JP4733517B2 - Picking system - Google Patents

Description

  The present invention relates to a picking system for picking and shipping instructed items from a plurality of received items in an instructed order, and more particularly to a picking system that prevents picking mistakes.

  As is well known, in recent years, for example, manufacturers have received various parts (items) for assembling products, and have picked various parts in order based on instructions from the manufacturer. The so-called order delivery work has been performed in which the picked order is stored in a pallet and shipped to a manufacturer.

  By the way, such an orderly delivery operation is still in the development stage, and there is much room for improvement in various points. In particular, this type of ordered delivery requires the development and the prevention of picking mistakes because the types and order of items stored in the shipping pallet need to correspond to the requirements from the manufacturer. .

Patent Document 1 discloses a configuration in which products are sequentially carried in and temporarily stored in a storage place, and then the correct order is instructed to reliably carry out the products. Further, Patent Document 2 discloses a configuration that prevents sorting errors by using an electronic tag and performing work in accordance with voice guidance. Further, Patent Document 3 discloses a configuration in which products assembled at each assembly station are once stored in a stock area together with a carriage, and are searched for in the product shipping order and moved to the shipping area.
JP 2005-179022 A JP 2005-239431 A JP 2005-177905 A

  Therefore, the present invention has been made in consideration of the above circumstances, so that the operation of picking and shipping the instructed items sequentially in the instructed order can be accurately executed while preventing picking mistakes as much as possible. An object of the present invention is to provide a picking system that is improved to be suitable for practical use.

  The picking system according to the present invention includes a plurality of pallets to which a first tag in which information relating to an item on which each is mounted is written is attached; a plurality of pallets are installed; An incoming pallet storage place where the installation position is set; and a pallet in which items extracted from a plurality of pallets installed in the incoming pallet storage place are installed. A shipping pallet storage site in which a tag is installed; instruction information including items to be taken out from a plurality of pallets installed in the incoming pallet storage site and the order in which they are taken out are stored in the vicinity of the first and second tags. A terminal capable of reading the information written on the terminal; the terminal reads the information read from the first tag and the instruction information Confirming items taken out from the pallets installed in the incoming pallet storage, and comparing the information read from the second tag with the instruction information by the terminal and storing them on the pallet installed in the shipping pallet storage Control means for alternately checking the items is provided.

  According to the above-described invention, the items taken out from the pallets installed in the incoming pallet storage site are checked and the items stored in the pallets installed in the shipping pallet storage site are alternately checked. As a result, the work of picking and shipping the instructed items sequentially in the instructed order can be performed accurately while preventing picking errors as much as possible, which is suitable for practical use.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 schematically shows a picking system described in this embodiment. In FIG. 1, reference numeral 11 denotes an incoming pallet storage, where various items received from an external item supplier are stored in a state of being loaded on a plurality of pallets 12 according to their types.

  Further, in this picking system, a plurality (three in the illustrated case) of picking work places 13, 14, 15 are installed in the vicinity of the incoming pallet storage place 11. At these picking workplaces 13, 14, and 15, picking workers perform ordering picking work based on different ordering instructions.

  That is, each picking work place 13, 14, 15 has an incoming pallet place 13a, 14a, 15a in which a plurality of pallets 12 can be installed, and a shipped pallet place 13b, 14b, 15b for placing the pallet 12 to be shipped, respectively. Printers 13c, 14c, and 15c for outputting work instructions given to picking workers are installed.

  For example, in the picking work place 13, a plurality of pallets 12 carrying items necessary for the picking work are not shown from the incoming pallet storage place 11 on the basis of the ordering instructions created corresponding to the picking work there. It is carried into the incoming pallet storage 13a by a forklift.

  The picking worker at the picking work place 13 picks the designated items in the designated order from the plurality of pallets 12 installed in the incoming pallet place 13a based on the ordering instructions in the work instruction sheet, and the shipping pallet place Store in the picked order in the shipping pallet 12 placed in 13b.

  When the picking operation for one shipping pallet 12 placed in the shipping pallet storage 13b is completed, the shipping pallet 12 is conveyed and stored in the shipping pallet storage 16 by a forklift. The pallets 12 stored in the shipping pallet storage 16 are sequentially sorted and shipped by customer.

  When the picked pallet 12 is carried out from the shipping pallet storage 13b to the shipping pallet storage 16, the empty pallet 12 is taken out from the empty pallet storage 17 by a forklift in order to perform the next order picking operation. Then, it is transported and installed in the shipping pallet storage 13b.

  Further, when there are not enough items on the pallet 12 installed in the incoming pallet storage place 13a in the picking work place 13, the forklift worker uses the replenishment request from the picking work person to place the pallet 12 loaded with the necessary items. The items are transported from the incoming pallet storage 11 to the incoming pallet storage 13a, where items are replenished.

  It should be noted that the above-described picking work at the picking work place 13 is similarly performed at the other picking work places 14 and 15.

  Next, FIG. 2 shows a control system of the picking system. That is, in FIG. 2, reference numeral 18 denotes an ordering system, and this ordering system 18 is connected to a management PC (personal computer) 21 via hubs 19 and 20.

  The management PC 21 functions as a database storing the ordering instruction data for each of the picking workplaces 13, 14, and 15, and at the same time, the management PC 21 receives, picks up, based on the ordering instruction data of the ordering system 18. In various work processes such as shipment and replenishment, work instructions are generated for workers such as a plurality of picking workplaces 13, 14, 15 and a plurality of forklifts, and mistakes described later are monitored.

  That is, the management PC 21 controls the plurality of printers 13c, 14c,... The management PC 21 can wirelessly communicate with a handy terminal 23 held by a forklift worker via a plurality of access points 22 connected to the hub 20.

  Furthermore, the management PC 21 can wirelessly communicate with a handy terminal 25 possessed by a plurality of picking workers via a plurality of access points 24 connected to the hub 20. The plurality of handy terminals 25 can wirelessly communicate with the corresponding wristband reader 26.

  In the picking system configured as described above, the detailed operation will be described below by dividing it into four steps at the time of item arrival, picking, shipping, and replenishment.

  FIG. 3 is a flowchart for explaining processing operations when items are received, that is, when various items that are loaded and received from an external item supplier on the pallet 12 are stored in the incoming pallet storage 11. FIG. 4 schematically shows the item arrival processing operation shown in FIG.

  This item arrival processing operation is started when the arrival truck 27 loaded with the item arrives (step S3a). Then, in step S3b, the forklift worker unloads the plurality of pallets 12 loaded with various items from the arrival truck 27 by using the forklift, and temporarily places each pallet 12 in a predetermined temporary storage place (not shown).

  Then, in step S3c, the forklift operator reads the various items described in the Kanban 28 attached to the pallet 12 in advance for each temporarily placed pallet 12, and stores them in the pallet 12. Incoming inspection work is performed to check the type and quantity of items.

  Thereafter, in step S3d, the forklift operator reads the bar code 28a of the kanban 28 attached to the pallet 12 that has been inspected by the handy terminal 23, and various information regarding the items mounted on the pallet 12. Is stored in the management PC 21. At the same time, the item arrival history is acquired.

  Then, the forklift worker writes the information of the pallet 12 acquired by the handy terminal 23 to the pallet IC tag (RFID) 29 in step S3e, and attaches the pallet IC tag 29 to the pallet 12 in step S3f. As a result, in addition to the kanban 28, the pallet IC tag 29 is attached to the pallet 12.

  Thereafter, in step S3g, the forklift worker transports and stores the pallet 12 with the pallet IC tag 29 from the temporary storage area to the predetermined position of the incoming pallet storage area 11 in step S3g. Is completed (step S3h).

  According to the arrival work as described above, at the time of arrival, information on the items mounted on the received pallet 12 is acquired, written to the database of the management PC 21, and written to the pallet IC tag 29. A tag 29 is attached to the pallet 12.

  As a result, at the time of the subsequent picking operation, the instructed item is obtained by communicating with the pallet IC tags 29 of the plurality of pallets 12 installed in the receiving pallet storage place 13a without sequentially referring to the database of the management PC 21. It is possible to confirm whether or not the items have been taken out in the order instructed.

  Further, if lot information is also added to the barcode 28a of the kanban 28, it can be used for lot confirmation and acquisition of information for traceability at the time of picking work.

  FIG. 5 shows a pallet for picking up an item, that is, a pallet for shipping placed in the shipping pallet storage 13b by picking the specified items from the plurality of pallets 12 installed in the receiving pallet storage 13a in the specified order. 12 is a flowchart for explaining a picking processing operation that is stored in the order picked at 12;

  In FIG. 5, for the sake of simplicity, the picking processing operation in the picking work place 13 will be described, but it goes without saying that the picking processing operations in the other picking work places 14 and 15 are performed in the same manner. FIG. 6 schematically shows the item picking processing operation shown in FIG.

  In other words, the item picking processing operation is started when the ordering instruction data is transmitted from the management PC 21 to the printer 13c of the picking work place 13 (step S5a).

  In step S5b, the printer 13c outputs a work instruction sheet 30 that describes the type and order of items to be picked. The work instruction sheet 30 describes the type and order of items to be picked, and is printed with a QR code 30a describing the work instruction information.

  Then, the picking worker acquires the work instruction information by reading the QR code 30a of the work instruction sheet 30 with the handy terminal 25 in step S5c. The acquired work instruction information is stored in the handy terminal 25.

  Thereafter, in step S5d, the picking worker picks the instructed item from the plurality of pallets 12 installed in the incoming pallet storage 13a based on the work instruction described in the work instruction sheet 30.

  As shown in FIG. 7, the picking worker wears a wristband reader 26 capable of wireless communication with a pallet IC tag 29 attached to the pallet 12 on his arm. When the picking worker takes out an item from the predetermined pallet 12 installed in the incoming pallet storage 13a, the information of the pallet IC tag 29 attached to the pallet 12 is automatically read by the wristband reader 26. Are transmitted to the handy terminal 25.

  As a result, the handy terminal 25 picks the correct item by collating the work instruction information obtained by reading the QR code 30a of the work instruction sheet 30 with the item information read by the wristband reader 26. If the item is not correct, the picking worker is warned by a display or an alarm.

  In addition, if lot information is added to an item, it is also possible to manage the first-in first-out by confirming the quantity of the extracted item for each lot.

  Thereafter, in step S5e, the picking worker stores the items taken out from the pallet 12 based on the work instruction sheet 30 on the pallet 12 installed in the shipping pallet storage 13b. In this case, a pallet IC tag 31 in which information unique to the shipping pallet is stored is installed in the shipping pallet storage 13b.

  When the picking worker stores the item in the pallet 12 installed in the shipping pallet storage 13b, information on the pallet IC tag 31 is automatically read by the wristband reader 26 and transmitted to the handy terminal 25. The

  As a result, the handy terminal 25 corrects the work instruction information obtained by reading the QR code 30a of the work instruction sheet 30 with the information on the pallet IC tag 31 read by the wristband type reader 26. It can be confirmed whether or not the item is stored in the predetermined pallet 12 within a predetermined time. When the item is not recognized as the correct pallet 12 or when the time is over, the picking worker is displayed by an indication or an alarm. To warn.

  Thereafter, in step S5f, the picking worker determines whether or not all the work instructions described in the work instruction sheet 30 have been completed. If not, the processes in steps 5d and 5e are performed. The operation is repeated until all the work instructions described in 30 are completed.

  If it is confirmed that all the picking operations described in the work instruction 30 have been completed, the picking worker reads the QR code 30a of the work instruction 30 again with the handy terminal 25 in step S5g. The work instruction 30 is attached to the pallet 12 installed in the shipping pallet storage 13b.

  After that, the pallet 12 installed in the shipping pallet storage 13b is inspected for the number of items stored in the pallet 12 and then transferred to the shipping pallet storage 16 by the forklift and stored therein. The item picking operation is completed (step S5h).

  According to the above-described picking work, the picking worker simply takes out or stores an item from the pallet 12, and the pallet IC tags 29, 31 are then moved by the wristband reader 26 attached to the arm. The information stored in the item and the information related to the picking instruction can be automatically read.

  That is, the picking worker does not need to perform a special operation for reading the information stored in the pallet IC tags 29 and 31, and can take out and store the items with both hands free. In addition to facilitating the picking work, the safety of the worker can be sufficiently ensured.

  Further, when an item is taken out from the pallet 12 installed in the incoming pallet storage place 13a, information on the item is read and collated from the pallet IC tag 29 attached to the pallet 12, and the taken-out item is sent to the shipping pallet storage place 13b. When storing in the installed pallet 12, information about the item is read and collated from the pallet IC tag 31 installed in the shipping pallet storage 13b.

  That is, whether the item is correct when it is removed from the pallet 12 is checked, and subsequently, whether the item is correct when the item is stored in the pallet 12 is checked. In short, after one item is taken out and stored, the next one item is taken out and stored, that is, the item is taken out and stored alternately. Is controlled.

  For this reason, for example, it is possible to eliminate an operation mode in which two or more items are collectively taken out from each pallet 12 installed in the incoming pallet storage 13a and stored together in the pallet 12 installed in the shipping pallet storage 13b. And picking mistakes can be prevented as much as possible.

  Further, even when the same item is taken out a plurality of times, the picking worker mistakes the number of times that the item is taken out, or the pallet IC tag 29 of another item is accidentally read by the wristband reader 26 It is possible to prevent picking mistakes.

  Furthermore, work instruction information and item inventory information can be described in the QR code 30a of the work instruction sheet 30, and the quantity for a lot can be managed to realize first-in first-out and traceability information acquisition. In that case, the item can be confirmed only by the handy terminal 25 without referring to the database of the management PC 21.

  In addition, it is confirmed whether or not an item has been reliably taken out from each pallet 12 installed in the incoming pallet storage 13a, and whether or not the item has been securely stored in the pallet 12 installed in the shipping pallet storage 13b. Therefore, picking up and storing items while measuring the weight for each pallet 12 enables more reliable picking.

  Further, it is more reliable to attach a sensor to the item delivery port or the item delivery port of the pallet 12 and confirm the loading / unloading of the item in conjunction with the communication with the pallet IC tags 29 and 31 by the wristband reader 26. High picking can be performed.

  Further, when the picking operation unit is completed, when the picking quantity is input to the management PC 21 or the like, it is possible to check whether the picking work has been performed correctly by comparing the quantity with the picking quantity according to the ordering instruction. Is possible.

  Further, the work instruction method includes a method of displaying on the wristband type reader 26, a method of displaying on the handy terminals 23 and 25, a method of displaying the screen on a PC installed in the picking workshops 13 to 15, items using pilot lamps, etc. A method of instructing the take-out order is conceivable.

  FIG. 8 is a flowchart for explaining the processing operation at the time of shipment of an item, that is, when the pallet 12 stored in the shipping pallet storage 16 is sorted and shipped by customer. This item shipment processing operation is started when the shipment truck 32 for shipping the item to the customer arrives (step S8a).

  Then, in step S8b, the forklift worker transports each pallet 12 stored in the shipping pallet storage 16 to a predetermined assortment site (not shown) by the forklift and temporarily places it.

  In step S8c, the forklift worker sequentially reads the QR code 30a of the work instruction sheet 30 attached to each pallet 12 temporarily placed in the assortment site with the handy terminal 23.

  As a result, the handy terminal 23 has information indicating the shipping destination, whether or not the shipping can be performed with respect to the pallet 12 that has read the QR code 30a of the work instruction sheet 30, and the order of shipping in the case of first-in first-out. Since it is displayed, the picking worker confirms the information displayed on the handy terminal 23 in step S8d. At the same time, the item shipment history is also acquired.

  Thereafter, in step S8e, the forklift worker loads the pallet 12 from the assortment site to the shipping truck 32 by using the forklift, and the item shipping operation is completed (step S8f).

  In the shipping work described above, the QR code 30a of the work instruction sheet 30 is read by the handy terminal 23 to confirm the order of shipment, but the QR code 30a of the work instruction sheet 30 is difficult to read at the time of shipment. The pallet IC tag storing the identification number or the like may be attached to the pallet 12 to be shipped for confirmation.

  FIG. 9 shows the pallet 12 loaded with necessary items from the incoming pallet storage 11 when the items are replenished, that is, for example, when there are not enough items on the pallet 12 installed in the incoming pallet storage 13a. It is a flowchart explaining the processing operation at the time of conveying to the storage place 13a and replenishing.

  This item replenishment processing operation is started when the picking worker recognizes that the items on the pallet 12 installed in the incoming pallet storage 13a are insufficient (step S9a). In this case, the picking worker inputs a replenishment request for the missing item to the handy terminal 25 and transmits it to the management PC 21 in step S9b.

  Then, in step S9c, the management PC 21 displays a replenishment request on the handy terminal 23 possessed by all forklift workers. As a result, a forklift worker located near the item to be refilled takes out the pallet 12 on which the necessary item is mounted from the incoming pallet storage 11 by a forklift and transports it to a predetermined position in the incoming pallet storage 13a. Install.

  Thereafter, in step S9d, the picking worker checks whether or not the pallet 12 transported from the incoming pallet storage 11 has been placed in the correct position in the incoming pallet storage 13a, and is placed in the correct position. If not, the forklift operator is instructed to re-enter the correct position, and the item replenishment operation is completed (step S9e).

  Here, as shown in FIG. 6, a location barcode 33 storing information indicating the type of item, the installation position, and the like is installed in the incoming pallet storage 13 a corresponding to each pallet 12 placed there. ing.

  Then, the picking worker reads the information of the pallet IC tag 29 attached to the pallet 12 conveyed from the incoming pallet storage 11 with the wristband reader 26 and also corresponds to the conveyed pallet 12. The location bar code 33 is read by the handy terminal 25.

  As a result, the handy terminal 25 compares the information of the pallet IC tag 29 with the information of the location bar code 33, and the pallet 12 conveyed from the incoming pallet storage 11 is placed at the correct position in the incoming pallet storage 13a. It can be confirmed whether or not it has been done.

  When the pallet 12 in the incoming pallet storage 13a becomes empty, the empty pallet 12 is transported to the empty pallet storage 17 by a forklift according to an instruction from a picking worker, and the pallet IC tag 29 is collected there.

  In the above replenishment work, when a picking worker makes a replenishment request using the handy terminal 25, the replenishment request is displayed on the handy terminals 23 possessed by all forklift workers. It can be used for replenishment work and is convenient.

  Note that the present invention is not limited to the above-described embodiments as they are, and can be embodied by variously modifying the constituent elements without departing from the scope of the invention in the implementation stage. Various inventions can be formed by appropriately combining a plurality of constituent elements disclosed in the above-described embodiments. For example, some components may be deleted from all the components shown in the embodiment. Furthermore, constituent elements according to different embodiments may be appropriately combined.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an embodiment of the present invention and is a diagram shown for schematically explaining a picking system. The block block diagram shown in order to demonstrate the control system of the picking system in the embodiment. The flowchart shown in order to demonstrate the processing operation at the time of the item arrival of the picking system in the embodiment. The figure shown in order to demonstrate typically the processing operation at the time of the item arrival of the picking system in the embodiment. The flowchart shown in order to demonstrate the processing operation at the time of the picking of the picking system in the embodiment. The figure shown in order to demonstrate typically the processing operation at the time of the picking of the picking system in the embodiment. The figure shown in order to demonstrate the wristband type reader used with the picking system in the embodiment. The flowchart shown in order to demonstrate the processing operation at the time of the item shipment of the picking system in the embodiment. The flowchart shown in order to demonstrate the processing operation at the time of item replenishment of the picking system in the embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Arrival pallet storage place, 12 ... Pallet, 13-15 ... Picking work place, 16 ... Shipment pallet storage place, 17 ... Empty pallet storage place, 18 ... Ordering system, 19, 20 ... Hub, 21 ... Management PC, 22 ... Access point, 23 ... Handy terminal, 24 ... Access point, 25 ... Handy terminal, 26 ... Wristband reader, 27 ... Incoming truck, 28 ... Kanban, 29 ... Pallet IC tag, 30 ... Work instruction, 31 ... Pallet IC tag, 32 ... shipping truck, 33 ... location barcode.

Claims (6)

A plurality of pallets to which a first tag written with information on the item on which each is mounted is attached;
The plurality of pallets are installed, and an incoming pallet storage place where an installation position is set for each pallet;
A pallet for storing items extracted from a plurality of pallets installed in the incoming pallet storage, and a shipping pallet storage having a second tag in which information unique to the shipping pallet is written; ,
A terminal that stores instruction information including items to be taken out from a plurality of pallets installed in the incoming pallet storage site and the order in which the pallets are taken out, and that can read the information written there in the vicinity of the first and second tags When,
The terminal collates the information read from the first tag with the instruction information to confirm an item taken out from the pallet installed in the incoming pallet storage, and the terminal performs the second And a control means for alternately checking the items stored in the pallet installed in the shipping pallet storage area by comparing the information read from the tag with the instruction information. Picking system to do. The terminal
A terminal in which the instruction information is stored;
The picking system according to claim 1, further comprising a reader that reads information written in the vicinity of the first and second tags and transmits the information to the terminal.   The picking system according to claim 2, wherein the terminal stores the instruction information by reading a code described in a work instruction.   The picking system according to claim 2, wherein the reader is a wristband reader.   2. The picking system according to claim 1, wherein information obtained by reading the kanban code attached to the received pallet by the terminal is written in the first tag. In the arrival pallet storage, a third tag in which information indicating a location to be installed corresponding to each installation position of a plurality of pallets is written,
The control means checks the pallet installed at each installation position of the incoming pallet storage site by comparing the information read from the third tag with the instruction information by the terminal. The picking system according to claim 1.

Images