JP2934194B2 - Loading method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of loading a large number of varieties into pallets at a distribution center or the like.

[0002]

2. Description of the Related Art In a conventional distribution center, picked loads are sorted from a sorting line into palletized packing lines in accordance with order data from a delivery destination (store), and then loaded from a packing line through a delivery line. It pays out to the place and packs it on pallets, and each pallet is loaded on a delivery car assigned to each delivery destination.

[0003]

However, the prior art has the following problems. At the branching point from the sorting line to the packing line, a sorting error based on a branching mistake may occur due to a high moving speed of the load. Also, when unloading the sorted pallets of the same load on the same pallet, a part of the same pallet's load stagnates on the load aligning line due to malfunction of the free roller conveyor that constitutes the load assortment line. May occur.

[0004] Despite the risk of sorting errors and payout errors, no inspection is performed at the sorting line to the loading station. For this reason, there is a possibility that the load on the pallets loaded at the loading site may be excessive or insufficient, which may be erroneously delivered to the delivery destination.

SUMMARY OF THE INVENTION An object of the present invention is to confirm whether or not the results of loading picked according to a picking plan, sorted by pallets, and loaded on each pallet conform to the picking plan, and guarantee the loading quality of each pallet. It is in.

[0006]

According to a first aspect of the present invention, there is provided a method for stacking loads to be sorted out on a pallet and sorted out on a pallet and then discharged from the pallet and stacked on a pallet. Sorting data for allocating the required number of loads to each pallet according to the required number of pallets and pallet data for allocating the required number of loads to each pallet according to the required number of pallets. After the completion of sorting to each assortment line, after the completion of sorting to each assortment line, the unloading process of unloading one pallet from the unloading line for each pallet based on the sorting data, and unloading from each assortment line A loading process where the pallets are loaded onto each pallet at the loading station,
Read the type and quantity of the load with a barcode reader before
The barcode reader reads the quantity of
By deducting the data from
Collet data and the actual loading result, and (a) Bar
Unexpected varieties of cargo arrived by reading code reader
If it is confirmed that the delivery line is stopped,
(B) 1
When it is confirmed that the delivery of
Output the excess / shortage information of the
(A) replenish the missing varieties at the stowage point,
Or (b) remove the missing pallets from the loading area and
Pick varieties that are missing from the foot pallet and collect
By replenishing the pallet, the loading quality is guaranteed on a pallet basis.

According to a second aspect of the present invention, in the first aspect of the present invention, the sorting data divides a load of one pallet into a plurality of groups in a delivery order, and divides the load of each group into a group. In this case, a different packing line is assigned to each group in the order of delivery.

[0008]

According to the first aspect of the present invention, the following is provided.,
Has the effect of Each pallet is stowed at the stowage
The actual loading data is the loading data for each pallet.
Check with the pallet data to see if there is any excess or
Wear. As a result, the sorting line-
Sorting mistakes and payment for the final stage of pallet packing
Inspect the excess or shortage of the load based on the unloading mistake and stack each pallet.
Quality can be guaranteed.Information on the excess or deficiency of cargo at the loading dock
Output, for example, on a label that indicates the delivery car to be loaded.
When the excess or deficiency information is printed, the operator
(A) If the missing varieties are near
Replenish the foot varieties at the loading area, and (b)
If not, remove the missing pallet from the loading area,
Later, pick the missing varieties of the missing pallets together
And can replenish the missing pallets.

According to the second aspect of the present invention, the following is provided. of
There is action. Assign loads to assortment lines by pallet
Sorting data can be used to group loads of one pallet
Divide into loops and load each group in order of group delivery
Assigned to different assortment lines by group
did. Therefore, the load on the pallet loaded on the carrier of the delivery vehicle
From the back side of the loading platform to the front side so that the
Multiple packages of one pallet's load in the delivery order
Divide into loops (4 divisions, 2 divisions, etc.)
Can be divided.

[0011]

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a schematic diagram showing a picking / sorting control system for a load, FIG. 2 is a schematic diagram showing a sorting station, FIG. 3 is a schematic diagram showing a packing line, and FIG. FIG. 5 is a flowchart showing a picking / sorting flow.

The picking / sorting control system includes an order processing CPU 11, a case (instep) picking CPU 12, and a case sorting CPU 1 in a distribution center.
3. Picking the load from an automatic warehouse, a fluidized shelf, or the like according to a picking plan, and transferring the picked load to a pre-merge storage line 15, a post-merge storage line 16, a sorting line 17, a large number of loads After passing through the line 18 and the payout line 19, the pallet 21 is loaded at the loading place 20. Then, it is checked whether the goods loaded on the pallets 21 are in conformity with the picking plan, and if there is an excess or shortage of the goods, it is possible to guarantee the varieties of the goods to be loaded on a pallet basis. Hereinafter, description will be given according to the flow of the picking / sorting flow.

(A) Creation of data (FIGS. 1 and 5) Based on order data from a delivery destination (shop), picking batch data is created by, for example, collecting about 3000 cases from the closest delivery destination. (3000 cases is the quantity of standard size cases that can be accommodated in the packing line 18). Batch data collects orders from many stores,
This is the sum of the quantities for each type.

Sorting data for allocating the required number of loads of each type collectively for each type based on the picking batch data to each predetermined palletizing line 18 for each pallet (for each delivery car) and each pseudo store, Pallet data for allocating a required number of loads to each pallet 21 is created. Here, the pseudo shop-by-store means that in the creation of sorting data, the load of one pallet is placed in the delivery order so that it is almost in the delivery order from the back of the carrier to the front so that the cargo can be easily unloaded from the carrier of the delivery vehicle. It is divided into a plurality of groups (4 divisions, 2 divisions, etc.), and the loads of each group are assigned to different packing lines 18 (adjacent packing lines 18) for each group in the order of group delivery.

(B) Picking (FIGS. 1, 2, and 5) The order processing CPU 11 transmits the above-described picking batch data to the case picking CPU 12. The case picking CPU 12 includes a crane of an automatic warehouse, and face pickers FP1, FP2, FP3 of picking equipment,
The supply car, the flow shelf, the picker P, etc. are driven to collectively pick the cases of the type specified in the batch data by the specified amount, and send the picked load to the storage line 15 before merging. The face picker picks up the pallet load discharged from the automatic warehouse by a crane on a surface basis, and supplies it directly to the storage line 15 before merging or to the fluidized shelf. The picker removes the load from the fluidized shelf and supplies it to the pre-merge storage line 15.

When the picking of each face picker (FP1, FP2, FP3) and picker (P) is completed, the case picking CPU 12 is connected to each of the face pickers (FP1, FP2, FP3) and picker (P). The case sorting CPU 13 sorts the picking results for each storage line 15 before merging to the case sorting CPU 13 (the case sorting CPU 13 sorts the cases from the storage line 15 before merging to the storage line 16 after merging, sorting from the sorting line 17 to each packing line 18, Loading dock 20
, Etc.).

When the case sorting CPU 13 reads the type bar code of the case flowing into each pre-merge storage line 15 by the bar code reader 31 (FIG. 2) provided at the entrance or intermediate portion of the pre-merge storage line 15. The picking of each storage line 15 before merging by the face pickers FP1, FP2, FP3 and the picker P is completed, and the picking results are stored in the case picking CPU 12 as described above.
When they are transmitted from the storage device, the actual performance of the picking is compared with the quantity of each product in each storage line 15 before the merge. Here, if there is a shortage, an error is displayed and the worker replenishes.

(C) Sorting (FIGS. 1 to 3 and FIG. 5) The case sorting CPU 13 controls the storage line 1 before merging.
When it is confirmed by the above-mentioned bar code reader 31 provided in the storage unit 5 that a group of cases having a certain length or more has accumulated in each of the storage lines 15 before merging, the storage lines 16 after merging are checked for an empty space in the storage line 16 before merging. Line 15
Are sequentially merged into the storage line 16 and then sent to the sorting line 17. Case sorting C
The PU 13 reads the type of the case of the storage line 15 before merging by the barcode reader 31 of the storage line 15 before merging, and completes the merging of the storage line 15 having a certain length or more to the storage line 16 after merging. Then, the case of another storage line 15 is merged with the storage line 16 after merging. As a result, the case sorting CPU 13 recognizes all the varieties of the cases joined to the storage line 16 after the joining and based on the recognition result and the above-described sorting data, the sorting line 17 of the cases to the packing line 18. Is determined, and sorting of each kind to each packing line 18 is executed. As a result, the loads of each type are sorted into each of the packing lines 18 determined for each pallet by the sorting data.

Each loading line 18 is divided into an upstream standby section 18A and a downstream charging section 18B by a stopper 32 provided at an intermediate portion. In this way, the case sorting CPU 13 releases the stopper 32 at the intermediate portion of each packing line 18 when all the cases have been joined and sorted, and advances the case to the leading end of each packing line 18. The reason why the packing line 18 is divided into two parts is that the case is discharged from the downstream input part 18B to the loading place 20 while the sorting is performed to the upstream standby part 18A, so that the picking / sorting efficiency is improved. It is for improving.

(D) Stowage (FIGS. 1 to 5) When the advance of the case is completed in each of the packing lines 18, the dispensing device 33 is sequentially positioned at the exit of each of the packing lines 18, and based on the sorting data described above. Then, a load of one pallet is sent out to the payout line 19 in units of the load assembling lines 18, and the payout of cases to the loading stations 20 is started.

In the present embodiment, one loading place 20 is prepared for 27 loading lines 18. Since about 4 delivery lines 18 are used for each delivery car, about 7 delivery cars are used for one loading area 20.
Stack with. A total of five loading stations 20 are provided, and a plurality of similar packing lines 18 are assigned to each of them.

At the loading station 20, the cases delivered by the delivery line 19 are loaded on the pallet 21. At this time, the case sorting CPU 13
Read the barcode of the case with the barcode reader 34 (Fig. 4) provided just before 0, for one delivery car (for one pallet. Actually, one delivery car is a two-ton truck with a unit pallet)
Add two and one unit pallets on a 1.5-ton, 2-ton long delivery vehicle) and add up the total number of products to be loaded for each product type. Actually, the case sorting CPU 13 reads the bar code of the case before stacking the case on the pallet, and reads the bar code reader from the quantity of the kind to be stowed, which is the aforementioned pallet data sent from the order processing CPU 11. 34
, The collation between the planned loading data (pallet data) and the accumulated loading quantity (loading result) is performed by deducting the quantity of the kind read by the company.

By reading the bar code reader 34, the case sorting CPU 13 confirms that an unscheduled type (a type that is not scheduled to be picked up, or one more type has already reached the planned quantity) has arrived. If you do
Immediately stop the payout line 19, display an error to that effect,
Report to worker. In this case, the worker removes the case (there is a possibility of a mistake in branching from the sorting line 17 to the packing line 18; therefore, the operator leaves the case and adds it later when the shortage occurs).

The case sorting CPU 13 emits light from the phototube 35A by means of the phototube 35A and the mirror 35B (also serving as the stopper 32) provided at each end of the loading section 18B of each loading line 18 and for confirming the completion of delivery. Is received by the photoelectric tube 35A, it can be confirmed that no case remains on the packing line 18, that is, the completion of case delivery. Thereby, when the case sorting CPU 13 confirms the completion of the delivery of the load for one pallet, the case sorting CPU 13 determines the load of each pallet based on the collation result of the above-described integrated loading quantity for each type and the loading schedule data (pallet data). Outputs excess / shortage information.

(E) Quality Assurance (FIGS. 1 and 5) The case sorting CPU 13 uses the car data display device 36 to store one pallet. The operator prints the information on a label indicating the number of the delivery car to be stowed.

[0027] The reason for the lack of varieties is as described above (sorting line 1
If there is an unscheduled product that has arrived at the loading area 20 due to a branch error from the 7 to the packing line 18 or the like, and there is an unscheduled product, the missing product is loaded (the label printing is erased). ).

If it is not near, it is removed (with a label attached) from the loading area 20, and the loading of the next car (pallet) is started immediately. Then, later, the missing items are collectively added and picked, and added to the insufficient pallets (at this time, a list indicating which varieties are to be loaded on which pallets is output and added while checking).

If the product cannot be shipped because the missing product is not in the distribution center or the like, a label is attached to notify the delivery staff, and when the product is delivered to the store, the fact is refused.

The above-mentioned excess / deficiency information output by the case sorting CPU 13 is transmitted to the order processing CPU 11. Then, the order processing CPU 11 outputs the delivery car quality assurance list, and if necessary, instructs the case picking CPU 12 to perform additional batch picking of missing parts.

The loaded pallets 21 are transferred to the truck yard 38 by the pallet transfer device 37 or the like, and are finally delivered to the delivery destination by the delivery vehicle.

According to this embodiment, the following operation is provided. The results of loading on each pallet at the loading site 20 are compared with pallet data, which is the data to be loaded on each pallet, and it can be confirmed whether there is no excess or shortage of the load. As a result, with respect to the pallet packing style at the final stage in the sorting line 17 to the loading area 20, it is possible to inspect the excess or deficiency of the load based on the sorting error or the delivery error, and to guarantee the loading quality of each pallet.

The sorting data for allocating the load to the packing line 18 for each pallet is such that the load for one pallet is divided into a plurality of groups in the order of delivery, and the load of each group is assigned to a different packing line 18 for each group in the order of delivery of the group. I made it. Therefore, in order to make it easier to unload the pallets loaded on the loading platform of the delivery vehicle, the load of one pallet is distributed in multiple groups (4 divisions, 2 divisions, etc.) so that the loading of one pallet is almost in the order of distribution from the back to the front. ) And can be sorted by group.

When the information on the excess or deficiency of the load is output at the loading site 20 and the information on the excess or deficiency is printed, for example, on the label indicating the delivery car to be loaded, the worker looks at this label and (a) If the missing varieties are near the loading area 20, the missing varieties are replenished at the loading area 20. (b) If the missing varieties are not near the loading area 20, the missing pallets are removed from the loading area 20. Later, the varieties of the missing pallets can be picked together and replenished to the missing pallets.

The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration of the present invention is not limited to this embodiment, and the design may be changed without departing from the scope of the present invention. The present invention is also included in the present invention.

[0036]

As described above, according to the present invention, it is checked whether or not the actual loading results of picking according to the picking plan, sorted by pallets and loaded on each pallet match the picking plan, and The stowage quality can be guaranteed.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing a picking / sorting control system for a load.

FIG. 2 is a schematic diagram showing a sorting place.

FIG. 3 is a schematic view showing a packing line.

FIG. 4 is a schematic view showing a loading place.

FIG. 5 is a flowchart showing a picking / sorting flow.

[Explanation of symbols]

 17 Sorting line 18 Loading line 19 Delivery line 20 Loading area 21 Pallet

Claims (2)

(57) [Claims] Claims: 1. A method for loading goods to be sorted out on a pallet according to a pallet and then discharged from the pallet and loaded onto a pallet, wherein a load of each kind is loaded on a pallet according to a required number. Sorting data to be assigned and pallet data to assign the required number of loads of each type to each pallet in advance. Sorting process to sort the loads into each packing line based on the sorting data. Sorting to each packing line. after completion, 1 pallet minute increments payout La based on the sorting data load of each load alignment line
In addition , the unloading process for unloading from the in-house, the loading process for loading the unloading cargo from each loading line on each pallet at the loading dock, and the bar code reading of the type and quantity of the loaded cargo before the loading dock.
And the number of the product type read by the barcode reader.
By deducting from the pallet data
Check the pallet data for each species with the loading results,
(a) By reading the bar code reader,
When it is confirmed that the cargo has arrived, stop the payout line.
Stop, announce to that effect and instruct the removal of the cargo,
(b) When it is confirmed that the delivery of one pallet load has been completed,
Outputs information on the excess or shortage of the load on each pallet, and
When indicating the presence of foot varieties, (a)
Refill, or (b) remove the missing pallets from the loading area,
Later, pick the missing varieties of the missing pallets together
A loading method that guarantees the loading quality of each pallet by refilling the missing pallets . 2. The cargo sorting system according to claim 1, wherein the sorting data divides the cargo of one pallet into a plurality of groups in the order of delivery, and assigns the cargo in each group to different assortment lines for each group in the order of delivery of the group. Stowage method.