conveys a collection box, and a storage shelf that is arranged along the collection conveyor and stores products for each product type. A digital order indicator is attached to each product outlet of the storage shelf or to the side of the collection conveyor. Workers take out products from the rack according to the instructions displayed on the order indicator, and collect goods. The product is put into a predetermined collection box that has been transported along the conveyor.

  Further, in such a picking system, as a method for assembling products more efficiently, for example, a multi-order type as shown in Patent Document 1 below is known. In the conventional general multi-order picking system disclosed in Patent Document 1, zones are divided into a plurality along the collection conveyor, and a plurality of collection boxes are intermittently moved (tact operation) in units of zones. Each of the workers arranged in (1) performs a picking operation on the collection boxes that are stopped.

Japanese Patent Laid-Open No. 09-301509

  However, in the conventional multi-order picking system described above, there is a problem that the goods to be picked are biased depending on the order tendency, and a worker is waiting in another zone even though he is busy in one zone. is there.

  In addition, since the operation is a tact operation in which the collection box is transported for each tact, the collection box does not move unless work is completed in all zones, and the work efficiency is further reduced.

  An object of the present invention is to provide a novel multi-order picking system capable of solving such problems in the prior art.

  In order to achieve the above object, the present invention according to claim 1 is set along a collection conveyor (14) for conveying a collection box (12) for storing products, and the collection conveyor (14). The storage shelves (18) for storing a plurality of types of products arranged in each of the plurality of zones (Z1 to Z6), and the storage shelves (18) provided in each of the zones (Z1 to Z6) ), An order indicator (20) for displaying the product to be taken out, the number thereof and the collection box (12) to be loaded, and one or more collection boxes (12) entering one zone for each tact as a group. Collection box supply means (16) for supplying to the collection conveyor (14), control means for controlling the collection conveyor (14), the order indicator (20), and the collection box supply means (16); In the picking system (10) comprising The control means recognizes the number of picking times in each of the zones (Z1 to Z6) based on the inputted order data, and the collection box (12) that enters one zone for each tact based on the number of picking times. And the predetermined number of collection boxes (16) is supplied from the collection box supply means (16) to the collection conveyor (14) for each tact. It is a feature.

  The present invention according to claim 2 relates to a picking system having the same components as the main part of the present invention according to claim 1. That is, the present invention according to claim 2 is directed to a collection conveyor (14) for conveying a collection box (12) for storing products, and a plurality of zones set along the collection conveyor (14) ( Z1 to Z6), storage shelves (18) for storing a plurality of types of products, and products to be taken out from the storage shelves (18) provided in each of the zones (Z1 to Z6), An order indicator (20) for displaying the number and collection boxes to be charged, and one or more collection boxes (12) entering one zone for each tact are supplied to the collection conveyor (14) as a group. The present invention relates to a picking system (100) comprising a collection box supply means (16), and a control means for controlling the collection conveyor (14), the order indicator (20), and the collection box supply means (16). And the feature is that each of the zones (Z1 to Z6) is further divided into at least two subzones (Z11, Z12; Z21, Z22; Z31, Z32; Z41, Z42; Z51, Z52; Z61, Z62). The storage shelves (18a ′, 18b ′; 18a ″, 18b ″; 18c ′, 18d ′; 18c ″, 18d ″; 18e ′, 18f ′; 18e ″, 18f ″) are arranged in each of the subzones. The goods stored in the storage shelves arranged in one of the sub-zones in one of the zones are stored in the storage shelves arranged in one of the sub-zones in the other one of the zones It is in the same kind as the product.

  According to the first aspect of the present invention, the number of picking times in each zone Z is recognized from the order data input to the control device, and from this picking number, the peak of the picking work amount is found, and the collection box supply means The number of collection boxes to be started is limited so that the upper limit of the number of picking is set to a certain value or less. Accordingly, the work efficiency can be improved by reducing the number of work peaks.

  According to the second aspect of the present invention, since the storage shelves in one zone are divided into two or more zones in the conventional case, the number of picking times is two or more. Can be assigned to different zones. This reduces the number of picking peaks and, on the other hand, fills the valleys, thus improving work efficiency.

1 is a perspective view showing a picking system according to a first embodiment of the present invention. It is a top view which shows schematically the picking system of FIG. It is a flowchart which shows an example of the program performed with the control apparatus in the picking system of FIG. It is a table | surface which shows the example of an order slip. (A) is a top view which shows roughly the picking system which concerns on 2nd Embodiment of this invention, (b) is a top view which shows a conventional structure schematically.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[First Embodiment]
FIG. 1 is a perspective view showing a multi-order picking system 10 according to a first embodiment of the present invention, and FIG. 2 is a schematic plan view thereof. The picking system 10 of the illustrated embodiment includes a collection conveyor 14 that conveys a collection box 12 into which products are placed. The illustrated collection conveyor 14 is composed of two belt conveyors 14a and 14b which are arranged in parallel to each other and are stepped up and down.

  A collection box supply unit (collection box supply means) 16 is connected to the collection box 12 at the upstream end of the collection conveyor 14. The collection box supply unit 16 controls the entire picking system 10 and sends a plurality of collection boxes 12 as a group to the collection conveyor 14 for each tact according to a command from a control device (control means) (not shown). In this embodiment, conventionally known types of accumulation conveyors 16a and 16b are used and connected to the upper and lower belt conveyors 14a and 14b, respectively.

  In addition, a plurality of zones Z1 to Z6 (six zones in the illustrated embodiment) are set along a predetermined portion of the collection conveyor 14, and each zone Z1 to Z6 has a predetermined interval between the lower belt conveyor 14a. A storage shelf 18 for commodities disposed opposite to each other is provided. Each storage shelf 18 is composed of, for example, a flow rack. A plurality of types of products are stored, and the products can be taken out from the side facing the collection conveyor 14.

  In the space between the collection conveyor 14 and the storage shelf 18, one worker is arranged for each of the zones Z1 to Z6, and the worker follows the instruction of the order indicator 20 that operates according to a command from the control device. Then, the commodity is taken out from the storage shelf 18 and the commodity is put into the designated collection box 12.

  The order display 20 can use what is known conventionally, and there are various types, mounting positions, etc. In this embodiment, the product to be picked and its quantity are digitally displayed. What can be used. The order indicator 20 is provided corresponding to the position of the collection box 12 that stops in each of the zones Z1 to Z6 during the picking operation. In this embodiment, as will be understood from FIG. 2, the collection boxes 12 are stopped at each of the zones Z1 to Z6, a maximum of five for each of the upper and lower belt conveyors 14a and 14b. . Ten order indicators 20 are installed in each of the zones Z1 to Z6 so as to be adjacent to the stopped collection box 12.

  In the picking system 10 having such a configuration, in the first embodiment of the present invention, the number of times of picking in each of the zones Z1 to Z6 in one tact is limited, thereby further improving the efficiency of the picking work.

  When a conventional general multi-order picking operation is applied in the above configuration (see FIG. 5B), a maximum of 10 collection boxes per tact are always moved together in units of zones. In that case, for 10 collection boxes for one tact, for example, picking work is performed according to order data for 10 orders (for 10 collection boxes) as shown in Table 1 below.

In this table, “order number” specifies the position of the collection box and the owner of the order within one tact. Further, “line” corresponds to a line in which the order product of the order slip is described. For example, in the order number 1, there are “rows” 1, 2, and 3, which indicate that three types of products have been ordered.

  In the example of Table 1, five times of picking are required in the first zone, but three times or less are picked in other zones. In this way, when the number of picking times in one zone is higher than in other zones, it will be understood that the picking work in this zone will take time and the movement of the collection box will also be delayed, so the work efficiency will deteriorate. Like.

  Assuming that it takes 5 seconds per picking, the picking work in the first zone takes 25 seconds. However, if the picking work time in each zone is limited to 20 seconds, the order number is “ If it is sufficient to process up to “6”, the number of picking times in the first zone is “4”, and the work time is also 20 seconds. That is, in the example of Table 1, by setting the number of collection boxes for one tact to “6”, the number of picking times is cut and the picking work is leveled. Since there is no picking number exceeding “5” except in the first zone, the number of collection boxes may be set to “9” by separating between the order number 9 and the order number 10.

  The first embodiment of the present invention has been made in accordance with this idea, and sequentially reads input order data to recognize the number of times of picking in each of the zones Z1 to Z6, and based on this number of times of picking, one zone in one tact. The number of collection boxes 12 per hit is determined, and for each tact, a predetermined number of collection boxes 12 are sequentially sent from the collection box supply unit 16 to the collection conveyor 14.

  Various means can be conceived as means for realizing such a method, and an example thereof is shown in FIG. 3 which is a flowchart of a program executed by a control device (not shown) and FIG. 4 which shows a main part of an order slip. It explains along.

  The following example is based on the configuration of FIG. 1 and FIG. 2, and the zone is up to 6 zones, and the maximum number of collection boxes 12 in one tact / one zone is “10”. Further, when the number of picking times in one zone exceeds “5”, it is regarded as an overload and the number of collection boxes 12 in one tact is limited.

  Further, in FIG. 4, it is assumed that the products having the product numbers a, b, c, d, e, and f are arranged in zones Z1, Z2, Z3, Z4, Z5, and Z6, respectively. In addition, it is assumed that a maximum of three items can be picked with one pick. That is, it is possible to work with one pick for two products and with two picks for four products.

  First, as a premise of the picking operation, it is assumed that a plurality of order data is input and accumulated in the storage unit of the control device based on the order slip shown in FIG.

  First, the control device performs an initialization process at step S1, sets the tact number N to “1”, the position (position in the tact) n of the collection box 12 in the tact “1”, and the accumulated picking count “0”. Set to.

  Next, in step S2, data of the first record, that is, data of the first row of order number 1 is read from the storage unit of the control device.

  Since the initially set order number and the read order number are the same “1”, the process proceeds from step S3 to step S4, and the cumulative number of picking times of the target zone is added. In the example illustrated in FIG. 4, the product number a1 is a product in zone 1 and the number of picking times is 4 products, so “2” is added to the cumulative number of picking times “0” in the target zone 1.

  Thereafter, the process returns to step S2, and the data of the next record, that is, the data of the first row of the order number 2 is read. Since the order number has changed from “1” to “2”, the process proceeds from step S3 to step S5. In step S5, “1” is added to the tact position. It should be noted that the position within the tact and the number of accumulated orders within the tact coincide with each other and become “2” at this time.

  In step S6, it is determined whether the cumulative picking number in any zone is 5 or more, or whether the position within the tact, that is, the cumulative order number within the tact is 11.

  In this case, since it does not yet correspond to any of the above, the process proceeds to step S7, and “2” of the in-tact position at that time is stored in the storage unit of the control device as the required number of collection boxes in the tact number 1.

  Thereafter, the process proceeds to step S4, and the picking number of the target zone is added based on the data in the first row of the order number 2. That is, “1” is added as the number of picking times for zone 1, and the cumulative number of picking times for zone 1 is set to “3”.

  After completion of step S4, the process returns to step S2 in the same manner as described above, and the data in the second row of order number 2 is read. However, since there is no change in the order number, the process proceeds to step S4 as it is. In step S4, the cumulative number of pickings in zone 3 is set to “2”.

  Thereafter, the same process is executed, and when the data of the first row of the order number 3 is read in step S2, the process proceeds from step S3 to steps S5 and S6 to step S7. In step S7, the number of necessary collection boxes in the previously stored tact number 1 is rewritten from “2” to “3” and stored in the storage unit of the control device.

  When the same processing continues and the first row data of the order data 4 is read in step S2, the process proceeds from step S3 to steps S5 and S6. Here, the cumulative picking number in zone 3 is “5”. Therefore, the process proceeds to step S8.

  In step S8, “1” is added to the tact number, and in step S9, the position in the tact is reset to “1”. In step S10, the cumulative number of picking times for all zones is returned to “0”.

  From order number 4 to order number 13, the number of pickings in each zone is small, and the maximum cumulative number of pickings is also “2”. For this reason, the process repeats steps S2, S3, S5, S6, S7, and S4 10 times, and “10” is stored in the storage unit of the control device as the number of required collection boxes in the tact number 2.

  Then, when the data in the first row of the order number 14 is read in step S2 and the process proceeds from step S3 to step S6, the number of orders in the tact is “11”. Through steps S8 to S10, this time the tact number 3 Enter the process.

As described above, the number of collection boxes required for each tact number is stored in the storage unit of the control device. The data stored in the storage unit is as shown in Table 2 below. In the table below, the order number is assigned in order from the top, and the position in the tact is automatically distributed from the number of collection boxes for each tact. Also, 1 to 10 positions in the tact correspond to the positions of the numbers entered in the collection box of FIG.

  When all the order data has been processed, the control device issues a command to the collection box supply unit 16 according to the data in Table 2 (Table 2 and FIG. 5) stored in the storage unit, and collects the necessary number of collections. The boxes 12 are grouped into a collection conveyor 14 in order of tact number.

  The group of collection boxes 12 conveyed by the collection conveyor 14 stops when entering the zones Z1 to Z6, and the workers in the zones Z1 to Z6 are displayed from the storage shelf 18 according to the display of the order indicator 20. The product is taken out and the product is put into a designated collection box 12. At this time, since the number of times of picking in each of the zones Z1 to Z6 is four or less, the picking operation in each of the zones Z1 to Z6 is completed within a short time, and the collection box 12 is moved to the next zone.

  Thus, according to 1st Embodiment of this invention, since the peak of the frequency | count of picking is shaved and the amount of work is equalized, work can be advanced efficiently.

  In the above embodiment, the number of zones is “6”, the maximum number of collection boxes in a zone is “10”, and the maximum number of picking times is “4”, but the number can be changed as appropriate. . For example, when the number of tacts may be increased, the maximum number of picking may be 3 or less. Conversely, when the number of tacts is decreased, the maximum number of picking may be 5 or more.

  Further, the types of the collection conveyor and the collection box supply unit are not limited to those described in the above embodiment.

[Second Embodiment]
Next, a second embodiment of the present invention will be described. The picking system 100 according to the second embodiment is schematically shown in FIG. 5 (a), and its main part is basically the same as the picking system 10 according to the first embodiment. The product conveyor 14, the storage shelf 18, the order indicator 20, the collection box supply part 16, and the control apparatus (not shown) are provided. Therefore, these components are denoted by the same reference numerals as those in the first embodiment, and detailed description thereof is omitted.

  The picking system 100 according to the second embodiment is different from the picking system 10 according to the first embodiment in that each of the zones Z1 to Z6 further includes two sub-zones Z11, Z12; Z21, Z22; Z31, Z32; Z42; Z51, Z52; Z61, Z62.

  In addition, a storage shelf 18 'is arranged in each subzone. In the illustrated embodiment, the storage shelf (18a ') arranged in one of the sub-zones (eg Z11) in a certain zone (eg Z1) and the one of the sub-zones (eg Z21) in the adjacent zone (Z2) are arranged. The storage shelves (18a ″) store the same type of products. The storage shelves (18b ′, 18b ″) arranged in the other subzone (Z12, Z22) also store the same types of products. Is different from the storage shelves (18a ′, 18a ″) of the previous subzone (Z11, Z21).

  Conventionally, as shown in FIG. 5 (b), it is common to have one storage shelf for each zone. For example, the first and fifth zones Z1 and Z5 have two rows of order data. Minutes (2 picks) hit, 4 rows for the 4th and 6th zones Z4, Z6, 6 rows for the 2nd zone Z2, and products to be removed for the 3rd zone Z3 In the case where there is not, there is a peak of the picking work amount in the second zone Z2, and a trough of the picking work amount in the third zone Z3. If there is a mountain in the amount of picking work, the next work cannot be performed in another zone unless the work in that zone is completed, resulting in wasted time. Further, the fact that there is a valley in the amount of picking work also puts a worker in that zone into a waiting state, which reduces the operating rate. This is particularly noticeable for high frequency products.

  Therefore, in the second embodiment of the present invention, the adjacent zone is divided into two in the conventional configuration, and half of each handled product is transferred to the other zone, thereby reducing the peak and valley of the work amount, and picking. The work is leveled.

  That is, in the picking system 100 according to the second embodiment of the present invention shown in FIG. 5A, the storage shelves 18a ′ and 18a ″ on the left side of the first zone Z1 and the second zone Z2 are of the same type. The storage shelves 18b 'and 18b "on the right side of the first zone Z1 and the second zone Z2 are of the same type. Also, the storage shelves 18c 'and 18c "on the left side of the third zone Z3 and the fourth zone Z4 are of the same type, and the storage shelves 18d' and 18d" on the right side of the third zone Z3 and the fourth zone Z4. And the storage shelves 18e 'and 18e "on the left side of the fifth zone Z5 and the sixth zone Z6 are of the same type, and the storage shelves 18f' on the right side of the fifth zone Z5 and the sixth zone Z6. , 18f ″ are of the same type.

  Thus, in the above example, hits for four rows in the first and second zones Z1, Z2, hits for two rows in the third and fourth zones Z3, Z4, and fifth and sixth zones Z5 , Z6 is a hit for three lines. In particular, it will be understood that the worker in the second zone Z2 has changed from six pickings to four pickings, and the picking work amount has been reduced to improve work efficiency. On the other hand, the worker in the third zone Z3 changes from 0 picking to 2 picking, and the valley of the picking work amount is filled here, and the useless time is eliminated.

  There are various conditions, such as order tendency and system scale, regarding how to distribute ordered products in adjacent zones, and can be determined as appropriate, and the controller instructs the order indicator according to the determined method. Will be issued.

  In the second embodiment, one zone is divided into two subzones, but a storage shelf may be arranged in each of the three subzones.

  DESCRIPTION OF SYMBOLS 10,100 ... Picking system, 12 ... Collection box, 14 ... Collection conveyor, 14a, 14b ... Belt conveyor, 16 ... Collection box supply part (collection box supply means), 18 ... Storage shelf, 20 ... Order display vessel

Claims (2)

A collection conveyor (14) for transporting a collection box (12) for storing products;
A storage shelf (18) for storing a plurality of types of products arranged in each of a plurality of zones (Z1 to Z6) set along the collection conveyor (14);
An order indicator (20) for displaying a product to be taken out from the storage shelf (18), the number thereof and a collection box (12) to be charged, provided in each of the zones (Z1 to Z6);
Collection box supply means (16) for supplying one or more collection boxes (12) entering one zone to the collection conveyor (14) as a group for each tact;
In a picking system (10) comprising the collection conveyor (14), the order indicator (20), and a control means for controlling the collection box supply means (16),
The control means is
Recognizing the number of picking times in each of the zones (Z1 to Z6) based on the input order data,
Based on the number of picking times, the number of collection boxes (12) entering one zone is determined for each tact,
A picking system configured to supply the predetermined number of collection boxes (12) from the collection box supply means (16) to the collection conveyor (14) for each tact. . A collection conveyor (14) for transporting a collection box (12) for storing products;
A storage shelf (18) for storing a plurality of types of products arranged in each of a plurality of zones (Z1 to Z6) set along the collection conveyor (14);
An order indicator (20) for displaying a product to be taken out from the storage shelf (18), its number and a collection box to be charged, provided in each of the zones (Z1 to Z6);
Collection box supply means (16) for supplying one or more collection boxes (12) entering one zone to the collection conveyor (14) as a group for each tact;
In a picking system (100) comprising the collection conveyor (14), the order indicator (20), and a control means for controlling the collection box supply means (16),
Each of the zones (Z1 to Z6) is further divided into at least two subzones (Z11, Z12; Z21, Z22; Z31, Z32; Z41, Z42; Z51, Z52; Z61, Z62), and the storage is performed in each of the subzones. Shelves (18a ′, 18b ′; 18a ″, 18b ″; 18c ′, 18d ′; 18c ″, 18d ″; 18e ′, 18f ′; 18e ″, 18f ″);
Goods stored in the storage shelves arranged in one of the sub-zones in one of the zones and stored in the storage shelves arranged in one of the sub-zones in the other one of the zones Picking system characterized by being of the same type.

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