JP2910219B2 - Distribution method and distribution system - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a physical distribution method and a physical distribution system for managing inventory of multi-products under conditions of same-day receipt and same-day shipment.

(Prior Art) Conventionally, as a logistics method for inventory management of various kinds of products, for example, as described in Nippon Jitsugyo Publishing Co., Ltd. It is a general inventory management method that attempts to facilitate product management by storing items in the same place.

Also, for example, published by Ryutsu Kenkyusha, "Unmanned Technology Vol. 31,
No. 7, page 52 ", a so-called three-dimensional automatic warehouse equipped with a large number of merchandise storage shelves, in which goods are automatically placed on each shelf and automatically taken out. There is a system that attempts to automate and unmanned picking by using it as a picking zone.

(Problems to be Solved by the Invention) By the way, it is preferable to process various types of products under the conditions of same-day delivery and same-day delivery in order to reduce inventory.

When storing multiple types of products, if the same type of products are stored in the same place as the former one of the above-mentioned conventional products, various products will be dispersed and arranged in a wide space, so picking when shipping the products, In doing so, the total moving distance for picking becomes large, and picking may take too much time. Therefore, it is difficult to process under the condition of same-day arrival and same-day shipment.
There has been a problem that the stock amount has increased and a huge amount of equipment has been required.

On the other hand, when using a three-dimensional automatic warehouse as the picking zone and processing a large variety of products as in the latter case, there is a limit to shortening the picking time. If the picking zone is stored in a warehouse, the size of the picking zone becomes too large, and there is a problem that capital investment costs increase.

In particular, since production, sales and distribution information is not centralized, it can be used for systems that ship products received several days ago, but as a system that satisfies the conditions for same-day arrival and same-day shipment. There was a problem that it was difficult to use.

The present invention has been made in view of such a point, and an object of the present invention is to provide three storage locations having different functions, arrange the same product separately in each storage location, and provide production, sales and distribution information. In this way, the inventory processing is carried out under the condition of arrival on the day and shipment on the day, thereby reducing the amount of inventory.

(Means for Solving the Problems) In order to achieve the above object, the means according to the invention of claim (1) is directed to a logistics method for managing a variety of products in stock on the same day of receipt and same day shipment. And

First, as a premise, a picking zone (P) in which products of each type are assorted for each type in an amount corresponding to the shipment amount on the day, and picking of each product is performed according to a shipping destination, and the picking zone (P) An assist zone (A) comprising a three-dimensional automatic warehouse for storing products of each type so that when the inventory of products of each type assorted in the shortage is less than the shipment amount on the day, the shortage is supplied to the picking zone (P). ), And a stock zone (S) for storing products that cannot be accommodated in the picking zone (P) and the assist zone (A) among the products of the above-described types.

And, on the basis of the average shipment amount of each type of product per day for a plurality of days before the day, the shipment amount of the day is predicted,
The difference between the stock amount of each type of product in the picking zone (P) and the predicted shipping amount of the day is calculated, and for the type whose difference is equal to or less than a predetermined value, the amount of arrival on the day in the picking zone (P) is given priority. While assigning and allocating the shortage from the assist zone (A), the rest of the received goods is instructed to be stored in the assist zone (A) and / or the stock zone (S), and the picking zone ( The difference between the total inventory amount of the P) and the assist zone (A) and the predicted shipment amount of the day is calculated, and for the varieties whose difference is not more than a certain value, the assist zone (A) and / or Alternatively, it is a method of instructing the picking zone (P) to replenish.

Means taken by the invention of claim (2) is directed to a physical distribution system in which a variety of products are stock-managed under conditions of same-day delivery and same-day shipment.

First, a picking zone (P), an assist zone (A), and a stock zone (S) are provided, which are the same as those of the first aspect of the present invention.

Then, as shown in FIG. 5, a shipment quantity prediction means (51) for predicting the shipment quantity of the day on the basis of the average shipment quantity of each kind on a plurality of days before the day, and the shipment quantity prediction means (51). ), The picking zone (P)
Means for calculating the difference between the product stock amount of each product type and the estimated shipping amount on the day as a safety stock amount, and the safety stock amount received from the safety stock amount calculating means (52). For the varieties of which is less than or equal to the predetermined value, the amount of arrival on the day is preferentially allocated to the picking zone (P) and the shortage is allocated from the assist zone (A), while the remainder of the received goods is the assist zone (A) or / Receiving the outputs of the allocation command means (53) for storing in the stock zone (S) and the shipment quantity predicting means (51), and picking zone (P) and assist zone (A) of each type of product. Inventory forecasting amount calculating means (54) for calculating the difference between the total inventory amount of the current day and the estimated shipping amount of the day as the inventory forecasting amount, and receiving the output of the inventory forecasting amount calculating means (54), the inventory forecasting amount is constant. For varieties below the value, Is obtained by a configuration in which a replenishing instruction means for instructing to replenishment from (S) to assist the zone (A) and / or picking zone (P) (55).

(Operation) The invention according to claims (1) and (2) has a picking zone (P) for picking out a shipped product and an adjusting function for replenishing a product that is insufficient in the picking zone (P). An assist zone (A) and a stock zone (S) for storing a product that cannot be accommodated in each of the zones (P) and (A) are provided. Since it is stored separately in (A) and (S), the time required for picking a product is reduced. In other words, for each type, the amount of products stored in the picking zone (P) is small, so that it is possible to store the products over many types, the moving distance for picking is short, and the picking time is shortened. . That is, the prerequisites for processing a wide variety of products on the same day delivery and same day delivery conditions are satisfied.

According to the invention of claim (1), when the shipment amount of each type of product on the day is predicted in advance and the difference between the stock amount of the picking zone (P) and the predicted shipment amount is calculated, the difference is determined by a predetermined amount. For the products whose value is less than or equal to the value, it is instructed to preferentially assign the products to be received and assign the shortage from the assist zone (A). Therefore, the movement of the products according to this instruction is performed via a conveyor line or the like. It is done, and the goods received on the same day are shipped on the same day in principle.

On the other hand, it is instructed to store the remaining goods which have been applied to the picking zone (P) in the assist zone (A) or the stock zone (S), and the inventory of the picking zone (P) and the assist zone (A) For varieties in which the difference between the total amount and the estimated shipment amount on the day is below a certain value,
Since it is instructed from the stock zone (S) to replenish the products in each zone (P), (A), each zone (P),
(A) and (S) are prepared so that the product storage amount can always correspond to prompt shipment.

Therefore, by improving picking speed and unifying production, sales and logistics information, the logistics lead time is shortened, and inventory management is performed for many types of products under the condition that the goods received on the same day are shipped on the same day. Inventories will be reduced as much as possible.

According to the invention of claim (2), the shipment amount prediction means (51), the safety stock amount calculation means (52), the allocation command means (53), the stock prediction amount calculation means (54) and the replenishment command means (55) Thus, the same operation as the above-mentioned claim (1) can be obtained.

(Example) Hereinafter, an example of the present invention will be described with reference to the drawings.

1 to 3 show a logistics system according to an embodiment of the present invention, and show a first floor, a third floor, and a fourth floor of a five-story building, respectively.
The layout of each facility on the floor is shown. As shown in FIG. 1, on the first floor, a loading / unloading berth (11) for receiving and unloading incoming products, and a sorting / receiving berth (11) for sorting products to be received or carried out. In / out sorting device (1
2) and an outbound berth (13) dedicated to unloading goods,
A sorting unit (14) for sorting out products to be delivered from the delivery berth (13), a first fluidized shelf (15) for storing particularly large products with a large amount of shipment, and a seasonal product. The first Nestenar storage unit (16) that stores large numbers of shelves on individual shelves ("Nestener" refers to AXIA ENTERPRISE in the United States.
A three-dimensional automatic warehouse (17) penetrating up to the 5th floor that stores various products on many shelves and automatically places and removes products, The first conveyor line (1) for transferring products between facilities
8) are provided as main equipment.

In addition, on the third floor, a second fluidized shelf (25) for storing small products with a large amount of shipment, a second nester storage unit (26) for mounting large products, and the products are transported between the above facilities. Second
Conveyor lines (28a) and (28b) are provided.

Further, on the fourth floor, a pallet storage unit (34) for storing products in pallet units, a third nester storage unit (36) and a third conveyor line (38) for transferring products between the respective facilities are provided. ing.

The fifth floor is provided with a stock zone (S) having the same configuration as the fourth floor (not shown). Also,
(L1) to (L4) are first to fourth vertical transporters for transporting the product up and down between floors, respectively.

Here, FIG. 5 shows the basic configuration of the physical distribution system of the present invention, in which the products of each kind are arranged in an amount corresponding to the amount shipped on the day for each kind, and the bicking of each product is performed according to the shipping destination. And the supply of the shortage to the picking zone (P) when the stock of the product of each kind arranged in the picking zone (P) is less than the shipment amount on the day. An assist zone (A) consisting of a three-dimensional automatic warehouse for storing products of each type, and a stock zone (S) for storing products that cannot be accommodated in the picking zone (P) and the assist zone (A) among the products of each type described above. )), And the products of each kind received in each zone (P), (A), (S) based on the stock amount and shipping amount of each zone (P), (A), (S). And picking Over down (P) products each berth were picked from (11) are adapted to ship via (13).

That is, the first and second fluidized shelves (15), (25),
In the second Nestener storage units (16) and (26), the products of each kind are arranged in line with the quantity shipped on the day for each kind, and picking is performed according to the shipping destination. 15), (16), (25) and (26) constitute a picking zone (P). On the other hand, the three-dimensional automatic warehouse (17) replenishes the shortage in the picking zone (P) to the picking zone (P) when the stock of each type of product assorted in the picking zone (P) is short of the same day shipment. The automatic three-dimensional warehouse (17) forms an assist zone (A). The pallet storage unit (34) and the third nester storage unit (36) store products that cannot be accommodated in the picking zone (P) and the assist zone (A) among the products of each type. The storage sections (34) and (36) form a stoock zone (S).

Each of the above conveyor lines (18), (28), (38)
Is equipped with a bar code reader (BR) that reads the bar code attached to the pallet being conveyed, and a terminal (TM) that inputs the flow of products to a computer based on a slip. Incoming / outgoing quantities, stocks, and the like in the zones (P), (A), and (S) are automatically checked and totalized.

Next, a method of processing products between the zones (P), (A), and (S) will be described with reference to the flowchart of FIG.

First, in step S1, the stock quantities pn, an, sn (where the stock amounts of the respective zones (P), (A), (S)) for each type of product are provided.
n is a type number provided for each type, and n =
1, 2,...) Are automatically input from the totaled result of the computer, and in step S2, the expected quantity in of each type of product is input according to information from a factory or the like, and in step S3, one week until the previous day. Is calculated as the scheduled shipment amount oyn. Then, in step S4, the picking zone (P) is determined for each type of product based on the above input and calculation results.
Xn (= pn-oy) between the stock quantity pn and the scheduled shipment quantity oyn
n) is calculated as the safety stock quantity, and in step S5, the safety stock quantity xn is set to a predetermined appropriate value zn of the picking zone (P).
(E.g., set to about 0.5 times the average daily shipment volume), it is determined whether or not xn≤zn, and the stocking amount of the picking zone (P) for the shipment on the day is sufficient. Then, the process proceeds to step S6, in which all the received products are allotted to the assist zone (A) or the stock zone (S). On the other hand, if the result of the determination in step S5 is xn≤zn, it is determined that the safety stock amount is not sufficient, and step S7
, And instructs the received product to be assigned to the picking zone (P). In steps S8 and S9, the stock amount pn and the safety stock amount xn of the picking zone (P) are updated to the value obtained by adding the received product. Then, in step S10, it is again determined whether or not the safety stock amount xn is equal to or less than the proper value zn. If xn ≦ zn is not satisfied, in step S11, the surplus product is removed from the assist zone (A).
Alternatively, if xn ≦ zn, the product is allocated from the assist zone (A) to the picking zone (P) in step S12.

As described above, when the received goods are assigned, step S13 is performed.
Then, the stock amount pn, an, s of each zone (P), (A), (S)
n is updated, and in step S14, the total stock amount (pn + a) in the picking zone (P) and the assist zone (A) is updated.
n) is subtracted from the expected shipment quantity oyn on the day, and the inventory forecast quantity yn (=
pn + an-oyn), and in step S15, it is determined whether or not the predicted inventory amount yn is equal to or less than an appropriate value wn (for example, a value about 1.5 times the daily shipment amount). In step S16, the types of products are replenished from the stock zone (S) to each of the zones (P) and (A).

As described above, when the allocation of the product before shipment of the product is completed and the shipment of the product is started, the shipment amount on is input in step S17, and the stock amount of the picking zone (P) is accordingly input in step S18. pn is updated, and in step S19,
If there is a product whose stock quantity pn of the updated picking zone (P) falls below a predetermined dangerous value un (for example, a value of about 50% of the average shipment quantity), in step S20, the assist zone (A), that is, the three-dimensional automatic The product is replenished from the warehouse (17) to the picking zone (P) for the product. And
The control of steps S17 to S20 is repeated until the shipment of the day is completed in the determination of step S21.

In the above flow chart, the control of step S3 constitutes a shipment amount predicting means (51) for estimating the shipment amount of the day on the basis of the average shipment amount of each type on a plurality of days before the day, and the control of step S4 The safety stock quantity which receives the output of the shipment quantity forecasting means (51) and calculates the difference between the product stock quantity pn of each type in the picking zone (P) and the shipment forecast quantity oyn of the day as a safety stock quantity xn. Computing means (52) is constituted, and picking is performed for a product whose safety stock quantity xn is equal to or less than a predetermined value (proper value) zn under the control of steps S5 to S12, receiving the output of the safety stock quantity computing means (52). On the day, the incoming quantity is preferentially allocated to the zone (P), and the shortage is allocated from the assist zone (A), while the rest of the received goods is stored in the assist zone (A) and / or the stock zone (S). Command to appropriation command means (53) is configured.

Also, in step S14, the shipment amount prediction means (5
In response to the output of 1), the total (pn) of the inventory amount of the picking zone (P) and the assist zone (A) of each type of product
+ An) and the difference (pn + an-oy) between the expected shipment amount oyn of the day.
n) is calculated as a predicted inventory amount yn. In step S16, the output of the predicted inventory amount calculation unit (54) is received, and the predicted inventory amount yn is set to a constant value (appropriate value). ) A replenishment command means (55) for instructing the replenishment from the stock zone (S) to the assist zone (A) and / or the picking zone (P) for varieties of wn or less is configured.

Therefore, in the above embodiment, the picking zone (P) for picking out the shipped product, the assist zone (A) having an adjusting function of replenishing the product that is insufficient in the picking zone (P), There is provided a stock zone (S) for storing products that cannot be accommodated in the zones (P) and (A), and products of the same kind are dispersed in these zones (P), (A) and (S). The time required for picking products is reduced because they are stored. That is, since the amount of the product stored in the picking zone (P) is small, a wide variety of products can be collectively stored, and the moving distance for picking can be reduced. Therefore, the picking time is shortened, and the prerequisites for processing a wide variety of products by the so-called kanban method under the condition of arrival on the day and shipment on the day are prepared.

Then, the shipment amount prediction means (51) predicts the shipment amount oyn of each type of product on the day in advance, and the safety stock amount calculation means (52) calculates the inventory amount pn shipment prediction amount oyn of the picking zone (P). Is calculated as the safety stock quantity xn, the allocation command means (53) preferentially assigns the planned product to be received to a product whose safety stock quantity xn is equal to or less than the appropriate value zn, Since the command is issued from the assist zone (A), the product is moved through the conveyor lines (18) and (28) in accordance with the command, and in principle, the goods received on the same day are shipped on the same day. .

On the other hand, by the above-mentioned assignment command means (53), if there is no need to assign the remaining received items to the picking zone (P) or the received items to the picking zone (P), all the received items are assisted. The picking zone (P) and the assist zone (A) which are commanded to be stored in the zone (A) or the stock zone (S), and which are calculated by the replenishment command means (55) by the inventory forecast amount calculating means (54).
For the varieties for which the predicted inventory amount yn is equal to or less than the appropriate value wn, the stock zones (S) to the zones (P), (A)
Is ordered to replenish the products, so that the product storage amount in each of the zones (P), (A), and (S) is always prepared to be ready for quick shipment.

In addition, picking zone (P) due to large shipment on the day
For the varieties whose stock quantity pn decreases and falls below the lower limit un, products are replenished from the assist zone (A) comprising the three-dimensional automatic warehouse (17), so that it is possible to cope with sudden fluctuations in demand. it can.

As described above, the normal distribution system is configured to ship products received two to three days before according to the order received until the previous day, whereas the distribution system of the present invention has By shortening and unifying production, sales and logistics information, the logistics lead time is shortened, and for many types of products, inventory management can be performed under the condition that products received on the same day are shipped on the same day. Inventories can be reduced as much as possible without causing shortage.

In this case, since the multi-story warehouse (17) is not used as the picking zone (P) as in the conventional distribution system but is used as the assist zone (A), the cost can be reduced by simplifying the equipment. .

In particular, the flow shelves (1
5), (25) and Nestener storage units (16), (26) are arranged.
If the amount of shipment is not so large,
6) and (26), the structure of the fluidized shelves can be simplified, and the equipment cost of the picking zone (P) can be reduced.

(Effect of the Invention) As described above, according to the invention of claim (1),
As a logistics method for inventory management of products of various types under the conditions of same-day arrival and same-day shipment, in addition to the picking zone and the stock zone, an assist zone for replenishing insufficient products in the picking zone is arranged, and the same day of the picking zone For varieties whose safety stock quantity is below the appropriate value for the planned shipment quantity, the goods received on the day are preferentially allocated and the shortage quantity is allocated from the assist zone, while the rest of the received goods are stored in the assist zone and stock zone. In addition to the above, for the varieties for which the estimated stock quantity in the picking zone and assist zone is less than a certain value, it is instructed to replenish them from the stock zone, so that the picking time is shortened and the production, sales and distribution information are unified. Can shorten the logistics lead time, and
With regard to a wide variety of products, it is possible to reduce the inventory amount under conditions of same-day arrival and same-day shipment without causing shortage of shipment.

According to the invention of claim (2), since the distribution system embodying the distribution method of claim (1) is configured, the effect of the invention of claim (1) can be obtained.

[Brief description of the drawings]

The drawings show an embodiment of the present invention. FIGS. 1 to 3 are plan views showing the configuration of the first, third and fourth floors of the distribution system, respectively. FIG. FIG. 5 is a flow chart showing the control contents, and FIG. 5 is a block diagram showing the structure of the invention of claim (2). P: Picking zone A: Assist zone S: Stock zone 15, 25: Fluidized shelves 16, 26: Nestener 17: Three-dimensional automatic warehouse 51: Shipment amount prediction means 52: Safety stock amount calculation means 53 … Assignment command means 54… Inventory predicted amount calculation means 55… Replenishment command means

──────────────────────────────────────────────────続 き Continuation of the front page (56) References Distribution Equipment Editing Committee, “Future Distribution Equipment-Picking / Automatic Sorting / Reading System,” March 1979, first edition, published by Nikkan Kogyo Shimbun, pages 81- Page 84 (58) Field surveyed (Int. Cl. ⁶ , DB name) B65G 1/00-1/20 G06F 19/00

Claims (2)

(57) [Claims] 1. A distribution method for managing inventory of multi-products under the condition of same-day receipt and same-day shipment, wherein products of each type are arranged in an amount corresponding to the same-day shipment for each product. Picking zone (P) in which each product is picked according to the picking zone (P)
Assist zone (A) consisting of a three-dimensional automatic warehouse that stores products of each type to replenish the shortage in the picking zone (P) when the inventory of products of each type assorted in the inventory is less than the shipment amount on the day. ), And a stock zone (S) for storing products that cannot be accommodated in the picking zone (P) and the assist zone (A) among the products of the above-described types, and each type of a plurality of days per day before the date. Of the day of shipment based on the average shipment amount of products of the same type, and calculating the difference between the inventory amount of each type of product in the picking zone (P) and the estimated shipment amount of the day, and this difference is equal to or less than a predetermined value. The varieties are preferentially allocated to the picking zone (P) on the day, and the shortage is allocated from the assist zone (A), while the remainder of the received product is the assist zone (A) or / and the stock zone (S). )
The difference between the total inventory amount of the picking zone (P) and the assist zone (A) of the product of each type and the predicted shipping amount on the day is calculated, and the stock zone (S) for the type whose difference is equal to or less than a certain value. A command for replenishment to the assist zone (A) and / or the picking zone (P) from the vehicle. 2. A distribution system in which a variety of products are stock-managed under conditions of same-day receipt and same-day shipment, wherein each kind of product is assorted in an amount corresponding to the same-day shipment amount. Picking zone (P) in which each product is picked according to the shipping destination, and the picking zone (P)
Assist zone (A) consisting of a three-dimensional automatic warehouse that stores products of each type to replenish the shortage in the picking zone (P) when the inventory of products of each type assorted in the inventory is less than the shipment amount on the day. ), And a stock zone (S) for storing products that cannot be accommodated in the picking zone (P) and the assist zone (A) among the products of the above-described types, and each type of a plurality of days per day before the date. Receiving the output of the shipment quantity prediction means (51) for predicting the shipment quantity of the day based on the average shipment quantity of the product;
A safety stock quantity calculating means (52) for calculating a difference between the product stock quantity of each type in the picking zone (P) and the predicted shipping quantity of the day as a safety stock quantity; and a safety stock quantity calculating means (52).
For the varieties whose safety stock amount is equal to or less than the predetermined value, priority is assigned to the picking zone (P) on the day, and the shortage is assigned from the assist zone (A), while remaining items are received. Receives the output of the allocation command means (53) for instructing to be stored in the assist zone (A) and / or the stock zone (S), and the output of the shipment amount prediction means (51);
A predicted inventory amount calculating means (54) for calculating a difference between the total inventory amount of the picking zone (P) and the assist zone (A) of each type of product and the predicted shipping amount of the day as the predicted inventory amount;
In response to the output of the inventory prediction amount calculation means (54), for a variety whose inventory prediction amount is equal to or less than a predetermined value, replenishment from the stock zone (S) to the assist zone (A) and / or the picking zone (P) is performed. And a replenishment instruction means (55) for instructing the logistics system to perform the operation.