JP4680547B2 - Individual distribution apparatus and operation method thereof - Google Patents

Description

The present invention relates to an individual distribution device and an operation method thereof, and more particularly, to an individual distribution device and an operation method thereof capable of performing sorting and distribution for individual delivery continuously and efficiently.

  2. Description of the Related Art Conventionally, an individual distribution method is known in which received products are sorted for individual delivery to a plurality of individuals. FIG. 10 is a block diagram schematically illustrating a work flow according to the conventional individual distribution method. As shown in FIG. 10, the goods received at a delivery center (not shown) or the like are temporarily placed and then replenished to the picking rack. From the picking rack, a personal picking system (DPS) that picks up the goods for each individual who is an individual delivery destination, and then puts the classified goods into a bag and attaches a label indicating the delivery destination Perform binding and labeling. If necessary, the bags with the labels attached are boxed (organized in a box) for each group provided in each region, and then dolly loaded and held horizontally.

  However, since the work by the conventional individual distribution method has a complicated work process and a wide variety of work contents, it is inevitable that it takes time and effort, and there are many errors in distribution. Therefore, it has been desired to increase the sorting accuracy as well as the efficiency of the distribution sorting work.

An object of the present invention is to provide an individual distribution apparatus and an operation method thereof that can increase the efficiency of the distribution sorting work and increase the sorting accuracy.

The inventions retrieves a plurality of workers items from a plurality of storage container product is housed, in a separate distribution device for distributing sorting individually into a plurality of empty containers,
A transport line for transporting a plurality of storage containers storing the products;
Provided in parallel on both sides of the transport line, comprising two rows of sorting lines for transporting the empty containers, each sorting line consists of upper and lower lines that are alternately and independently transported,
Branching from a plurality of locations in the transport direction of the transport line, comprising a branch line that feeds the storage container to be positioned in front of each worker,
In each of the sorting lines, when one batch of distribution sorting to a plurality of empty containers on the upper or lower line by a plurality of workers is completed, only the upper or lower line with the already sorted containers Transported,
It is characterized by that.

The operation method of the individual distribution device of the present invention is as follows:
(A) The transport line includes a step of transporting a plurality of storage containers in which the products are stored;
(B) Each branch line sends out the storage container transported by the transport line so as to be positioned in front of each worker, and is provided for distribution sorting by each worker;
(C) In each sorting line, when one batch of distribution sorting to a plurality of empty containers on the upper or lower line by a plurality of workers is completed, the upper or lower stage having the already sorted containers A process of transporting only the distribution line, transporting the sorted and sorted containers to the next area, and transporting an empty container in front of each worker,
(D) performing the step (c) alternately on the upper and lower lines;
It is characterized by including.

According to the present invention, it is possible to improve the sorting accuracy with efficient allocation sorting work, Ru can be implemented together to improve the reduction and sorting accuracy in human by improving productivity.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram schematically illustrating the overall flow of individual distribution work . As shown in FIG. 1, for example, when receiving an order for a product for home delivery that delivers various products to each home, etc., the order contents are arranged in units of work batches, and wirelessly based on the work contents for each work batch unit. A picking instruction is sent to work zones A to C by communication.

  In response to the picking instruction, total picking (seamless picking) in units of work batches is performed in each work zone A to C. In picking, the work batch is divided into sequencing (SEQing) group units, and the group is collectively picked. Total picked goods are transported directly from each work zone A to C (storage block) to the assorting line. After assorting and packing, they are sorted and then dolly packed and shipped sideways. Become.

The individual distribution method described below for individually distributing various products S for each delivery destination for home delivery has the following characteristics.
1. Automatic generation of data Based on the order data, batch numbers of work orders are automatically generated for each of a plurality of sorting lines. In other words, a working group sequencing group (SEQ / G) is automatically generated by shipping order maintenance by the shipping master. FIG. 2 is an explanatory diagram showing work batch numbers automatically generated for each assorting line. As shown in FIG. 2, for example, in each of the assorting lines (No. 1 line and No. 2 line) formed in two upper and lower stages, the work order 1 is the upper stage, the work order 2 is the lower stage, and the work order. The work order is determined alternately in the upper and lower stages, such that No. 3 is the upper stage.
2. Work seamlessness By automatic SEQ / G generation, communication is controlled by making distribution instructions seamless so that work can be alternately performed on the upper and lower assorting lines alternately.
3. Improvement of work visibility Product is transported continuously in front of the worker who performs the distribution work, and the distribution destination displays the direction and quantity of the distribution hit front simultaneously on the display device, improving work productivity To do.
4). Distribution error prevention check Distribution errors in distribution work are automatically checked by linking the display device and the line sensors installed at the distribution hits.
5. Multi Induction System in flexibility in stock automation level, warehouse (Automat ed Strage / Retrieval System: AS / RS) and automatic container supply for automatic Integrative Deployment, interleaving control in the AS / RS, seamless A sorting Control, RFID (Radio Frequency IDentifi
data management by catenation), high-speed shipping order control by cirque sort, container auto stacking, etc., all of the automation levels are modularized so that free combinations are possible.
6). Realization of traceability and visibility network Integration with visibility network by track & tracing management using container RFID.

Figure 3 is an illustration of a specific example of an individual-specific allocation methodologies number distribution business flow. As shown in FIG. 3, when a vendor carries in merchandise, first, merchandise arrival processing by multi-induction is performed. In addition, an empty container is returned. Next, merchandise conveyance processing is performed by determination of the picking area classification and subsequent conveyance by area. The returned container is automatically transported. After the conveyance by area, the storage / storage process is performed through automatic storage in the storage area of the product and subsequent automatic replenishment, or by automatic storage in the picking area directly from the conveyance by area. The automatically transported container is stored in a predetermined place.

  Next, collection / sorting processing is performed by total picking and subsequent assorting of the products stored in the picking area. In assorting, a label is attached to a container, which is an empty container automatically supplied from a storage location. At this time, broken material processing such as a cardboard box in which a product to be picked is packed is performed as necessary.

  Next, the refrigerated product goes through the storage of the cold storage agent and the subsequent dolly packing, and the frozen glossary product goes through the basket car automatic loading and is temporarily stored, respectively. The stacking process is performed through stacking or directly by loading a delivery vehicle. After each of these processes, the product is shipped and delivered to an individual delivery destination (for example, a member of an organized union).

  Hereinafter, an outline of specific business contents and basic functions in each process of the individual workflow described above will be described with reference to FIGS.

FIGS. 4A and 4B show the arrival to the arrival conveyance in the individual distribution work flow of FIG. 3, where FIG. 4A is an explanatory view of the arrival work, and FIG. 4B is an explanatory view of the work on the induction line. As shown in FIG. 4, in arrival to arrival conveyance, first, a product S is introduced from a vendor's delivery vehicle 10 to an induction line 11 using a belt conveyor, and arrival induction loading is performed (see (a)). Product S arrives.

  Subsequently, the operator P uses the wireless terminal 12 to scan an ITF (Interleaved-2 of 5 code) or JAN (Japan Article Number) code for the product S transported on the induction line 11 (see (b)). . Based on the information obtained by this code scanning, freshness management work (expiration date, quantity input, etc.) is performed, and the cart ID (IDentification) and the product S are linked. At this time, the product label without the ITF or JAN code is attached with a product label. The palletized product is automatically conveyed to a palletizing line (not shown).

  In other words, in the incoming to incoming delivery processing, it is possible to contribute to the simplification and efficiency of the incoming work by performing the incoming inspection using the ITF or JAN code. Further, by performing freshness management by inputting the expiration date, management data can be updated in real time by integrating the mechanisms of freshness management and inventory management.

  FIG. 5 shows storage / storage in the individual workflow shown in FIG. 3, where (a) is an explanatory diagram of the storage area, and (b) is an explanatory diagram of the picking area. As shown in FIG. 5, in storage and storage, the received goods S are automatically divided into a pallet stock stored in pallets and a case stock stored in cases, and storage area 13 ((a) Stored). Replenishment from the storage area 13 to the picking area 14 (see (b)) is also automatically performed, and replenishment picking can be automated.

  That is, in the storage / storage process, the location-based inventory management system enables one-item multiple-location inventory, and also enables freshness management for each location. Moreover, the freshness reversal phenomenon can be prevented by location management for each freshness date.

FIG. 6 is an explanatory diagram showing picking in the individual workflow shown in FIG. As shown in FIG. 6, in the picking area 14, first, the worker P moves to the designated location and performs total picking of the designated quantity of products S according to a picking instruction digitally displayed on a display device (not shown). Next, the worker P performs an operation of allocating the product S to the tote tray ( conveyance tray ) 15 which is a product storage container according to the tote distribution instruction, and then the tote tray 15 on the picking product conveyance line 16 using the conveyance means. . The tote tray 15 in which the picked product S is stored is automatically transported to the assorting area by the picking product transport line 16. The transport means, conveyor belts and the low LA conveyor or the like is used.

  The picking product conveyance line 16 is arranged at a height in consideration of the work efficiency of the worker P, and an empty tote tray return line 17 using a conveying means for returning the empty tote tray 15 is provided thereon. Furthermore, the lavish conveyance line 18 using the conveyance means which conveys the lavish (broken material) which came out by the broken material processing after taking out the goods S is each arrange | positioned.

In other words, in picking, the troublesome work plan for automatic combination and continuation of work units (batching and sequencing) is automatically generated and optimized to maximize productivity in each work area. And continuous (seamless). Further, the relational picking system links the picking work and the assorting work in real time without interruption, so that the work balance can be made more efficient. In addition, the total picking system enables total picking in the corresponding batch (SEQ / G unit) and automatic distribution of picking data to workers by automatic management of work progress.

  FIG. 7 is an explanatory diagram showing assorting in the individual workflow shown in FIG. As shown in FIG. 7, when the tote tray 15 storing the picked products S is sent from the picking area 14 to the assorting area 19, the products S in the tote tray 15 are individually provided for each delivery destination. Sorting is performed to sort the items.

  In the assorting area 19, an assorting product conveyance line 20 using, for example, a belt conveyor, which is continuous with the picking product conveyance line 16, has one row on both sides thereof, for example, an assorting line 21 using a belt conveyor, 22 is arranged. Each of the assorting lines 21 and 22 has a height that takes into consideration the work efficiency of the worker P, and is formed in two upper and lower stages, and further on the upper assorting lines 21a and 22a, the picking area 14 An empty tote tray return line 17 is extended and arranged.

  For example, a belt conveyor can branch the plurality of assorted product conveyance lines 20 in the middle of the conveyance direction almost perpendicularly to the assorted product conveyance line 20 and send the products S to the lower assorting lines 21b and 22b. A branch line 23 is provided. An operator P is positioned outside each of the assorting lines 21 and 22 where the branch line 23 is located so as to face each of the assorting lines 21 and 22, that is, on the extension of the branch line 23 (see FIG. 8 shows eight branch lines 23 facing each other at four locations and eight workers P).

  In each of the assorting lines 21 and 22, the upper stage and the lower stage operate independently, and the upper assorting line 21a and the lower assorting line 21b can alternately carry. Similarly, the upper assorting line 22a and the lower assorting line 22b also perform the conveying operation alternately. In each of these assorting lines 21a, 22a, 21b, and 22b, a plurality of distribution ports for each worker P to perform assorting are set in a certain range on both sides of each worker P. An empty container 24 is arranged.

  In the assorting area 19 having such assorting lines 21 and 22, assortment by the worker P is performed, and the products S are individually distributed for each delivery destination. The tote tray 15 in which the product S is stored is transported from the picking product transport line 16 to the assorted product transport line 20 as needed, and is further transferred from the assorted product transport line 20 via the branch line 23 to each worker P. Sent in before. The tote tray 15 stores an appropriate amount of products S necessary for each worker P to perform assorting.

  Although not shown, the branching line 23 that feeds the tote tray 15 in front of the worker P does not affect the transport movement of the assorting lines 21 and 22 and does not affect the sorting line 21. , 22 are arranged independently at different heights.

  Each worker P takes out the product S from his / her previous tote tray 15 and designates the designated product for each container 24 serving as a different delivery destination of a plurality of containers 24 juxtaposed around him / her. Distribute and sort S by the specified number.

  When the distribution and sorting of the necessary amount of products S for each container 24 is completed, the containers 24 on the assorting lines 21 and 22 are transported and moved by the transporting operation of the assorting lines 21 and 22, and the distribution sorting is completed. The container 24 is sent out to the shipping area. The tote tray 15 that has become empty due to the distribution and sorting of the products S is placed on the empty tote tray return line 17 and returned by the operator P.

  FIG. 8 is an explanatory diagram in which a part of the assorting line in FIG. 7 is enlarged. As shown in FIG. 8, when the tote tray 15 storing the product S is conveyed in front of the worker P in each of the assorting lines 21 and 22, the worker P is attached to the tote tray 15. A bar code (not shown) is scanned by a scanner (not shown).

  By scanning the bar code, the indicator (not shown) arranged in front of the worker P has the distribution instruction information of the product S for informing the worker P based on the information obtained by the scanning. Is displayed. The worker P looks at the distribution instruction information on the display and performs frontage distribution work for distributing and sorting the products S to the designated containers 24. When performing the frontage allocation work, the worker P is alternately placed between the upper and lower stages, that is, the upper assorting line 21a and the lower assorting line 21b, or the upper assorting line 22a and the lower assorting line 22b. Work alternately with.

  That is, when the product S is sent by the tote tray 15, the worker P first performs the frontage distribution work of the lower assorting line 21b (or 22b). The worker P who has finished the distribution work on the lower assorting line 21b (or 22b) then performs the frontage distribution work on the upper assorting line 21a (or 22a).

  When the distribution work for one batch in the lower assorting line 21b (or 22b) is finished, the lower assorting line 21b (or 22b) is transported and the goods S are sorted. The loaded container 24 is sent to the shipping area. At the same time, an empty container 24 is carried in front of each worker P by the conveying operation of the lower assorting line 21b (or 22b).

  Subsequently, the worker P who has finished the frontage allocation work on the upper assorting line 21a (or 22a) has already carried a new empty container 24, and the lower assorting line 21b (or 22b). Perform frontage allocation work.

  When the distribution work for one batch in the upper assorting line 21a (or 22a) is completed, the upper assorting line 21a (or 22a) is transported and the container 24 loaded with goods is shipped to the shipping area. And send it out. At the same time, the empty container 24 is carried in front of each worker P by the conveying operation of the upper assorting line 21a (or 22a).

  Thereafter, the upper and lower stages of the assorting lines 21 and 22 are alternately transported and moved every time one batch of distribution work is completed, so that an empty container 24 is supplied as needed. The frontage distribution work (assorting) can be performed alternately (see FIG. 2). Therefore, the assorting of the products S for each stage in the assorting lines 21 and 22 is performed continuously from the stage after the assorting to the next stage as long as the products S are in the tote tray 15. Each worker P can perform another stage of assortment simultaneously with the end of the work of one stage without waiting for the work of another worker P to end.

  That is, each worker P first performs the assorting of the lower assorting line 21b (or 22b), but the worker P who finished the work earlier continues the upper assorting line 21a (or 22a) can be performed. Here, there is a variation for each worker P. Within that, assembling for one batch in the lower stage is completed, and the container 24 loaded with products is sent out, and the next empty container comes in the lower stage. Next, the worker P who has finished the assembling in the upper stage moves to the assembling in the lower stage, and within that, the assorting for one batch in the upper stage is finished, and the container 24 loaded with the products is sent out. The next empty container will come.

  In this way, the upper assorting line 21a (or 22a) and the lower assorting line 21b (or 22b) are alternately transported and moved, so that the assorted container 24 having been loaded is finished. Since the assorting line 21a (or 22a) and the lower assorting line 21b (or 22b) are sent out in order, the delivery of the containers 24 loaded with products is continued in the order of loading onto the truck at the time of shipment. . In addition, the worker P can perform assorting continuously regardless of the work progress status of other workers P.

  That is, in this assorting, the distribution mouth is automatically set so that the work for each worker P is leveled. In addition, the sensor monitoring and the alarm processing for preventing the product S from being erroneously put in can realize the distribution with 100% accuracy without causing the error. In addition, it is also possible to output a content detail label by delivery store separate mouth record management. In addition, since the product S to be sorted is shot in front of the worker P without any interruption, it is possible to eliminate the idling (standby time) of the work and realize high work productivity.

  FIG. 9 is an explanatory diagram showing loading to shipping in the individual workflow shown in FIG. As shown in FIG. 9, containers 24 in which products are loaded in the order of loading are conveyed from the assorting lines 21 and 22 in the assorting area 19 to the shipping area 26 via the shipping and conveying line 25. Under the supervision of the worker P, the container 24 having been loaded with merchandise transferred to the shipping area 26 is automatically stacked from the shipping transfer line 25 to the dolly 27.

  The container 24 loaded with goods stacked in the dolly 27 is placed on a transfer vehicle 29 that moves on a shipment standby line 28, and then automatically held by the transfer vehicle 29 in a shipment standby area 30.

As described above, according to this individual distribution method , it is possible to contribute to simplification and efficiency of the arrival work, and the management data can be updated in real time by combining the mechanisms of freshness management and inventory management. In addition, it is possible to stock one item at a plurality of locations, and it is possible to manage freshness in units of locations, thereby preventing a freshness reversal phenomenon. In addition, the productivity of each work area can be maximized and continuous (seamless), and work balance can be made more efficient. In addition, total picking in the corresponding batch (SEQ / G unit) and automatic distribution of picking data to the worker unit by automatic management of work progress can be performed. In addition, the distribution mouth is automatically set so that the work for each worker P is leveled, and it is possible to realize 100% accuracy distribution without erroneous input, and also output the contents detail label Therefore, idling (standby time) of work can be eliminated, and high work productivity can be realized.

  As a result, compared with the conventional individual distribution method, it is possible to realize a reduction in man-hours and an improvement in sorting accuracy by improving productivity, and it is possible to easily cope with differences in product categories. In addition, the system modules can be freely combined according to the scale of the quantity handled.

  In the above embodiment, the assorting lines 21 and 22 are not limited to the upper and lower two stages, and may be a plurality of upper and lower three or more stages. Further, in the assorting, the case of eight workers P is shown (see FIG. 7), but the number of workers P may be seven or less or nine or more as required.

It is a block diagram which illustrates roughly the flow of the whole work of individual distribution work . It is explanatory drawing which shows the work batch number automatically produced | generated for each conveyance line. It is an illustration of a specific example of an individual-specific allocation methodologies number distribution business flow. FIGS. 3A and 3B show the arrival to the arrival conveyance in the individual distribution work flow of FIG. 3, wherein FIG. 3A is an explanatory view of the arrival work, and FIG. FIGS. 3A and 3B illustrate storage and storage in the individual workflow shown in FIG. 3. FIG. 3A is an explanatory diagram of a storage area, and FIG. 3B is an explanatory diagram of a picking area. It is explanatory drawing which shows the picking in the individual distribution work flow of FIG. It is explanatory drawing which shows the assorting in the individual distribution work flow of FIG. It is explanatory drawing which expanded a part of assorting line of FIG. It is explanatory drawing which shows the loading-shipment in the individual distribution work flow of FIG. It is a block diagram which illustrates roughly the flow of the operation | work by the conventional separate allocation method.

DESCRIPTION OF SYMBOLS 10 Delivery vehicle 11 Induction line 12 Wireless terminal 13 Storage area 14 Picking area 15 Tote tray 16 Picking goods conveyance line 17 Empty tote tray return line 18 Rabish conveyance line 19 Assorting area 20 Assorting goods conveyance line 21, 22 Assorting line 21a 22a Upper assorting line 21b, 22b Lower assorting line 23 Branch line 24 Container 25 Shipping conveyance line 26 Shipping area 27 Dolly 28 Shipping standby line 29 Transfer beagle 30 Shipping standby area P Worker S Product

Claims (5)

In an individual distribution device for a plurality of workers to take out products from a plurality of storage containers in which products are stored, and to individually distribute and sort into a plurality of empty containers,
A transport line for transporting a plurality of storage containers storing the products;
Provided in parallel on both sides of the transport line, comprising two rows of sorting lines for transporting the empty containers, each sorting line consists of upper and lower lines that are alternately and independently transported,
Branching from a plurality of locations in the transport direction of the transport line, comprising a branch line that feeds the storage container to be positioned in front of each worker,
In each of the sorting lines, when one batch of distribution sorting to a plurality of empty containers on the upper or lower line by a plurality of workers is completed, only the upper or lower line with the already sorted containers Transported,
Individual distribution device characterized by that. From the storage container sent out by the branch line, comprising two rows of return lines for returning the storage containers emptied by the sorting of the empty containers on the upper or lower line by each worker, The individual distribution apparatus according to claim 1, wherein each of the return lines is provided on each of the upper lines. 3. The display device according to claim 2, further comprising: a display for displaying product distribution instruction information disposed in front of each worker; and a sensor for checking a distribution error for preventing a product distribution error. Individual distribution device as described. The individual distribution apparatus according to claim 1, 2 or 3, wherein the conveyance line, the sorting line, and the branch line are a belt conveyor or a roller conveyor. In the operation | movement method of the separate distribution apparatus of Claim 1,
(A) The transport line includes a step of transporting a plurality of storage containers in which the products are stored;
(B) Each branch line sends out the storage container transported by the transport line so as to be positioned in front of each worker, and is provided for distribution sorting by each worker;
(C) In each sorting line, when one batch of distribution sorting to a plurality of empty containers on the upper or lower line by a plurality of workers is completed, the upper or lower stage having the already sorted containers A process of transporting only the distribution line, transporting the sorted and sorted containers to the next area, and transporting an empty container in front of each worker,
(D) performing the step (c) alternately on the upper and lower lines;
A method of operating an individual distribution device, comprising:

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