JP2974220B2 - How to store goods - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a storage method for storing articles in a storage facility such as an automatic warehouse.
The present invention relates to a method of storing articles that are calculated beforehand by calculating the number of articles that cannot be stored in the storage facility, and that are set to be stored in such a way that the non-storable articles are stored in another storage means, and then stored.

[0002]

2. Description of the Related Art Conventional techniques relating to a warehousing method include:
Japanese Patent Publication No. 62-21681 is known.

[0003] However, Japanese Patent Publication No. Sho 62-21681 discloses that a pallet (article) conveyed to a delivery facility is stored in an automatic three-dimensional warehouse (storage facility), articles are unloaded and stored on a picking shelf, and An article handling facility for extracting an article quantity from a picking shelf is described.

[0004]

However, the above prior art has the following problems.

That is, the article handling facility described in Japanese Patent Publication No. Sho 62-21681 does not disclose a method for judging whether or not the article to be stored in the storage facility can be stored before storing the article. There is no suggestion. If the storage is performed without knowing that the number of empty storage shelves is less than the number of goods to be stored, the storage shelves of the storage facility are full during the storage and the goods are stored randomly. In some cases, it is not possible to store items that are really needed to be stored (items with low inventory) that were actually scheduled for storage. Useless work such as storing goods occurs.

Accordingly, an object of the present invention is to make it easy to perform a warehouse process.
In advance, it is calculated in advance whether or not all the goods to be received can be stored in the automatic warehouse, and if all the goods cannot be stored, the goods that need to be stored (the stock is small) are preferentially stored. In addition to making possible
An object of the present invention is to provide a storage method that can be easily performed .

[0007]

According to the first aspect of the present invention, a plurality of article storage shelves and an overflow area are provided.
With reference to an automated warehouse comprising, as well as enabling Receipt to the automatic warehouse goods pallet units stock of pallets loads exceeding the vacant shelves number of automatic warehouse is carried into Overclocking flow area to the overflow area This is a method for storing goods in which the type and quantity of goods carried in are stored in a control device, and calculates the total number of pallets of incoming goods, and when the total number of pallets exceeds the number of empty shelves in an automatic warehouse, an overflow occurs. of the corresponding varieties and the number and Stock varieties and Stock quantity
Outputting an overflow list that records the shelf inventory amount, based on the overflow list, varieties of articles to overflow after setting registered in the control unit quantity, and receipts all stock articles to the automatic warehouse, and varieties of all stock articles In addition to inputting the quantity of the actual arrival to the control device, the articles to be overflowed are carried into the overflow area, and the other articles are stored on the shelves .

According to a second aspect of the present invention, in the first aspect of the present invention, if the scheduled quantity to be received in the automatic warehouse is smaller than the possible quantity to be stored , and there is any article in the overflow area , calculates the quantity of the article being stored on SL overflow area, informs outputs vacant shelf number and the overflow area stock varieties automated warehouse, the overflow re receipts list that records the quantities and shelf inventory quantity <br/> It is like that.

[0009]

[0010]

[0011]

[Function] It is calculated whether all goods can be stored on the shelves of the automatic warehouse before warehousing , and if all the goods cannot be stored, unnecessary goods can be stored in the overflow area for the time being . Necessary articles (articles with low stock) can be preferentially stored on the shelf . An overflow list is output when the incoming luggage is stored in the overflow area. The operator can select an article to be overflowed, a quantity, and the like using the overflow list as a guide. Enter all stock goods in the automated warehouse
By warehousing, it is possible to branch and store each of the overflow articles and other articles to a predetermined storage destination simply by putting all of the overflow articles and other articles into the automatic warehouse from the same place, and the storage processing is easy. It is possible to easily perform the goods receipt inspection by having all the incoming goods stored in the automatic warehouse and inputting the arrival result information (type, quantity). For moving the article to the shelf from overflow <br/> Eria in an automated warehouse, it is performed to confirm in advance that there is an empty-out shelves. Therefore, the movement from the overflow area to the shelf can be performed smoothly.

[0012]

1 is a layout diagram showing a first floor layout of a distribution center having an automatic warehouse (storage facility) to which the present invention is applied, FIG. 2 is a layout diagram showing a second floor layout and a third floor layout, and FIG. Is a flow chart showing a distribution system to which is applied, FIG. 4 is a block diagram showing a control system of the distribution system, FIG. 5 is a schematic diagram showing a storage frame of an automatic warehouse, FIG. 6 is a flow chart showing a warehousing processing flow, and FIG. 8 is a flowchart showing a calculation processing flow, FIG. 8 is a flowchart showing a warehouse setting processing flow, and FIG.
9 is a flowchart showing an automatic stock transfer processing flow.

(Automatic Warehouse) The automatic warehouse 10 has a first rack 11 having racks arranged in a plurality of stages and a plurality of rows.
(Main storage facilities) No. 2 and No. 3 racks 12, 13 (auxiliary storage facilities) are arranged in parallel, and each rack 11, 12, 13
Each is provided with an individual stacker crane 14.

Description of First Floor Layout (See FIG. 1) The automatic warehouse 10 includes a three-story warehouse building 101,
The center 100 is constituted. On the first floor of the warehouse building 101, a loading / unloading conveyor 1 for transferring articles loaded on pallets and placed in cartons between a forklift and the like.
5. Receiving conveyor 16 for receiving articles from the stacker cranes 14 of the racks 11 to 13 and unloading conveyor 1 for receiving articles from the stacker cranes 14 of the racks 11 to 13.
7. Branching end of the conveyor 15 for both entry and exit and all conveyors 1
A traverser 18 for transferring articles between the traversers 6 and 17 is provided.

On the first floor, there are 23 independent pallet flow conveyors (PFCs) 19 for each of the 23 varieties in order to unload and pick up 23 varieties of A-managed items to be described later.
(A managed product picking facility) is installed.

Further, on the first floor, a pallet rack 20 (BC-managed product picking equipment) divided for each type of BC-managed product for picking a BC-managed product to be described later.
Is installed.

Further, a loading area 21 is set on the first floor.

Explanation of the layout of the second and third floors (see FIG. 2) The layout of the second and third floors of the warehouse building 101 is the same.
On the second and third floors, an in / out conveyor 22 and an in / out conveyor 22 for transferring articles to and from a forklift.
, A delivery conveyor 24 for transferring goods from the stacker crane 14 of each of the racks 11 to 13, a delivery conveyor 24 for delivering goods from the stacker crane 14 of each of the racks 11 to 13 to the storage / conveyor 22, and a storage / conveyance conveyor 22. A traverser 25 for transferring articles between the conveyors 23 and 24 is provided.

On the second and third floors, an overflow area 26 (another storage means) for storing overflow products to be described later is set.

(Distribution System and Control System) A distribution system using the automatic warehouse 10 (see FIG. 3) A prescribed number of articles in a container to be delivered to the distribution center 100 by trucks or the like are placed for each product type. In particular, a full pallet can be formed, and the full pallets are stored in the racks 11 to 13 of the automatic warehouse 10.

In this embodiment, the full pallets are packed in one type. For example, the pallets are divided into tall (high) and low (low) pallets, and the automatic warehouse 10 is used.
May be prepared in two types corresponding to each load.

Articles to be stored in the automatic warehouse 10 are stored in any of the racks 11 to 13 according to the “automatic warehouse control concept” described later, or are stored in the overflow area 2.
Stored at 6. Note that the articles stored in the overflow area 26 are then re-stocked in the racks 11 to 13.

The racks 11 to 13 of the automatic warehouse 10
Out of the articles stored in the pallet flow conveyor 19 in full pallet units by the stacker crane 14 of the No. 1 rack 11 among the articles stored in the pallet flow conveyor 19, and are picked from the pallet flow conveyor 19 in carton units. The stackers 14 and 14 of the No. 2 rack 12 and the No. 3 rack 13 leave the shelves via the delivery conveyor 17, the traverser 18, and the loading / unloading conveyor 15 in units of full pallets, and are supplied to the pallet rack 20 by a forklift. Picking is performed from the rack 20 in units of cartons. The picked A-managed product and BC-managed product are shipped by truck or the like via the packing area 21.

Control System for Automatic Warehouse 10 (See FIG. 4) The control system for the automatic warehouse 10 includes a host CPU 31, a physical distribution CPU 32, and a control CPU 33.

The host CPU 31 performs sales information processing by transmitting order information data to the distribution CPU 32 and receiving a delivery result from the distribution CPU 32.

The physical distribution CPU 32 transmits the scheduled arrival data, the article code and the like to the control CPU 33, and
A receipt schedule plan, a picking plan, and a replenishment plan are created by receiving actual receipt data, inventory data, and the like from the server 33.

The control CPU 33 uses the keyboard of the control CPU 33, the first floor storage setting terminal, the second floor re-entry terminal, and the third floor re-entry terminal to carry out the operation of loading and unloading articles to and from each of the racks 11 to 13. Controls the conveyors 15, 16, 17, 22, 23, and 24 and the traversers 18 and 25, and the crane control device 35 controls the stacker cranes.

(Concept of Control of Automatic Warehouse) Storage Frame of Automatic Warehouse 10 (See FIG. 5) The automatic warehouse 10 has the first rack 11 as a main storage facility.
The No. 2 and 3 racks 12 and 13 are used as auxiliary storage facilities.

The No. 1 rack 11 is provided with an A-managed product dedicated storage unit dedicated to each type of A-managed products (PFC registered products) delivered by the pallet flow conveyor 19, and an A-managed product. A that can store any variety
It has a common storage unit for managed products.

The No. 2 and No. 3 racks 12 and 13 store a BC-managed product common storage unit that can store any type of the BC-managed product and a BC-managed product. And a common storage unit for obtaining ABC managed products.

In the present embodiment, the top 23 products from the varieties with the largest shipment volume are designated as A-managed products, and the others are designated as BC-managed products. In general, A-managed products are products that are arranged in descending order of shipment volume, and products whose cumulative shipment volume from the top product type is up to 80% of the total, and B-managed products are products whose cumulative shipment volume is the remaining 15% of the total. , C-managed products refer to products in the lower 5%.

Here, the number of storage frames of each managed item in the automatic warehouse 10 is determined in consideration of the minimum storage quantity of each type in the automatic warehouse 10. The required minimum storage quantity is 1
This is a quantity that is sufficient for the number of shipments per day or one day.

Overflow Processing When there is an incoming quantity exceeding the total number of racks in the automatic warehouse 10, some types of A-managed products and BC-managed products are limited and overflowed to the overflow area 26 on the second or third floor. .

Incidentally, the overflow processing is specifically,
This is performed according to the flow of FIGS. 7 and 8 described later.

Automatic warehouse priority storage of BC-managed items No. 2 and No. 3 racks 12 and 13 are shared with the BC-managed item common storage unit.
Although a BC-managed product common storage unit is provided, the ABC-managed product common storage unit can preferentially store BC-managed products that are stored in excess of the number of storage slots of the BC-managed product common storage unit. This is because all types of BC-managed products must be stored in racks No. 2 and 3 so that A-managed products are not put in the BC-managed product common storage unit. In addition, many kinds of BC
If the controlled items overflow, the type of re-stocking will be frequently set and it will be troublesome for operation. Therefore, the BC managed items should be stored in a rack in principle, and the A managed items with few types and easy management It is intended to overflow.

The first rack minimum stock of A-managed products and the automatic stock transfer Each type of A-managed products is sequentially replenished and delivered to each of the pallet flow conveyors 19 provided for each type along the first rack 11. You. Therefore, it is necessary to always store a fixed amount of all types of A-managed products in the first rack 11. Therefore, the A-managed product frame (dedicated storage unit)
For example, 10 pallets (10 shelves) per product type in No. rack 11
The storage unit (shelf) of the other first rack 11 is set as a common storage unit for A-managed items as described above,
This is to ensure that controlled items can be stored. When the storage quantity of the certain type of A-managed product in the first rack 11 becomes only four pallets, the stock is automatically moved from the second and third racks 12 and 13 to the first rack 11 in units of six pallets.

Here, the reason why the dedicated storage unit for the A-managed products is set to 10 pallets per product is the maximum quantity (expected value or measured value) of the once or daily shipment amount.
The pallet is the average quantity (actual value) of the shipment quantity per day or one day, or the quantity which does not run out of stock until the stock is moved from the No. 2 and No. 3 racks 12 and 13.

In addition, moving in units of 6 pallets requires 2
-Outgoing conveyors 17 and 24 of No. 3 racks 12 and 13 (2
This is because the amount of pallets that can be stored at one time on the storage conveyors 16 and 23 (2 pallets) of the No. 1 rack 11 and the pallets × 2 lines).

Note that the automatic stock transfer is specifically performed according to the flow of FIG. 9 described later.

Inventory Management Method The inventory management of the articles stored in each of the racks 11 to 13 of the automatic warehouse 10 is performed by first-in, first-out in lots on the day of receipt (based on the date of entry into the automatic warehouse 10). And maintain the quality of each article.

Crane Entry / Exit Priority Processing The entry / exit function of the stacker crane 14 in each of the racks 11 to 13 is as follows: (a) Pallet flow conveyor 1 for A-managed items
9; (b) A-managed items and BC-managed items to the overflow area 26; and BC-managed items to the pallet rack 20; (c) Automatic inventory transfer of A-managed items; (d) A
There are functions of newly receiving a managed product and a BC managed product, and re-entering from the overflow area 26.

In this embodiment, if the stacker crane 14 equally services each work, each work will be prolonged. Therefore, it is assumed that concentrated processing is performed by limiting the number of processing lots from the highest priority. . That is, the priority order shall be lower in the order of (a) → (b) → (c) → (d), and the number of processed lots shall be 1 pallet for (a) and 1 pallet for (b). There are 10 pallets, 6 pallets for (c), and 1 pallet for (d).

(Specific Example of Distribution Process) (1) Warehousing Process (See FIG. 6) The warehousing process for articles in the automatic warehouse 10 is performed, for example, as follows.

The control CPU 33 receives the scheduled arrival data (container code, article name, quantity) from the distribution CPU 32 by, for example, the day before the arrival, and writes it in the scheduled arrival file.

Before the start of storage (morning of the day), when the operator starts up the control CPU 33, the control CPU 33 enters an overflow calculation process of FIG.
Perform each overflow calculation for managed products and create an overflow list.

The operator determines the articles to be overflowed, the quantity, etc., based on the above-mentioned overflow list, and registers the setting of the overflow articles in the control CPU 33. The control CPU 33 writes the overflow registration data (container code, article name, quantity, overflow area floor) in the storage schedule file.

The operator makes the following storage settings (a) and (b) for the control CPU 33 based on the storage schedule file written in the control CPU 33.

(A) By operating the first floor storage setting terminal of the control CPU 33, a "storage scheduled menu screen" is opened, a container code to be stored is to be input, and a "container-specific menu screen" is opened. The "menu screen for each container" displays the names of the articles and the number of cartons contained in the container.

(B) If the pallet packing of the article to be stored in (a) is a full pallet (a pallet on which articles of a specified number of cartons are to be loaded), enter the article name and the number of pallets.

On the other hand, if the pallet packing of the article to be stored in (a) is a fractional pallet (a pallet less than the specified number of cartons of a full pallet), after inputting the article name and the number of cartons, It shall be stored outside the rack and overflow area of the warehouse 10.

In the automatic warehouse 10, even when the quantity actually delivered is larger than the expected storage quantity, or even when the article actually delivered is not planned, the storage can be performed. In addition, the first-floor storage setting terminal displays the scheduled arrival quantity and the received result, so that the operator can carry out the storage inspection based on the scheduled arrival information and the storage result information.

By the above-mentioned storage setting, the control CPU 3
3 enters the storage setting process of FIG. 8 described later, and drives the conveyor control device 34 and the crane control device 35.

At this time, the control CPU 33 executes the following (a) to
The storage control of (d) is performed.

(A) The stacker crane 14 of each of the racks 11 to 13 is assigned as follows in accordance with a branch request signal indicating that the pallet has reached the branch end of the storage / entry conveyor 15.

The A-managed product is assigned preferentially to the stacker crane 14 of the first rack 11, and the BC-managed product is assigned only to the stacker crane 14 of the second and third racks 12 and 13.
However, one of the stacker cranes 14 goes down, and the receiving conveyors 16 and 2 corresponding to the stacker cranes 14
3 failure or full or the stacker crane 14
When the rack corresponding to (1) is full, it is assigned to another empty stacker crane 14.

(B) Inventory of A-managed product is rack No. 2.3
The stock of the corresponding type of the first rack 11 is 10
If the pallet is less than the pallet (including the case where the stock is 0), the pallet waits to be allocated to the first rack 11. That is, the type with the A-managed product is the 2.3 rack 1
There is no 10 pallets in No. 1 rack 11 of the same type, which are not in 2 and 13 (less than the amount of the dedicated storage space for A-managed products)
In this case, even if the goods are stored in the second and third racks 12 and 13, a command to move to the first rack 11 is issued immediately.
The stacker crane 14 of the No. 1 rack 11 is in a standby state or waits until the storage conveyor 16 of the No. 1 rack 11 becomes empty.

The BC-managed products are racks Nos.
Is allocated so as to have an equal amount of stock. In other words, for the BC-managed products, the same type is placed in each of the 2.3 racks 12 and 13 so that the shipping operation does not stop even if one of the stacker cranes 14 of the racks 2.3 and 13 goes down. Stock an equal amount.

(C) The control CPU 33 allocates (searches) the rack goods from the empty shelf near the loading station of the storage conveyor 16 (the tip conveyor of the storage conveyor 16), and outputs an operation command to the stacker crane 14. I do.

When the A-managed product enters the first rack 11, if the pallet flow conveyor 19 is out of stock, the pallet flow is directly delivered to the pallet flow conveyor 19.

(D) The control CPU 33 confirms that the condition for enabling the conveyor to be shipped on the overflow area floor is satisfied for the overflow product, and outputs an operation command for the stacker crane 14.

When the sub-conveyors on the second and third floors are full due to overflow products, the stacker crane 14
Can not output the operation command, so wait as it is.

While the second and third floors are being used as a restocking line for overflow products, after the set contents have been processed, the stocking operation may be stopped to allow overflow.

The storage result data (container code, article name, number of storage results for each storage location) of the completed container is stored from the memory of the control CPU 33 to a floppy disk (F).
D) and sends it to the distribution CPU 32. Logistics CP
U32 updates the stock based on the stocking result data.

(2) Overflow calculation processing (see FIG. 7) In the above (1) warehousing processing, the above-described overflow calculation processing and setting registration of overflow products are performed as follows.

First, in step S1, the number of empty shelves (rack containing no articles) in the A-managed item dedicated storage unit of the first rack 11 is calculated. That is, the number of products (the number of actual shelves) in the dedicated storage unit of the first rack 11 is checked for each A-managed product, and the number of empty shelves in the dedicated storage unit of the first rack 11 is obtained for each product type. Then, the number of empty shelves determined as described above is totaled to determine the number of empty shelves in the dedicated storage unit of the first rack 11. Then, the number of empty shelves obtained as described above is totaled, and the first rack 1
The number of empty shelves in one dedicated storage unit (the total number of empty shelves in the dedicated storage unit) is determined in advance.

Subsequently, in step S2, the number of empty shelves in the A-managed item common storage unit of the first rack 11 is obtained as follows.

That is, the total number of empty shelves (total number of empty racks in the No. 1 rack) of the A-managed item dedicated storage unit and the A-managed item common storage unit of the No. 1 rack 11 is checked from the empty rack file. The number is obtained by subtracting the total number of empty shelves for the A-managed product exclusive storage unit obtained as described above from the number.

In step S3, it is determined whether there is an arrival today (whether there is data to be received), and if so, the number of arrivals is totaled for each A-managed product and BC-managed product (step S3-1). If not, the scheduled arrival number is set to 0 (step S3-2), and the process proceeds to step S4.

In step S4, the quantity of the BC managed product to be overflowed is calculated.

The quantity of the BC-managed goods that cannot be accommodated in the empty shelves of the No. 2 and 3 racks 12 and 13 is the quantity to be overflowed. If there is no quantity to overflow and there are empty shelves in the BC-managed goods common storage unit even if all of the BC-managed goods are stored, the number of empty shelves is used as the margin for the BC-managed goods.
Re-stocking for the overflow of C-managed items is possible. Less than,
The details will be described.

First, 2 ·
If the value obtained by subtracting the number of empty shelves of the No. 3 racks 12 and 13 is a positive number, all or some of the BC-managed products are stored in the No. 2 and No. 3 racks 1.
There are no empty shelves to be stored in 2 and 13, and the value of the difference is defined as the number of overflows of the BC managed product. In this case, the quantity that can be stored in the No. 2 and 3 racks 12 and 13 (the quantity that can be stored) is 0.

If the value obtained by subtracting the number of empty shelves of the No. 2 and 3 racks from the expected quantity of BC-managed goods is 0 or a negative value, B
Assuming that the number of overflows of the C-managed product is 0, the surplus number of racks storing the BC-managed product is calculated. That is, the spare number of racks for storing the BC-managed items (the spare number of BC-managed items).
Is the current number of BC-managed racks No. 2.3 racks and the number of BC-managed items (the number of shelves in the BC-managed items common storage unit).
Subtract the scheduled number of managed items to be obtained.

If the number of spare racks for BC-managed products is a negative value, the number of spare racks for BC-managed products is set to 0, and the number of A-managed products that can be stored in the second and third racks 12 and 13 is determined.
If the value is 0 or a positive value, the number of racks No. 2.3 and 1 of the A-managed product is used by using the number of spare racks for the BC-managed product.
The number that can be stored in 3 is calculated.

The number of the A-managed products that can be stored in the No. 2 and No. 3 racks 12 and 13 is calculated based on the number of empty shelves of the No. 2 and No. 3 racks 12 and 13 by the expected number of BC-managed products and the number of surplus BC-managed items Draw and ask. Hereinafter, the above contents are shown as equations (1) and (2).

The number of spare racks for BC-managed products = the number of storage frames for BC-managed products-the number of stocks of BC-managed products-the expected number of BC-managed products to be received ... Number of empty shelves of racks No. 2.3 and 3-Number of BC-managed products to be received-Number of surplus BC-managed racks ... (2) When the number of surplus BC-managed racks <0-> Number of surplus BC-managed racks = 0 BC management When the number of spare racks ≥ 0 → B obtained by equation (1)
Use the number of spare racks for C-managed products.

If an overflow of BC-managed products occurs, the A-managed products cannot enter the 2.3 racks 12 and 13. If there are empty shelves in the ABC-managed goods common storage unit even if all the BC-managed goods are received, the number of empty shelves is 2.
This is the number that can be stored in the No. 3 rack. Then, if the scheduled quantity of the A-managed items is larger than the total number of the A-managed items that can be stored in the racks No. 2 and 3 and the number of empty shelves in the A-managed item common storage unit, the A-managed items are overflown. Overflow products can be restocked. In step S5, the number of overflows of the A-managed product is obtained by the following procedure.

The number of overflows is calculated based on the expected number of A-managed items to be received in step S4. And ask for it. If the number of overflows is a positive number (there are no empty shelves for storing all or some of the A-managed items), the number of spare racks for storing the A-managed items (the number of spare racks for all the 1.2.3 racks) Is set to 0, and if the overflow number is 0 or a negative value, the overflow number is set to 0 (no overflow is necessary), and the rack margin number of the A managed product is obtained. The number of spare racks for the A-managed products is calculated as the estimated number of A-managed products to be stored based on the sum of the number of A-managed products that can be stored in the No. 2.3 racks and the number of empty shelves in the common storage unit of the No. And ask for it.

At step S6, the BC management product or A
It is determined whether or not the control product needs to overflow by checking the presence or absence of the overflow number obtained in steps S4 and S5. If there is an overflow number, an overflow list is output (step S6-
1) If not, display "No overflow" is displayed on the screen of the control CPU 33 (step S6-).
2).

The contents of the overflow list include the number of overflows, the kind to be received, the quantity to be received, and
This is the amount of stock for each type of rack . The operator determines the article to be overflowed, the quantity, and the like based on the overflow list, and performs setting registration of the overflow product.

At this time, when performing the overflow setting, the operator should limit the selection to a part of the types, rather than overflowing all or most of the types to be stored in an amount that cannot be accommodated in all the racks of the automatic warehouse 10. There are the following operational advantages.

(A) The type setting of the overflow product may be small.

(B) The type setting frequency of the restocking of the overflow product may be small.

For this reason, it is preferable to set the same type as the previous type or the type that has already overflowed (the type in stock in the overflow area 26) as the current product to be overflowed.

When the overflow is set,
It is preferable that the operator set so that goods not needed for the time being are stored in the overflow area 26 and necessary goods (articles with less stock) are preferentially stored in the racks 11 to 13.

In steps S7 to S9, the scheduled arrival quantity is smaller than the possible storage quantity and the overflow area 26
If any of the items is present, the number of the items stored in the overflow area 26 that can be stored in each of the racks 11 to 13 is calculated, and an overflow re-entry list is output.

That is, it is always checked whether or not there is any article in the overflow area 26, and if not, the process is completed, and if there is, it is determined whether or not there is a rack margin.

If there is a rack margin, an overflow re-entry list is output; otherwise, the process ends.

The contents of the overflow re-stocking list include the number of spare racks, the stock type and quantity of the overflow area, the location of the overflow area, the stock amount of each rack , the stocking date, and the like.

The operator determines the articles to be re-stocked, the quantity, etc. based on the overflow re-stocking list, and performs the re-stocking setting of the overflow product from the re-stocking setting terminal provided on the floor of the corresponding overflow area.

At this time, when performing the overflow re-entry setting, the operator leaves unneeded articles in the overflow area 26 and preferentially puts necessary articles (articles with low stock) into the racks 11 to 13. Is preferably set.

(3) Warehousing setting process (see FIG. 8) In the above (1) warehousing process, the above-described warehousing setting process is performed as follows.

The pallet arrives at the branch end of the incoming / outgoing conveyor 15 which receives the incoming instruction data (step S).
1) and the following processing are performed to determine the storage destination.

In step S2, it is determined whether or not the article is an article to be overflowed (an article for which overflow has been set). If it is an overflow product, step S10
Then, the stacker crane 14 to be used is determined (the stacker crane 14 to be used is determined to be a non-operated one or one with less operation reservation). If it is not an overflow product, the process proceeds to step S3.

In step S3, it is determined whether the received product is an A-managed product. If it is not an A-managed product, step S9
Then, it is determined that the goods are to be stored in the second and third racks 12 and 13. If it is an A-managed product, the process proceeds to step S4.

In step S4, it is determined whether or not the same article as the warehousing item is stocked in the racks No. 2 and 3, and if there is stock in the racks No. 2 and 3, the process proceeds to step S6. If there is no stock, the process proceeds to step S5.

In step S5, the first rack 11
Is determined to be less than the required number of shelves in the storage unit dedicated to the A-managed product of the first rack (10 racks per type as described above in this embodiment).
It proceeds to 7 and decides to store in the A-managed item dedicated storage unit of the first rack 11. If the number is equal to or more than the required number of shelves, the process proceeds to step S6.

In step S6, the A of the first rack 11
It is determined whether or not there is an empty shelf in the managed article common storage unit. If not, the process proceeds to step S9, and if there is, the process proceeds to step S8.

In step S8, the A of the first rack 11
It is determined that the goods will be stored in the managed goods common storage unit.

As described above, steps S7 and S
8. When the storage location is determined in each of step S9 and step S10, the control CPU 3 determines in step S11.
Numeral 3 outputs a storage command to the conveyor control device 34, and the stored goods are stored in designated storage locations (the first rack 11, the second rack 1).
The vehicle starts moving toward the racks 11 to 13) where the stacker cranes 14 used for moving to the second and third racks 13 or the overflow area 26 exist.

The pallet for which the storage command has been output in step S11 is conveyed to the loading station of the specified storage conveyor 16. When the pallet arrives at the loading station, the control CPU 33 determines a storage shelf, outputs crane operation data to the crane control device 35, and the control CPU 33 updates the inventory file and the shelf file (step S12).

The stacker crane 14 puts the pallets on the loading station into the designated shelves or leaves the pallets on the designated overflow floor.

(4) Delivery Process of BC-Managed Items The delivery process for replenishing BC-managed items to the pallet rack 20 is performed, for example, as follows.

The operator operates the control CPU 3 based on the delivery instruction list output (printed) from the physical distribution CPU 32.
The delivery setting is performed by 3.

The control CPU 33 performs a stock check of the racks Nos. 2 and 3 of the automatic warehouse 10 at the time of setting out of the warehouse, and displays a shortage alarm on the screen if the stock is not enough.

The control CPU 33 writes the exit setting data (exit floor, article name, number of pallets) in the exit setting file.

The control CPU 33 is the conveyor control device 3
4. The crane control device 35 is controlled to execute the above-mentioned delivery setting data. At this time, the control CPU 33 assigns the stacker crane 14 attached to the rack storing the oldest warehousing date pallets for each warehousing date lot. If the oldest storage date pallets are in a plurality of racks, the empty stacker crane 14 is allocated.

(5) Outgoing Processing of A-Managed Articles Outgoing processing for replenishing A-managed articles to the pallet flow conveyor 19 is performed, for example, as follows.

When the control CPU 33 detects the empty of the A-managed items in the pallet flow conveyor 19, the control CPU 33 assigns the oldest pallet rack in the first rack 11 and sends an operation command of the stacker crane 14 to the crane control device 35. Output.

When the number of pallets stored on the oldest storage day in the first rack 11 has reached four pallets, the control CPU 33 sets the number of pallets to two.
If the oldest receiving pallet is on No. 3 racks 12 and 13, 6
In units of pallets, racks 2 and 3 of the pallets concerned,
An inventory transfer plan file is created from 13 to the first rack 11.

The conveyor used for transferring the A-managed items stored in the No. 2 and 3 racks 12 and 13 to the No. 1 rack 11 is, in principle, a conveyor arranged on the second floor. When the second floor is in the retrieval operation, the third floor is used.

Here, the above-mentioned automatic stock movement is performed as follows (see FIG. 9).

In step S1, when the unloading from the pallet flow conveyor 19 proceeds and a vacancy of the load is detected (empty detection) on the pallet flow conveyor 19, the process proceeds to step S2. Repeat S1.

In step S2, the control CPU 33
Inspects the articles registered therein from the pallet flow conveyor 19 where the empty is detected, and places the articles in the first rack 1
Pallet flow conveyor 1
In order to release the stacker crane 14 from the stacker crane 14
Releases the specified article.

The control CPU 33 updates the empty shelf file to indicate that the contents of the shelf location instructed to be taken out have become empty shelves, and stores the A of the first rack 11 in the A-managed item common storage unit of the first rack 11. It is checked whether any of the goods stored in the storage unit for exclusive use of the managed goods is stored on the same day as the one stored on the latest day (step S3).

If step S3 is affirmative, the flow advances to step S4 to move the data from the A-managed item common storage unit of the first rack 11 to the A-managed item dedicated storage unit of the first rack 11 (the stored shelves). Location remains the same).

If step S3 is negative, the process proceeds to step S5, where the cargo stored in the A-managed product common storage unit of the first rack 11 is stored in the ABC-managed product common storage unit of the second and third racks 12 and 13. Check if there is something that has been received earlier. If not, the process proceeds to step S4, and the items stored next to the latest storage date in the storage unit dedicated to the A-managed product of the first rack 11 are transferred from the common storage unit of the A-managed product of the first rack 11 to the A of the first rack 11. Move to the managed goods dedicated storage unit (movement of data only).

In step S5, the first rack 11 is stored in the ABC-managed product common storage unit of the second and third racks 12 and 13.
If there is any goods stored before the goods stored in the A-managed goods common storage unit, the flow advances to step S6 to move the goods from the 2.3 racks 12 and 13 to the 1 rack 11. That is, after the control CPU 33 automatically designates the conveyor to be used for the movement (priority is given to the conveyor on the second floor, and if the conveyor on the second floor is in operation, the conveyor on the third floor is selected), the control CPU 33 executes the inventory movement. By instructing, 2-3
The corresponding articles stored in the ABC-managed goods common storage section of the No. racks 12 and 13 are unloaded and stored in the A-managed article dedicated storage section of the No. 1 rack 11. In this case, the A of the first rack 11
Even if the goods are stored in the storage for exclusive use of managed goods, the storage date is not updated again. That is, the warehousing date is the date when the warehousing is first performed via the automatic warehouse 10 and does not change.

In step S6, the movement of each pallet has been described. However, the present invention is not limited to this embodiment. In the case of "YES" in step S5, the pallets may be moved simultaneously by a plurality of pallets. For example, if the empty shelves for 6 pallets do not move until they are generated in the storage section dedicated to the A-managed items of the No. 1 rack 11, if 6 pallets are moved simultaneously when 6 pallets are generated, the conveyor can operate simultaneously for a plurality of pallets. , Work efficiency is improved.

In the automatic warehouse 10, the control CP
U33 is based on the incoming and outgoing information in each of the racks 11 to 13 and the overflow area 26,
The inventory files in each of these storage locations are constantly updated and grasped.

In the automatic warehouse 10, the common storage section of the first rack 11 may store A-managed items or articles other than A-managed items.

According to this embodiment, the following effects are obtained. Before storing, it is calculated whether all the articles can be stored in the racks 11 to 13 of the automatic warehouse 10 , and if all the articles cannot be stored, the unnecessary articles can be stored in the overflow area for the time being. Ten luck
Necessary articles (articles with low stock) can be preferentially stored in the stores 11 to 13 . When the luggage is stored in the overflow area 26, an overflow list is output. The operator can select an article to be overflowed, a quantity, and the like using the overflow list as a guide. Be to warehousing all stock articles in the automated warehouse 10, the overflow articles also other articles even only all put in the automated warehouse 10 from the same place, branch each article to a predetermined goods receipt destination, it shall be stored, storage operation is Easy. It is possible to easily perform a goods receipt inspection by causing all of the incoming goods to be stored in the automatic warehouse 10 and inputting the received result information (type and quantity). In the automatic warehouse 10, the movement of the articles from the overflow area 26 to the racks 11 to 13 is performed after confirming in advance that there are empty shelves in the automatic warehouse 10. Therefore, the movement from the overflow area 26 to the racks 11 to 13 can be performed smoothly.

As described above, according to the present invention, the warehousing process
While the ease, all of the articles that are in stock in advance calculating whether it can Receipt in the automated warehouse, if not be receipts all goods, goods receipt (less inventory) required articles preferential , And all the goods arrived
Inspection can be performed easily .

[Brief description of the drawings]

FIG. 1 is a layout diagram showing a first floor layout of a distribution center having an automatic warehouse (storage facility) to which the present invention is applied.

FIG. 2 is a layout diagram showing a second floor and a third floor layout.

FIG. 3 is a flowchart showing a physical distribution system to which the present invention is applied.

FIG. 4 is a block diagram showing a control system of the physical distribution system.

FIG. 5 is a schematic diagram showing a storage frame of an automatic warehouse.

FIG. 6 is a flowchart showing a storage processing flow.

FIG. 7 is a flowchart showing an overflow calculation processing flow.

FIG. 8 is a flowchart showing a storage setting processing flow.

FIG. 9 is a flowchart showing an automatic stock transfer processing flow.

[Explanation of symbols]

10 automatic warehouse 14 stacker crane 26 overflow area

Claims (2)

(57) [Claims] 1. A multi-item storage shelf and an overflow
Using an automated warehouse comprising a area, thereby enabling Receipt to the automatic warehouse goods pallet units stock of pallets loads exceeding the vacant shelves number of automatic warehouse is carried into Overclocking flow area, this This is a method of storing goods, in which the type and quantity of goods carried into the overflow area are stored in the control device, and the total number of pallets of incoming goods is calculated, and the total number of pallets exceeds the number of empty shelves in the automatic warehouse. When, the number of overflows, the varieties to be received, the quantity to be received and the shelf stock of the varieties
After outputting the overflow list that records the quantity , based on the above overflow list, the type and quantity of the article to be overflowed are set and registered in the control device, then all the incoming goods are stored in the automatic warehouse , and the type and quantity of all the incoming goods are checked. A method of storing articles, wherein a record of arrival is input to a control device, articles to be overflowed are carried into an overflow area, and other articles are stored on shelves . 2. A Stock quantity to the automatic warehouse is less than receipts possible quantity, if any one of the articles in the overflow area, calculates the quantity of the article being stored on SL overflow area, automated warehouse 2. The article receiving method according to claim 1, wherein an overflow re-entry list in which the number of empty shelves, the type of the overflow area, the quantity and the quantity of the shelf inventory are recorded and output is notified.