JP5795173B2 - Product sorting system and product sorting program - Google Patents

Description

  The present invention relates to a product sorting system, a product sorting program, and a product quantity distribution program.

  Sorting work methods in logistics operations can be classified into so-called seeding methods and picking methods. Here, when there is a characteristic that goods are received sequentially while performing store sorting work like daily goods, sorting work by so-called seeding method is mainstream. Daily products include, for example, bread and confectionery, but it is difficult to achieve automatic sorting by machine for products that are easily damaged, such as soft or easy to collapse. . In addition, automatic sorting by machine leads to an increase in cost. For this reason, in reality, sorting by an operator's hand is required. Under such circumstances, a seeding method by an operator is mainly used for sorting daily items.

  When performing product sorting by the sowing method, the worker sorts products while moving. The movement range of the worker becomes wider as the number of delivery destination stores increases. Here, if there are products that can be delivered only to a small number of stores, the sorting work amount is small, but a wide range of movement is involved, and work efficiency deteriorates. In sorting work for handling various types, the sorting area must be reciprocated many times, increasing the burden on the operator.

  Conventionally, as a solution to such a problem, a proposal using a multi-stage rack in which weights are arranged in the vertical direction is known (for example, Patent Document 1). A sorting method is disclosed in which goods are delivered in a weight based on the display on the display.

Japanese Patent Laid-Open No. 6-80218

  In the product sorting method disclosed in the above-mentioned Patent Document 1, the upper limit of the amount of sorted items is limited by the size of the particular weight. For this reason, when it is necessary to sort a large amount of products for the same store (same shipping destination), multiple weights are used, or sorting work is divided into multiple times (multiple batches). There must be. Moreover, when goods are distributed and received like daily goods, sorting work for one store cannot be completed at a single arrival timing. When products are received at a plurality of timings in this way, it is necessary to temporarily avoid the weight at which some of the products are input and install them again at the product input place. In addition, if the use of avoiding the re-use of the number of loads is avoided in this way, the number of numbers for the store increases, and the loading efficiency and delivery efficiency of the transport truck are deteriorated.

  Thus, the product sorting system disclosed in this specification has an object of realizing an efficient product input to a watch weight while allowing an operator to work at a fixed position.

The product sorting system disclosed in this specification includes a sorting line in which a plurality of sorting conveyors each associated with a shipping destination are arranged in parallel, a sorted product storage unit provided for each of the plurality of sorting conveyors, and the sorting Each conveyor has a product entry port, and a worker's product entry port, a product distribution processing unit that distributes the received product to the division port, and a product that is distributed by the product distribution processing unit A pre-sorting product transport unit that transports the product to the sorting port, and the product sorting processing unit performs past work of an operator who is in charge of sorting work at each sorting port each time a received product is registered. Based on the actual results, the worker who has the most margin in the possible burden ratio is determined, and the products are distributed to the above-mentioned working mouths that the worker is in charge of .

  Since the sorting conveyor is associated with the shipping destination, one sorting conveyor is for one shipping destination. An operator inputs a product into a product input port provided for each sorting conveyor, that is, for each shipping destination, in one sorting port. Thus, the worker can perform the sorting work at the fixed position. In addition, the product input from the product input port is temporarily stored in a sorted product storage unit for each shipping destination. For this reason, it is sufficient to pack products in order from the sorted product storage unit. As a result, it is possible to efficiently put products into the weight and to reduce the number of weights used for one shipping destination.

  According to the product sorting system disclosed in this specification, it is possible to allow an operator to work at a fixed position and to efficiently put a product into a watch.

FIG. 1 is a conceptual diagram showing a state of sorting by the product sorting system. FIG. 2 is an explanatory diagram showing a schematic configuration of the product sorting system. FIG. 3 is a block diagram illustrating an example of a hardware configuration of the control unit. FIG. 4 is a functional block diagram of the control unit. FIG. 5 is an explanatory diagram schematically illustrating an example of an operation performed by the control unit. FIG. 6 is a flowchart showing an example of control of the product sorting system. FIG. 7 is a flowchart illustrating an example of a product sorting process performed in the product sorting system. FIG. 8 is an example of a table showing work performance data for each worker. FIG. 9 is an example of a table showing the work-by-work worker data. FIG. 10 is an example of a table showing the distribution amount distribution data for each work. FIG. 11 is an example of a table showing order details data. FIG. 12 is an example of a table showing product information (stock product information) data. FIG. 13 is an example of a table showing product registration data created sequentially. FIG. 14 is another example of the table showing the product registration data created sequentially. FIG. 15 is an example of a table showing product distribution data classified by mouth. FIG. 16 is a flowchart showing an example of control of sorting measures performed in the product sorting system. FIG. 17 is an example of a table showing sorted product input information. FIG. 18 is an example of a table showing sorting result data.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. However, in the drawings, the dimensions, ratios, and the like of each part may not be shown so as to completely match the actual ones. Further, depending on the drawings, for the sake of explanation, the originally equipped parts may be removed and not shown.

  First, the state of product sorting by the product sorting system 1000 of the embodiment will be described with reference to FIG. First, when a product (article) is received, the product to be sorted is registered. Then, the product is transported to the worker who stands by at the serving mouth. One worker is responsible for sorting work for the same type of product. For example, the product X001 is handled by the worker a, and the worker b does not handle the product X001. The product X003 is handled by the worker b, and the worker a does not handle the product X003. The worker inputs goods to a plurality of stores (shipping destinations) at the working portion in charge. For example, when the product X001 in charge is received from the store 101 and the store 103, the worker a receives from the product input port corresponding to the sorting conveyor associated with the store 101 as the shipping destination and the sorting conveyor associated with the store 103. An order quantity of products X001 is introduced. Also, when the product X003 in charge is received from the store 103 and the store 105, the worker b receives the order quantity of the product from the product input port corresponding to the sorting conveyor associated with the store 103 and the sorting conveyor associated with the store 105. Insert X003. In this way, in the product sorting system 1000, a product sorting operation for one store (shipping destination) can be performed by a plurality of workers. The products thrown into the sorting conveyor are sent to and stored in a sorted product storage section provided for each sorting conveyor. Here, when all the products for the orders from the stores are ready, they are loaded onto a truck and delivered to each store.

  Next, a schematic configuration of the commodity sorting system 1000 will be described with reference to FIG. The product sorting system 1000 includes a product registration unit 1, a pre-sorting product transport unit 2, and a sorting line 3. In addition, the product sorting system 1000 includes a control unit 4 that is a computer. Further, the product sorting system 1000 includes a sorted product storage 50. In the product registration unit 1, the type and number of products received are registered. The pre-sorting product conveyance unit 2 includes a main conveyance conveyor 20 and branch conveyance conveyors 21 to 25 branched from the main conveyance conveyor 20. The pre-sorting merchandise transporting unit 2 transports the merchandise sorted by the merchandise sorting processing unit 4c shown in FIG. The sorting line 3 includes sorting conveyors 31 to 36, and the sorting conveyors 31 to 36 are associated with the stores 101 to 106 that are shipping destinations, respectively. The plurality of sorting conveyors of the present embodiment arranged in parallel are the first sorting conveyor 31 to the sixth sorting conveyor 36, and can handle six stores at the same time. The first sorting conveyor 31 is associated with the store 101 and conveys ordered products from the store 101. In the same manner, each sorting conveyor is associated with a store and conveys ordered products from the associated store. The inside of the sorted product storage 50 is divided into six regions, and forms sorted product storage units 51 to 56 provided for the sorting conveyors 31 to 36, respectively.

The merchandise sorting system 1000 is provided with sorting ports 11 to 15 where an operator performs merchandise input work. Although a single serving mouth may be used, it is common to provide a plurality of serving mouths as in this embodiment. In this example. There are five working ports, a first working port 11 to a fifth working port 15. As a result, up to five workers can be assigned and sorting operations can be performed simultaneously. Each of the sorting ports 11 to 15 includes a product input port 11a4 for each of the sorting conveyors 31 to 36. Six product entry ports are provided in each work opening. This corresponds to the fact that there are six sorting conveyors. For example, the product input port 11a4 is for inputting products to the fourth sorting conveyor 34 in the first sorting port 11. Similarly, the product input port 12a3 is used to input products to the third sorting conveyor 33 in the second sorting port 12. Similarly, product inlet is provided in each sorting frontage. A display unit with a completion button is provided on the side of each product slot. For example, a display 11b4 is provided on the side of the product inlet 11a4. The completion button is pressed when the operator inputs the designated quantity of products, and transmits information to the control unit 4 that the product has been inserted. The same applies to other displays (for example, the display 12b3).

  Next, the control unit (computer) 4 included in the product sorting system 1000 will be described with reference to FIGS. FIG. 3 is a block diagram illustrating an example of a hardware configuration of the control unit 4. FIG. 4 is a functional block diagram of the control unit 4. The control unit 4 includes a hard disk 41, a CPU (Central Processing Unit) 42, and a memory 43. The control unit 4 includes a junction box control driver 44 and a network controller 45. The control unit 4 is connected to the junction box 5 and the sequencer 6 through the LAN. The hard disk 41 stores a product sorting program and a product quantity distribution program, and the product sorting system 1000 operates according to these programs. The control unit 4 fulfills the functions of a worker-specific work record storage unit 4a, a sorting mouth-specific worker assignment unit 4b, a product distribution processing unit 4c, a sorting line control unit 4d, and a sorting completed product take-out control unit 4e. The control unit 4 that functions as the work result storage unit 4a for each worker accumulates the past work results of each worker and updates the work result information when a new sorting work is performed. The control unit 4 that functions as the categorized-worker-by-worker assigning unit 4b associates the categorized mouth with the worker. The control unit 4 functioning as the product distribution processing unit 4c distributes the received products to the partition doors based on the past work results of the worker in charge of the sorting work at each sorting port. At this time, the past work results of a plurality of workers in charge of sorting work are referred to at the same time, and the work load ratio of the worker is increased as the work ability in the past work results is higher. As a result, the quantity of merchandise distributed to the working mouths handled by the worker is increased. This improves the efficiency of the entire sorting operation. And the control part 4 which functions as the goods distribution process part 4c is made to convey to the dispensing ports 11-15 by the pre-sorting goods conveyance part 2. FIG. The control unit 4 functioning as the sorting line control unit 4d controls the sorting line 3 with reference to the status of the products input from each product input port. The control unit 4 functioning as the sorted product removal control unit 4e issues an instruction for taking out the products sorted at a predetermined timing from the sorted product storage unit 50 and loading them on the truck.

  Next, an example of an operation performed by the control unit 4 of the product sorting system 1000 will be described with reference to FIG. First, the accumulation of daily work results for each worker is accumulated as work result data D1 for each worker in the work result storage unit 4a for each worker. Then, the product distribution processing unit 4c determines the productivity of all workers who simultaneously perform the sorting work from the work result data D1 by worker. In addition, a worker is assigned to each work mouth by the work mouth assignment worker assignment unit 4b. Worker productivity is evaluated by the concept of the number of lines of work. Here, the number of lines of work refers to work for sorting one type of product for one store. For example, when two types of products are sorted for one store, the number of work rows is two. In addition, when one kind of product is sorted for the three stores, the number of work lines is three. Depending on the product, there may be a large amount of sorting operations, but by sorting many products, it can be considered that the amount of motion due to some of the products will be leveled, so it is necessary to evaluate the productivity of workers. Adopt the concept of the number of rows. The number of lines of work per unit time is the worker's productivity (the amount of work per unit time).

  Based on this productivity, the quantity distribution ratio data D3 classified by work amount is created. Specifically, a large quantity is allocated from producers who have sufficient capacity. The product information D5 is allocated to the categorized product quantity distribution ratio, and the product quantity distribution process is performed to create the categorized product-by-item product distribution information D6. The control unit 4 (product distribution processing unit 4c) controls the pre-sorting product transport unit 2 based on the product distribution information D6 for each sorting mouth, and transports the products to the sorting ports 11 to 15. Further, when there is a product input, the purchase product input information D7 is created with reference to the product distribution information D6 classified by order. The sorting line control unit 4d controls the sorting line 3 in accordance with the state of product introduction. When the sorting of the designated product is completed, the sorting completion product take-out control unit 4e issues a take-out instruction.

  FIG. 6 is a flowchart showing an example of control of the product sorting system. Control is performed by the control unit 4 which is a computer. First, in step S1, the control unit 4 performs product distribution processing. And it conveys to each sorting mouth 11-15 in step S2, and sorts goods. In step S3, the sorted product is taken out.

  FIG. 7 is a flowchart for explaining in detail the processing in step S1, and shows an example of a product sorting process performed in the product sorting system. In step S11, a batch start instruction is issued. In step S12, the work performance data for each worker is obtained by referring to the work performance data for each worker D1. FIG. 8 is an example of a table showing work performance data for each worker. A case will be described in which worker a, worker b, and worker c are simultaneously in charge of sorting work. For example, the worker a has a work amount of 8,150 rows with a work time of 8.0 hours. The worker b performs a work amount of 7590 rows with a work time of 6.5 hours. The worker c has a work amount of 5630 rows with a work time of 7.5 hours. The merchandise distribution information D6 4c calculates the productivity of each worker, that is, the work ability from these data. Specifically, as a work amount per unit time, the work capacity of the worker a is 1019 by 8150 ÷ 8.0, the work ability of the worker b is 1168 by 7590 ÷ 6.5, and the work of the worker c The ability becomes 751 with 5630 ÷ 7.5. It should be noted that at this stage, which worker is in charge of which division mouth is input with reference to the division mouth operator information D2. FIG. 9 is an example of a table showing the work-by-work worker data. In the present embodiment, the first work opening 11 is assigned to the worker b, the second work opening 12 is assigned to the worker c, and the third work opening 13 is assigned to the worker a.

  In step S13, the quantity of the product for which each worker is in charge of the sorting work is determined according to the working ability of each worker. The quantity of the product in charge is represented by the proportion that can be borne by the operator. Specifically, first, the numerical values indicating the work ability of the workers a to c who are simultaneously working at this time are summed, and the value indicating the work ability of each worker is divided by the total value. That is, for operator a, 1019 ÷ (1019 + 1168 + 751) = 35%. For worker b, 1168 ÷ (1019 + 1168 + 751) = 40%. For worker c, 751 ÷ (1019 + 1168 + 751) = 26%. That is, the optimum work ratio of the workers a to c is worker a: worker b: worker c = 35: 40: 26. FIG. 10 is a table showing the work-by-item amount distribution data D3 created by calculation in this way. The total may be 100% depending on how the data is rounded.

  In step S14, product information is entered. Specifically, the order detail data D4 and the product information D5 are read. FIG. 11 is an example of a table showing order details data. In this example, 30 items X001 are received from the store 101, and 45 items X001 are received from the store 102. The store 104 has received orders for 25 items X001 and 30 items X002. These are a part of the order data, and there are more orders. On the other hand, referring to the product information D5, 100 products X001 are received. 50 items X002 are received. As for other products, the number of items received is included in the product information D5.

  In step S15, information on the number of work rows for the product is acquired. Specifically, since the product X001 has been ordered from three stores 101, 102, and 104, the number of rows of the product X001 is three. That is, the number of orders received for one product corresponds to the number of work rows. Similarly, data on the number of work lines is created for other products received.

  In step S <b> 16, product charge assignment is performed from the worker who has the most allowance for the burdenable ratio. Specifically, description will be made with reference to the product registration data shown in FIG. In addition, the processing order of goods shall be the order registered. First, an operator (sorting mouth) responsible for sorting the earliest registered product X001 (registration order 1) is determined. First, it is the worker b that has the most allowance ratio (working capacity) in a state where no product is distributed to anybody. For this reason, the product X001 is distributed to the worker b. Since the worker b is in charge of the first work opening 11 as shown in FIG. 9, the product X001 is transported to the first work opening 11. The situation at the stage where the product X001 is assigned to the worker b will be described. Since nothing is assigned to the worker a, the difference from the optimal ratio of 35% is 35% as it is. Since worker b is undertaking 100% of the currently distributed products, the difference from the optimal ratio of 40% is 40% -100% =-60%. The worker c, like the worker a, has a difference of 26% from the optimum ratio.

  Here, the process of step S17 is performed once. That is, data for conveying the product X001 to the first work opening 11 is created. In step S18, it is determined whether or not one batch of product registration has been completed. At the stage where the registration of the product X001 is completed, it is determined No in step S18, and the processing from step S16 is repeated.

Next, an operator (sorting mouth) in charge of sorting the second product X002 (registration order 2) registered in step S16 is determined again. At the stage when the distribution of the product X001 is over, the worker a who maintains the ability of 35% has the most margin in the possible share ratio. For this reason, the product X002 is distributed to the worker a. Since the worker a is in charge of the third working mouth 13 as shown in FIG. 9, the product X002 is transported to the third working mouth 13. The situation at the stage where the product X002 is assigned to the worker a will be described. The worker a is undertaking the number of lines 2 with respect to the total number of work lines, that is, the total number of lines 5 up to that including the number of work lines 3 of the product X001 and the number of work lines 2 of the product X002. Therefore, the worker a is undertaking 40% (= 2 ÷ 5) of the currently distributed products. Then, the difference between the optimum proportion 35% - 5%. The worker b has contracted 3 lines for the product X001 with respect to the total number of 5 lines, so he has contracted 60% (= 3 ÷ 5) of the products distributed at this next point. The difference from the optimal ratio of 40% is −20%. Since worker c has not yet been allocated a product, worker c still maintains the optimum ratio of 26%.

Next, an operator (sorting mouth) in charge of sorting the product Y001 (registration order 3) registered third in step S16, which is performed again after performing the processing of step S17 and step S18, is determined. At the stage when the distribution of the product X002 is over, the worker c who has 26% ability has the most margin in the possible burden ratio. For this reason, the product Y001 is distributed to the worker c. Operator c in order to charge the second sorting frontage 12 as shown in FIG. 9, item Y00 1 will be conveyed to the second sorting frontage 12. Explained situation of stage product Y00 1 is assigned to the worker c. The worker c has undertaken the number of lines 5 for the total number of work lines, that is, the number of work lines 3 of the product X001, the number of work lines 2 of the product X002, and the total number of lines 10 so far including the product Y001. . Therefore, the worker c is undertaking 50% (= 5 ÷ 10) of the currently distributed products. The difference from the optimum ratio of 26% is -24%. Since the worker a is undertaking 2 for the product X002 with respect to the total number of rows 10, he is undertaking 20% (= 2 ÷ 10) of the products distributed at this next point. The difference from the optimum ratio of 35% is 15%. The worker b has contracted 3 rows for the product X001 with respect to the total number of rows 10, so he has contracted 30% (= 3 ÷ 10) of the products distributed at this next point. The difference from the optimal ratio of 40% is 10%.

  When product registration for one batch is completed, “Yes” is determined in step S18, and the process ends.

  As described above, when the distribution to the workers is repeated, the optimum load ratio is gradually approached. FIG. 14 is an example of another batch. By repeating the same calculation, the optimum load ratio is almost converged. FIG. 15 is an example of a table that shows the product distribution data D6 for each work mouth created in the process of step S16.

  The merchandise sorting system 1000 performs the control shown in FIG. 16 together with the control based on the flowchart shown in FIG. In step S21, a store for each sorting conveyor is determined. That is, the sorting conveyors 31 to 36 are associated with the store. In step S22, data relating to the product input slot is created. Thereby, the sorted product input information D7 is created. FIG. 17 is an example of a table showing sorted product input information. As a result, the data of the serving port, the type of the product, the product input port (instruction input port) store, and the specified quantity are prepared.

  In step S23, opening control of the product inlet and lighting control of the display are performed. Each worker inputs the quantity of products displayed on the display unit into the opened product insertion slot. Then, when the number of instructions has been input, the completion button is pressed. If it is determined in step S24 that the completion button has been pressed, the process proceeds to step S25, and the closing control of the corresponding insertion port and the turn-off control of the display are performed. In step S26, sorting result data D8 is created. FIG. 18 is an example of a table showing sorting result data.

  In step S27, it is determined whether or not processing for all products has been completed. When it is determined No in step S27, the processing from step S22 is repeated.

  When all the ordered products from the store are ready, the merchandise sorting system 1000 packs the merchandise stored in the sorted merchandise storage 50 into a truck and loads them on a truck. Even when all the products are not collected in one batch, all the ordered products are prepared in the sorted product storage 50, so that the products can be efficiently packed in the weight.

  Thus, a series of processes is completed. As described above, according to the product sorting system 1000 of the embodiment, the worker can work at the fixed position and can efficiently implement the product into the weight.

  Although the preferred embodiments of the present invention have been described in detail above, the present invention is not limited to the specific embodiments, and various modifications, within the scope of the gist of the present invention described in the claims, It can be changed. The product sorting system disclosed in the present specification can also perform product sorting operations by replacing products with products when sorting a group of products. That is, the merchandise sorting system disclosed in this specification can also be used when sorting goods other than merchandise.

1000 Product sorting system 1 Product registration unit 2 Product sorting unit before sorting 4 Control unit 4a Results storage unit by worker 4b Sorting worker assignment unit 4c Product sorting processing unit 4d Sorting line control unit 4e Sorting completed product takeout control unit 11 1st sorting port 12 2nd sorting port 13 3rd serving port 14 4th serving port 15 5th serving port 20 Main transfer conveyor 21-25 Branch transfer conveyor 3 Sorting line 31 1st sorting conveyor 32 2nd sorting conveyor 33 3rd Sorting conveyor 34 Fourth sorting conveyor 35 Fifth sorting conveyor 36 Sixth sorting conveyor 50 Sorted goods storage 51 First sorted storage section 52 Second sorted storage section 53 Third sorted storage section 54 Fourth sorted storage Part 55 Fifth Sorted Storage Unit 56 Sixth Sorted Storage Unit

Claims (4)

A sorting line in which a plurality of sorting conveyors each associated with a shipping destination are arranged in parallel;
A sorted product storage unit provided for each of the plurality of sorting conveyors;
A product entry port is provided for each of the sorting conveyors;
A product distribution processing unit that distributes the received products to the working minutes;
A pre-sorting product transport unit that transports the products sorted by the product sort processing unit to the sorting port;
With
The merchandise distribution processing unit determines the worker who has the most possible burden ratio based on the past work results of the worker who is in charge of the sorting work at each sorting mouth each time the received product is registered. And a merchandise sorting system for sorting merchandise to the sorting mouths handled by the worker . The product distribution processing unit
Refer to the past work results of multiple workers in charge of sorting work at the same time,
The product sorting system according to claim 1 , wherein the work load ratio of the worker is increased as the work capability in the past work performance is higher, and the product to be distributed to the sorting mouth handled by the worker is determined . On the computer,
Each time a received product is registered, based on the past work results of the worker in charge of sorting work in each sorting mouth, the worker who has the most margin for possible burden is determined, and the worker is in charge of the above Sort products to the mouth
A delivery instruction to deliver the sorted product to the sorting port by the pre-sorting product transport unit;
Products that are provided for each of the plurality of sorting conveyors that are associated with the stores, and that instruct the opening and closing of the product insertion opening that opens and closes at the distribution opening, and that indicate the number of products that are to be inserted into the product insertion opening that is open Sorting program. The product sorting program according to claim 3 , wherein the work performance is determined based on a work amount per unit time.

Images