JP6084042B2 - Product sorting system and product sorting method - Google Patents

Description

  The present invention saves workers while bringing all kinds of goods, goods, articles (hereinafter referred to as “product items”) into a primary warehouse for compact storage, carrying, storage, sorting and unloading. The present invention relates to a product sorting system and a product sorting method that can process these work procedures in a short time.

  In factories that manufacture various products, distribution centers that distribute products, and accumulation warehouses that accumulate and distribute products, one or more types, one or more items of items (product items) Group) must be sorted into delivery cases. For example, it is necessary to deliver two merchandise items A, three merchandise items B, and one merchandise item C to a certain delivery destination. At this time, it is necessary to sort the merchandise items into one or a plurality of delivery cases, and to deliver the delivery cases to the next stage delivery business.

  Here, the above-described factories, distribution centers, and accumulation warehouses have automatic warehouses that temporarily store merchandise items that require sorting. The automatic warehouse is a structure having a three-dimensional shape and composed of a plurality of rows and stages, and is basically like a large shelf. Since it is a shelf, various types and numbers of merchandise items are temporarily placed (stored) in each row or stage. In merchandise sorting, merchandise items necessary for a delivery destination are selected from a plurality of types and a plurality of merchandise items arranged in the automatic warehouse, packed in a delivery case, and delivered to a delivery service.

  As a matter of course, the operator may search for a product item that is required manually from a plurality of shelves (stages and columns) constituting the automatic warehouse and pack it in a delivery case. However, the sorting work that relies on the physical burden and ability of the worker is not preferable for any of the work speed, work efficiency, and work precision, and especially at the present time when international competition is severe, reduction of work cost in the factory is required. For this reason, it is difficult for a product sorting operation that relies only on an operator to be employed in a factory or a distribution center.

  On the other hand, an automatic warehouse that temporarily stores merchandise items includes a crane that installs merchandise items stored on the shelves of the automatic warehouse on the shelves and takes out merchandise items stored on the shelves. With this crane, it is conceivable that various merchandise items stored on a shelf of an automatic warehouse are directly packed in a delivery case. As a result, it is considered that human labor can be saved.

  However, automatic warehouses used in factories, distribution centers, etc. have a predetermined size even if they are small, and the cranes move one after another to the position of product items stored around the shelf. Thus, it is inefficient to pack a plurality of products in one delivery case. If the crane has to move one after another to product items stored at various positions, the amount of movement of the crane, the number of movement direction changes, and the like will naturally increase. This only increases the operation time of the crane, and it is difficult to reduce the work time even if the accuracy is improved compared to human power. Further, since the crane operation requires mechanical operation and electric operation, problems such as energy cost and noise may occur.

  For this reason, at present, an intermediate element in which sorting target products called flow racks are arranged in a concentrated manner between automatic warehouses and sorting into delivery cases is used. In other words, from a large warehouse with many shelves (that means that product items are stored over a wide range) to a flow rack in which product items to be sorted are concentrated in a narrow range, The item moves. With this flow rack as an intermediate element, product sorting is performed from this flow rack, in which an operator packs necessary product items in a delivery case (see, for example, Patent Document 1 and Patent Document 2).

JP 2004-123283 A JP 2007-176658 A

  Each of Patent Document 1 and Patent Document 2 discloses a technique required for a product sorting device or a product sorting device. In the techniques disclosed in these patent documents, a flow rack is provided in an automatic warehouse, and a commodity item is moved from the automatic warehouse to the flow rack automatically or manually by a crane or the like. Next, since the merchandise items necessary for sorting are arranged in the flow rack, the operator takes out the necessary merchandise items from the flow rack and packs them in a delivery case. The delivery case is installed on the conveyor line, and the delivery case packed with necessary product items is discharged to the next stage in accordance with the movement of the conveyor line.

  In the next stage, the delivery cases are collected on a pallet or a large case for actual delivery, and are transported from the factory or distribution center to various places (such as a store, the next factory, or the next delivery center).

  In the past, mass production of small varieties was mainstream, and automatic warehouses were very large, and product sorters with very long conveyor lines were mainstream. Since there are few merchandise items to be sorted, it is possible to pack merchandise items into many delivery cases at a time, so the flow rack becomes larger according to the size of the automatic warehouse. For this reason, a wide working space can be secured, and many workers can be arranged in this large working space, and many workers can simultaneously perform sorting work (work for packing product items from a flow rack into a delivery case). It was mainstream.

  As mentioned above, this was mainly due to the fact that mass production of small varieties was mainstream, and it was possible to place many automated warehouses in factories and distribution centers on vast sites. Categorize different types of product items in a centralized manner with a product sorter centered on a certain automated warehouse, and sort items for different types of product items centered on another automated warehouse. It has also been performed intensively with the product sorting apparatus.

  However, in recent years, properties in factories and distribution centers have changed, such as high-mix low-volume production and high-mix high-volume production. In addition, there is a risk for companies to carry a risk liability because taking a large factory or distribution center site, there is a strong demand for compact work on a compact site. In particular, the final destination for shipping product items from factories and distribution centers is often at convenience stores and small stores, and various types of product items are packed into small delivery cases. Work is required.

  These have become prominent in, for example, food, clothing, machine parts, daily necessities, etc., and as before, in large factories and distribution centers, large automatic warehouses, The product sorting apparatus, which arranges a large number of workers, is gradually getting out of the mainstream.

  Currently, there is a need for high-mix low-volume production, compacting of factories and distribution centers, labor-saving, and a reduction in the number of people. The product sorting device itself has also been made compact, and product items are sorted by labor-saving work. It is required to be In particular, as companies that have factories not only in Japan but also in emerging countries are increasing, there is a tendency that compact product sorting devices are required. This trend is expected to become more prominent with changes in the industrial structure.

  In light of this tendency, the conventional product sorting apparatuses represented by Patent Document 1 and Patent Document 2 have the following problems.

(Problem 1) Since it is premised on the mass production of small varieties, goods items are stored in the automatic warehouse, the product items are placed on the shelf of the automatic warehouse, the product items are moved from the automatic warehouse to the flow rack, and the delivery case is sent from the flow rack. Each element necessary for the product sorting device, such as packing into a container and discharging a delivery case, is separated or not organized, and the product sorting device is not compact.
If it is not compact, if it is applied to a factory that produces a wide variety of products in small quantities, waste and overwork will increase.

  (Problem 2) When placing product items on shelves in an automated warehouse, product items of different sizes and shapes depending on the variety are placed in the same row or row, making the storage capacity of the automated warehouse more efficient Operation was not possible (leading to the inability to downsize the automated warehouse).

  (Problem 3) Based on Problem 2, the travel distance of the crane becomes too large, and wasteful time and energy costs are spent on the placement of product items in the automatic warehouse and the movement of product items from the automatic warehouse to the flow rack. It was necessary.

  (Problem 4) Based on problems 1 and 2, the receipt of the product item to the automatic warehouse, the storage of the received product item on the shelf to the automatic warehouse, the movement of the stored product item to the flow rack, the product item Such as transporting a shipping case for stuffing, sorting and packing items from a flow rack to a shipping case, discharging a shipping case packed with shipping items, transporting a discharged shipping case to the next stage, etc. There are problems such as the individual processing procedures are difficult to form a series, unnecessary duplication occurs, and the procedures are switched. As described above, there is a problem that an extra time is required for product sorting because the processing procedure does not proceed smoothly.

  (Problem 5) Due to the large variety, when all the merchandise items that need to be packed in one delivery case are not arranged in the flow rack, a so-called in-process delivery case in which sorting is not completed occurs. Such in-process delivery cases are temporarily accumulated in a separate space from the product sorting device, and are put into the product sorting device again to pack the missing product items (in some cases, sorting more than 3 times) There was a problem that the work also occurred). In this case as well, there is a problem in that downsizing of the product sorting apparatus is hindered, an extra worker is required, and the work load on the worker is increased.

(Problem 6) If problem 5 is to be solved, it is necessary to increase the size of the flow rack so that all product items are always arranged in the flow rack. There are also problems such as the problem of not being able to save labor due to the line becoming larger, and the need for more workers.
(Problem 7) When an error in product sorting such as problems 5 and 6 occurs, there is a problem that all work procedures must be redone. In merchandise sorting, not all merchandise items that should be packed in a certain delivery case are always complete, so it is often necessary to deal with such inconsistencies. However, in the conventional product sorting apparatus, it is difficult to deal with such inconsistencies, and it is often necessary to perform re-processing or extra supplementary processing.

  A compact product sorting device that integrates these issues 1-7 and adapts to changes in the current industrial structure, and is a product sorting system and product sorting method that are more labor-saving, more automated, and less costly. There was a problem that could not be realized.

  An object of the present invention is to provide a compact and labor-saving product sorting system and a product sorting method adapted to the current industrial structure requirements by solving these problems 1 to 7.

In view of the above problems, the product sorting system of the present invention includes an automatic warehouse having a plurality of arrangement shelves partitioned by a plurality of rows and stages, a warehousing line for receiving a plurality of types of product items in the automatic warehouse, and a plurality of arrangements. Among the multiple types of merchandise items stored on the shelves, a flow rack that installs certain types of merchandise items for the operator's sorting, and merchandise items that arrive from the warehousing line are placed on the placement shelf , A crane that moves the product items stored on the arrangement shelf to a flow rack and installs them, and a transport lane that transports a delivery case that packs product items sorted from the flow rack, and one of the transport lanes is a delivery It has an input part for supplying the case, and the other has an output part for discharging the delivery case. A work area for workers provided at opposing positions, and the warehousing line transports the product items to receive the product items in the automatic warehouse, and the crane holds the product items received from the warehousing line. The crane moves and places it on one of the placement shelves, and the crane moves the product items that are candidates for sorting among the product items stored on the placement shelf to the flow rack and installs them. In the area, among the product items installed in the flow rack, the product items to be packed in the delivery case transported to the transport lane are selected and packed, and the flow rack is a predetermined delivery that is a work target of the worker. The target product items to be sorted into cases are provided with a display unit that displays them. A product item that is removed from the product and packed in a delivery case to be worked on, and the product items remaining after the sorting operation for at least one of the predetermined time and the predetermined number of sorting operations are defined as remaining product items. And returned from the flow rack to the arrangement shelf.

  The merchandise sorting system of the present invention includes the receipt of merchandise items in an automatic warehouse, the placement of merchandise items on the shelves of the automatic warehouse, the movement of merchandise items from the automatic warehouse to the flow rack, the packing from the flow rack to the delivery case, the delivery case The product sorting system, which is the entire mechanism including the processing procedure, can be made compact by combining the elements required for the product sorting device such as the discharge of the product according to the work process.

  In particular, by introducing a configuration that solves the above problems 5 to 7, which has been a hindrance to downsizing, the final product sorting is completed and transported only by a compacted product sorting system. Can be sorted to state.

  According to these results, since a small number of workers can perform sorting work with a small number of traffic lines, labor costs and the like can be reduced, and the work load on the workers can be reduced. Naturally, the mental and physical burden on the worker is reduced and the occupational health conditions are improved.

BRIEF DESCRIPTION OF THE DRAWINGS It is a whole schematic diagram of the goods sorting system in Embodiment 1 of this invention. It is a front view of the automatic warehouse in Embodiment 1 of this invention. It is a flowchart of the process of the goods sorting system in embodiment of this invention. It is an enlarged view of the automatic warehouse in Embodiment 1 of this invention, and is a front view which shows an arrangement | positioning shelf in detail. It is a side view of the flow rack in Embodiment 1 of this invention. It is the front view and top view of an automatic warehouse. It is explanatory drawing which shows the operator's working state in embodiment of this invention. It is drawing which shows the positional relationship of an automatic warehouse and a crane. It is a perspective view which shows the state by which slip prevention was given to the arrangement | positioning shelf in embodiment of this invention. It is a schematic diagram of the goods sorting system in Embodiment 3 of this invention.

  The product sorting system according to the first aspect of the present invention includes an automatic warehouse having a plurality of arrangement shelves partitioned by a plurality of rows and stages, a warehousing line for receiving a plurality of types of product items in the automatic warehouse, Among the multiple types of product items stored on the placement shelf, place a predetermined type of product item for the operator's sorting on the placement shelf and a product item that is received from the receipt line on the placement shelf In addition, a crane that moves the product items stored on the arrangement shelf to the flow rack and installs them, and a transport lane that transports a delivery case that packs the product items sorted from the flow rack, one of the transport lanes, It has an input part that inputs a delivery case, and the other has a discharge part that discharges a delivery case. A work area of workers provided at opposite positions, and the warehousing line transports the merchandise item to move the merchandise item into the automatic warehouse, and the crane moves the merchandise item received from the warehousing line. The crane is placed on one of the placement shelves, and the crane moves the product items to be sorted among the product items stored on the placement shelf to the flow rack and installs them in the work area. Among the product items installed in the flow rack, the product items to be packed in the delivery case transported to the transport lane are selected and packed.

  With this configuration, the product sorting system can be very compact, including the work area of the worker, and can be flexibly installed in various factories and distribution centers. The wide range of applications will promote dissemination.

  In the merchandise sorting system according to the second invention of the present invention, in addition to the first invention, in the work area, a delivery case transported on the transport lane reaches the front of the worker, and is behind the worker. The flow rack where the item to be sorted is placed is located, and the operator selects the item to be packed in the delivery case that reaches the front from the items placed in the flow rack located behind. And pack it in a delivery case.

  With this configuration, the flow line of the worker is reduced, and the efficiency of the sorting work performed by the combination of the worker and the apparatus is increased.

  In the commodity sorting system according to the third aspect of the present invention, in addition to the first or second aspect, the delivery case is transported from one of the workers having the transport lane in front to the other. In the work area, the product items to be sorted are packed in a delivery case at a standing position in a substantially constant range by a flow line centering on the front and rear.

  With this configuration, the flow line of the worker is reduced, and the efficiency of the sorting work performed by the combination of the worker and the apparatus is increased.

  In the merchandise sorting system according to the fourth aspect of the present invention, in addition to any of the first to third aspects of the invention, the transport lane extends in a direction away from the automatic warehouse from the input section, and is curved when the predetermined distance is extended. Or it bends and extends substantially parallel to the automatic warehouse and reaches the discharge section.

  With this configuration, the transport lane has a form corresponding to an automatic warehouse, and the apparatus portion related to the product sorting system can be downsized while securing a work area.

  In the commodity sorting system according to the fifth aspect of the present invention, in addition to any one of the first to fourth aspects, the crane has at least one of the same type, the same shape and the same size on each of the plurality of arrangement shelves. Place one or more product items that can be arranged in a single box.

  This configuration enables efficient use of the arrangement shelf. In addition, the traffic flow of the crane is reduced and energy consumption is also reduced.

  In the commodity sorting system according to the sixth aspect of the present invention, in addition to the fifth aspect, when the crane arranges a plurality of commodity items on each of the plurality of arrangement shelves, the distance between the plural commodity items is determined. These are arranged at substantially equal intervals.

  This configuration enables efficient use of the arrangement shelf. In addition, the traffic flow of the crane is reduced and energy consumption is also reduced. In particular, the crane can eliminate the need for image processing or the like in the movement of the commodity item from the arrangement shelf to the flow rack on the basis of the coordinate numerical value, thereby realizing low cost.

  In the commodity sorting system according to the seventh aspect of the present invention, in addition to any one of the first to sixth aspects, the flow rack faces a part of the plurality of arrangement shelves and has a height direction of the automatic warehouse. A display unit is provided that displays a target product item that is attached to one of the horizontal arrangement shelves and sorts into a predetermined delivery case that is a work target of the worker.

  With this configuration, the movement of merchandise items from the automatic warehouse to the flow rack, from the flow rack to the worker, and from the worker to the delivery case is linear, and the efficiency of the sorting work is improved.

  In the merchandise sorting system according to the eighth aspect of the present invention, in addition to the seventh invention, the operator takes out the merchandise item whose display section is displayed as the sorting target from the flow rack, and puts it in the delivery case to be worked. After the sorting operation, the delivery case is divided into a delivery case (hereinafter referred to as a “completed delivery case”) in which all necessary product items are packed in the delivery case to be worked on, It is divided into a delivery case in which a necessary item for the delivery case is insufficient (hereinafter referred to as “in-process delivery case”).

  With this configuration, the product sorting system can perform various measures according to the state of sorting work.

  In the product sorting system according to the ninth aspect of the present invention, in addition to any of the seventh and eighth inventions, the product remains until a period exceeding at least one of the predetermined time and the predetermined number of sorting operations after the sorting operation. Merchandise items are defined as remaining merchandise items and returned from the flow rack to the placement shelf.

  With this configuration, the use efficiency of the flow rack is increased, and the flow rack can be downsized.

  In the merchandise sorting system according to the tenth invention of the present invention, in addition to the ninth invention, the flow rack records a history of merchandise items that are likely to become remaining merchandise items, and the crane receives the merchandise that is received from the warehousing line. Items are placed on a placement shelf far from the position of the flow rack.

  With this configuration, the flow line of the crane can be made more efficient, and work efficiency can be improved and energy can be reduced.

  In the merchandise sorting system according to the eleventh aspect of the present invention, in addition to any of the eighth to tenth inventions, the transport lane branches before the discharge section, and the leading lane branches to the automatic warehouse. The in-process delivery case is returned to the arrangement shelf provided in the automatic warehouse through the branch lane after the sorting operation.

  With this configuration, it is not necessary to temporarily store the in-process delivery case outside the merchandise sorting apparatus, so that extra space and extra re-injection work are not required.

  In the merchandise sorting system according to the twelfth aspect of the present invention, in addition to the eleventh aspect, the crane moves and arranges the in-process delivery case that has reached the tip of the branch lane to the arrangement shelf.

  With this configuration, the in-process delivery case is again put into the transfer lane from the automatic warehouse, and the sorting operation into the completed delivery case is performed.

  In the merchandise sorting system according to the thirteenth aspect of the present invention, in addition to the twelfth aspect, the in-process delivery case returned to the placement shelf is put into the transport lane again from the loading section, and in the sorting process again, It can be packed with missing item items installed in the flow rack.

  With this configuration, the in-process delivery case completion process is resumed from the arrangement shelf and is efficient.

  In the merchandise sorting system according to the fourteenth aspect of the present invention, in addition to any of the eighth to tenth inventions, the branch lane is a completed delivery case. Return to the automatic storage rack.

  With this configuration, even in a completed delivery case, a certain amount can be temporarily stored in an automatic warehouse if the same type or the like. As a result, the time and space until actual delivery can be shortened.

  In the merchandise sorting system according to the fifteenth aspect of the present invention, in addition to the fourteenth invention, the predetermined condition is that when a predetermined number or more of completed delivery cases in which the same combination of merchandise items are packed under the same sorting condition, It includes at least one case where it is continuous for a predetermined time, when it is a predetermined number or more within a predetermined period, and when it is not ready for the next process for handling a completed delivery case after discharge.

  With this configuration, even in a completed delivery case, a certain amount can be temporarily stored in an automatic warehouse if the same type or the like. As a result, the time and space until actual delivery can be shortened.

  In the merchandise sorting system according to the sixteenth aspect of the present invention, in addition to the fourteenth or fifteenth aspects, the transport lane sends out a completed delivery case to the discharge section when conditions other than predetermined conditions are met.

  With this configuration, the completed delivery case is delivered to the next stage of delivery.

  In the commodity sorting system according to the seventeenth aspect of the present invention, in addition to any one of the first to sixteenth aspects, at least a part of the plurality of arrangement shelves contacts at least a part of the bottom surface of the commodity item It has a non-slip.

  With this configuration, even if an earthquake or sudden accident occurs, the product item does not fall from the placement shelf or shift from the placement shelf, so that recovery from a disaster or the like is facilitated.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Overview)
First, an overall outline of the commodity sorting system in the first embodiment will be described. FIG. 1 is an overall schematic diagram of a product sorting system according to Embodiment 1 of the present invention. FIG. 1 shows a state where the entire product sorting system is viewed from above, and shows a state where essential elements and optional elements are combined.

  The product sorting system 1 includes an automatic warehouse 2, a warehousing line 4, a flow rack 5, a crane 6, and a transport lane 7. These are the main elements constituting the product sorting system 1. In addition, one end of the transport lane 7 has a loading unit 8 for loading the delivery case 200, and the other end of the transport lane 7 has a discharge unit 9 for discharging the delivery case 200.

  The merchandise sorting system 1 has an incoming direction to the automatic warehouse 2 and an outgoing direction from the automatic warehouse 2 around the automatic warehouse 2 that stores the received commodity items 100. The warehousing direction is a warehousing line 4 for warehousing the commodity item 100 into the automatic warehouse 2 and a re-stocking line 50 for warehousing again from the transport lane 7 through the branch lane 30 described later.

  On the other hand, the loading direction is the loading unit 8 for loading the delivery case 200, and the crane 6 is configured to move and set the product item 100 from the arrangement shelf 3 of the automatic warehouse 2 to the flow rack 5. Moreover, although it is not direct delivery from the automatic warehouse 2, the discharge part 9 which discharges the delivery case 200 in which the sorting and jamming in the transport lane 7 is completed is one of the delivery directions. In addition, a collective delivery line 40 that connects the automatic warehouse 2 and the transport lane 7 is provided. When a completed delivery case, which will be described later, is temporarily stored on the arrangement shelf 3, the collective delivery line issues a plurality of stored delivery cases together and discharges them from the discharge unit 9.

  That is, in the commodity sorting system according to the first embodiment, the transport lane 7 is arranged so as to face each other with the automatic warehouse 2 as a reference, and entering the automatic warehouse 2 and unloading from the automatic warehouse 2 (or the transport lane 7) , Has a directionality. When this directionality is realized by an appropriate structure, warehousing and warehousing with the automatic warehouse 2 as a base point is realized, and product sorting becomes easy.

  The automatic warehouse 2 has a plurality of arrangement shelves 3 partitioned by a plurality of rows and stages. FIG. 2 is a front view of the automatic warehouse according to the first embodiment of the present invention. The automatic warehouse 2 has a column 20 and a column 21 (and it may be unclear in FIG. 2 but may also have a column using depth). It has the some arrangement | positioning shelf 3 enclosed. Each of the plurality of arrangement shelves 3 temporarily stores the merchandise item 100.

  The flow rack 5 stores a predetermined type of merchandise items 100 among the merchandise items 100 temporarily stored in each of the plurality of arrangement shelves 3 (for packing in a certain delivery case 200). For example, when a delivery case 200 is transported to a predetermined store or another factory, one or a plurality of product items 100 that need to be transported are packed in the delivery case 200. The product item 100 for this stuffing is selected (which is defined as sorting in some cases including stuffing) and installed.

  The crane 6 is movable in the horizontal direction and the vertical direction of the automatic warehouse 2, and arranges the commodity item 100 that is received from the storage line 4 on the arrangement shelf 3. In addition, the crane 6 moves the product item 100 temporarily stored on the arrangement shelf 3 to the flow rack 5 and installs it. In this way, the merchandise item 100 sequentially moves to the warehousing line 4, the arrangement shelf 3 of the automatic warehouse 2, and the flow rack 5.

  The worker works in a work area 10 formed between the flow rack 5 and the transport lane 7. An operator may work while standing or sitting. The worker performs the above-described sorting in the work area 10. That is, in the work area 10, the worker selects the product item 100 that is installed in the flow rack 5 and is to be packed in the delivery case 200 that has been transported immediately in the transport lane 7. Then, it is taken out manually and packed in the delivery case 200.

  The conveyance lane 7 is provided at a position facing the automatic warehouse 2 with the flow rack 5 interposed therebetween, and the input unit 8 and the discharge unit 9 are provided on both sides of the automatic warehouse (not limited to both ends, (It may be a position close to the side). As shown in FIG. 1, the transport lane 7 extends so as to protrude with respect to the automatic warehouse 2 at the loading unit 8, and then bends at the curved portion 7 </ b> A so as to be parallel to the automatic warehouse 2. Stretch. When extending parallel to the automatic warehouse 2, the flow rack 5 is sandwiched.

  As described above, the product sorting system 1 has the configuration as shown in FIG. 1, so that the operator's work area 10 can be formed in the space between the transport lane 7 and the flow rack 5. The worker executes the actual sorting work in this work area 10. As can be seen in FIG. 1, the work area 10 has a very small flow line for the worker. Since the flow line is small, the operator can take out the product items 100 to be sorted from the flow rack 5 and pack them in the delivery case 200 with a small amount of movement.

  Further, in FIG. 1, the transport lane 7 extends in the lateral direction of the product sorting system 1, and is the lateral length of the automatic warehouse 2 and the transport lane 7, and the lateral length of the product sorting system 1. Roughly determined. On the other hand, the conveyance lane 7 is provided so as to face the automatic warehouse 2, and the vertical length (width) of the automatic warehouse 2 and the vertical length of the conveyance lane 7 (width including the curve 7 </ b> A). Thus, the approximate length (width) in the vertical direction of the product sorting system 1 in FIG. 1 is determined.

  The work area between the horizontal length and the vertical length (width) of the product sorting system 1 becomes a worker's space. The product sorting system 1 including other elements is a useless element, No space, area, or area is created. Further, the above-described various elements necessary for product sorting do not need to be provided at completely different locations.

  As a result, the product sorting system 1 according to the first embodiment is very compact in both the horizontal and vertical directions, and only in this compact space, product introduction, temporary storage of the product item 100, and flow of the product item 100 are performed. A series of flows including movement to the rack 5, sorting and packing of the merchandise item 100, and transporting and discharging of the delivery case 200 packed with the merchandise item 100 can be performed including human work. That is, it is possible to prevent an increase in size and cost, which are problems of the prior art. As a result, a good product sorting system 1 that can cope with a small variety of products and a changing speed of product items (product cycle speed) is realized.

  Further, as described above, since the work area 10 is formed between the flow rack 5 and the straight portion of the transport lane 7, the work area 10 becomes a narrow area and the flow line of the operator is reduced. Increases efficiency. In recent factories and distribution centers, the goal is to reduce the flow of workers. This is because, by reducing the flow line of the worker, it is considered that not only the work man-hour per unit time of the worker is improved, but also the physical and mental burden of the worker is reduced.

  As described above, the product sorting system 1 according to the first embodiment is suitable for the problems of the prior art, in particular, downsizing, compactness optimized for a large variety of products, ease of installation, and short changes in product cycle. It is possible to solve the difficulty of installing and configuring a finely-tuned product sorting system.

  In the above description, the work area 10 is assumed to be a human worker, but the workers in this specification include not only human workers but also machines such as work robots and semi-machines. It is a concept.

(Description of operation and details of each part)
Next, the detail of each part is demonstrated according to operation | movement description of the goods classification system 1. FIG. The product sorting system 1 is a product item by merging the structure (hardware) such as the automatic warehouse 2 and the transfer lane 7 described with reference to FIGS. 1 and 2 and the work (software) by the worker in the work area 10. 100 sorts are performed. FIG. 3 is a flowchart of the process of the product sorting system of the present invention. The product sorting system 1 executes each step (ST1 to ST7) of the flowchart of FIG. At this time, a step performed only by the structure (machine / hardware), a step performed by fusion of the structure and the worker (fusion of hardware and software), and a step performed by only the worker (software only) The product sorting system 1 includes

  The outline of the process of the product sorting system 1 will be described with reference to FIG. Following the process overview, details of each process will be described.

  First, in step ST <b> 1, the product sorting system 1 stores the product item 100 in the automatic warehouse 2. Next, in step ST <b> 2, the merchandise sorting system 1 places merchandise items on the arrangement shelf 3 of the automatic warehouse 2. Next, in step ST3, the commodity sorting system 1 moves and installs the commodity from the arrangement shelf 3 to the flow rack 5. Next, the product sorting system 1 inputs the delivery case 200 into the transport lane 7 via the input unit 8 in step ST4. Further, the product sorting system 1 causes the delivery case to reach the work position in step ST5.

  Next, in step ST6, the operator sorts and selects the products installed in the flow rack 5. Next, in step ST <b> 7, the operator packs the selected product into the delivery case 200. Thereafter, the product sorting system 1 is divided into a completed delivery case, an in-process delivery case, and a re-entry, and the product sorting system 1 transports the delivery case 200 through the transport lane.

(ST1: Goods item receipt)
In step ST1, the product sorting system 1 causes the automatic warehouse 2 to store the product item 100. In this warehousing, the warehousing line 4 causes the automatic warehouse 2 to receive the merchandise item 100. The warehousing line 4 has a conveyor and a roller, and the product item 100 installed in the warehousing line 4 is conveyed toward the automatic warehouse 2. At this time, the worker may place the product item 100 on the warehousing line 4 manually, or the work machine (working robot) may place the product item 100 on the warehousing line 4. Alternatively, another conveyor may be connected to the warehousing line 4 (not shown in FIG. 1), and the commodity items 100 may be sequentially carried from the conveyor to the warehousing line 4.

  That is, the goods storage process of the commodity item 100 in step ST1 is a case of processing only by a machine (in the case of processing only by hardware) and a case of processing by a machine and human power (processing by fusion of hardware and software). In the case of

  The warehousing line 4 may be provided at any position in the product sorting system 1 and the automatic warehouse 2, but the loading part 8, the discharging part 9, the work area 10, etc. of the delivery case 200 are arranged in a compact installation area ( In order to secure in the installation area of the product sorting system 1, it is preferable that the product sorting system 1 is on one side and opposite to the input unit 8. This is because the transportation lane 7 and the work area 10 can be secured in a compact installation area. In FIG. 1, the warehousing line 4 is provided near the right end of the commodity sorting system 1 and the automatic warehouse 2.

  Alternatively, the goods sorting system 1 may be made compact by providing the warehousing line 4 on the back side of the automatic warehouse 2. This is because downsizing in the vertical direction is achieved.

  The merchandise item 100 has various types and is different as a merchandise, and has different sizes, widths, heights, lengths, weights, shapes, and the like. These various types of merchandise items 100 are stored in the automatic warehouse 2 from the receiving line 4 one after another (of course, it may be intermittent).

(Step ST2: Arrangement on arrangement shelf)
The merchandise item 100 received from the warehousing line 4 to the automatic warehouse 2 is arranged on the arrangement shelf 3 provided in the automatic warehouse 2 in step ST2. Specifically, the crane 6 arranges the item 100 to be received through the storage line 4 on the predetermined arrangement shelf 3. Since the crane 6 is provided in accordance with the automatic warehouse 2, the commodity item 100 received from the warehousing line 4 can be arranged on the arrangement shelf 3, and the commodity item 100 is taken out from the arrangement shelf 3 (removal) To move to the flow rack 5).

  FIG. 2 shows a plurality of arrangement shelves 3 formed by the automatic warehouse 2 and the steps 20 and rows 21 of the automatic warehouse 2 as described above. FIG. 4 is an enlarged view of the automatic warehouse in the first embodiment of the present invention, and is a front view showing the arrangement shelf in more detail.

  As is clear from FIG. 4, the automatic warehouse 2 has a plurality of arrangement shelves 3. Moreover, since the arrangement | positioning shelf 3 stores the merchandise item 100 temporarily, it has what is called a horizontal bottom face, However The vertical and horizontal length may be various. Of course, depending on circumstances, the depth may be different for each of the plurality of arrangement shelves 3.

  Here, the crane 6 is singly or plurally arranged so that the product items 100 arranged in at least one of the same type, the same shape, and the same size are arranged in a certain arrangement shelf 3, respectively. Deploy. Details will be described with reference to FIG.

  For example, in FIG. 4, the automatic warehouse 2 includes an arrangement shelf 3A, an arrangement shelf 3B, an arrangement shelf 3C, an arrangement shelf 3D, and an arrangement shelf 3E (of course, other arrangement racks 3 are provided). Each of the placement shelves 3A to 3E has a placement shelf 3 having a different height and a placement shelf 3 having the same height. In FIG. 4, each of the placement shelves 3B, 3C, and 3D has substantially the same height, but the placement shelves 3A and 3E have different heights. As described below, this is in accordance with the characteristics of the product item 100 placed on the placement shelf 3. However, it does not necessarily have to be the height of such an arrangement shelf 3.

  The crane 6 arranges only the commodity item 100A having a certain size on the arrangement shelf 3A. Similarly, the crane 6 arranges the product item 100B having a different size from the product item 100A on the arrangement shelf 3B different from the arrangement shelf 3A. Similarly, the crane 6 arrange | positions the merchandise item 100C from which the size differs from merchandise item 100A, 100B on the arrangement | positioning shelf 3C different from arrangement | positioning shelf 3A, 3B. Furthermore, the crane 6 arrange | positions the merchandise item 100D in which size differs from merchandise item 100A-100C in the arrangement | positioning shelf 3D different from arrangement | positioning shelf 3A-3C. Furthermore, the crane 6 arranges the merchandise item 100E having a size different from that of the merchandise items 100A to 100D on the arrangement shelf 3E different from the arrangement shelves 3A to 3D.

  As a result, in the same arrangement shelf 3, only the commodity items 100 arranged in at least one of the same type, the same shape, and the same size are arranged and stored.

  At this time, the crane 6 may arrange the product items 100 at substantially equal intervals when arranging the plurality of product items 100 on one arrangement shelf 3. In the case of this substantially equal interval, as described above, there may be a case where only a commodity item 100 arranged in at least one of the same type, the same shape, and the same size is arranged on a certain arrangement shelf 3, and depending on circumstances. May be the case where product items 100 having at least one of the same type, the same shape, and the same size are arranged.

  The processing described above is to appropriately arrange the commodity items 100 received by the crane 6 (the commodity sorting system 1) into the automatic warehouse 2 on the arrangement shelf 3 in step ST2. In the crane 6, the product sorting system 1 performs placement on the placement shelf 3 according to the product item 100 as described above by a predetermined computer program or operator operation.

  In this way, only the product items 100 arranged in at least one of the same type, the same shape, and the same size are arranged on one arrangement shelf 3 (in some cases, the product items 100 are arranged at substantially equal intervals. ), The arrangement of the product items 100 on the arrangement shelf 3 can be effectively used as the area ratio. As a result, the automatic warehouse 2 itself can be reduced in size with respect to the number and types of the merchandise items 100.

  In addition, the crane 6 moves and installs the product item 100 stored in the arrangement shelf 3 to the flow rack 5 when it is to be sorted, but the same product item 100 is stored in the same arrangement shelf 3. ing. For this reason, when moving and installing a plurality of the same product items 100 on the flow rack 5, the moving distance and moving time of the crane 6 can be shortened. Moreover, the installation work by moving from the arrangement shelf 3 to the flow rack 5 by the crane 6 is shortened and simplified, so that the flow rack 5 can be reduced in size and the position of the flow rack 5 can be set in the work area 10. It becomes easy to match.

  By taking these into account, the entire product sorting system 1 can be made compact.

  In FIG. 4, a plurality of product items 100 </ b> A to 100 </ b> E are arranged on each of the placement shelves 3 </ b> A to 3 </ b> E. A plurality of arrangement shelves 3 may be provided.

(Step ST3: Move to flow rack)
Next, in step ST3, the merchandise sorting system 1 selects merchandise items 100 necessary for sorting among the merchandise items 100 stored in the arrangement shelf 3 (the merchandise items 100 to be packed in the delivery case 200 to be loaded). The crane 6 is used to move to the flow rack 5 for installation. The merchandise sorting system 1 may move the merchandise item 100 necessary for sorting from the arrangement shelf 3 to the flow rack 5 by operating the crane 6 by an operator's operation or a computer program stored in advance.

  In this way, the movement of the commodity item 100 from the arrangement shelf 3 to the flow rack 5 is executed by hardware alone or hardware and software (software is a concept including a computer program and human operation).

  FIG. 5 is a side view of the flow rack according to Embodiment 1 of the present invention. The flow rack 5 is mounted so as to face a part of the arrangement shelf 3 of the automatic warehouse 2. Since they are mounted so as to face each other, they may be mounted in contact with the automatic warehouse 2 or may be mounted at a certain distance from the automatic warehouse 2. In the latter case, for example, a movement line in which the crane 6 moves between the automatic warehouse 2 and the flow rack 5 is secured.

  Further, the flow rack 5 is mounted corresponding to either the height direction or the horizontal direction of the arrangement shelf. Since FIG. 5 is a side view, it can be confirmed that the flow rack 5 protrudes from the arrangement shelf 3. In this way, the flow rack 5 is provided so as to protrude from the arrangement shelf 3 to the outside (when viewed in FIG. 1, the delivery lane 7 side). By such a protrusion, the operator takes out the commodity item 100 installed in the flow rack 5 in the work area 10 formed between the flow rack 5 and the transport lane 7, and the delivery case in the transport lane 7. 200 can be packed.

  Of course, since the work area 10 is secured between the flow rack 5 and the transport lane 7 in a state where the automatic warehouse 2, the flow rack 5 and the transport lane 7 are aligned, the worker can work with less traffic lines. Work in area 10 can be performed. Considering the operator as the center, there is a transport lane 7 through which the delivery case 200 flows, and a flow rack 5 on the back. Since it is only necessary to take out the merchandise item 100 installed in the flow rack 5 on the back and pack it in the delivery case 200 on the front, the worker only needs to move along the flow line that changes the body direction back and forth. For this reason, since the work area 10 is also small, the product sorting system can be made compact and the efficiency of the human sorting work by the operator can be improved.

  As shown in FIG. 5, the flow rack 5 has a plurality of steps 51 in accordance with the steps of the arrangement shelf. The merchandise item 100 is moved and installed by the crane 6 in each of the plurality of steps 51. Further, the step 51 has a depth due to the protrusion when viewed from the operator. That is, as can be seen by combining FIG. 1 and FIG. 5, the flow rack 5 has the merchandise item 100 installed three-dimensionally.

  In FIG. 1, the flow rack 5 is attached to a part of the automatic warehouse 2 in the lateral direction. The flow rack 5 is mounted in a narrow range in the horizontal direction of the automatic warehouse 2. That is, since the flow rack 5 does not occupy a large amount in the lateral direction, the lateral direction of the automatic warehouse 2 and the transport lane 7 is naturally reduced in size.

  In addition, since the flow rack 5 is three-dimensional and is small in the lateral direction, the flow line of the operator is reduced.

  Further, as shown in FIG. 5, the flow rack 5 (in the case where the flow rack 5 has a plurality of stages 51) is inclined obliquely downward from the automatic warehouse 2 toward the transport lane 7. It is also suitable. Further, although not shown, it is also preferable that the flow rack 5 or the stage 51 has a stopper for the commodity item 100 to be installed. By having the stopper, even if the flow rack 5 or the step 51 is inclined obliquely downward, the product item 100 does not have to worry about falling or sliding off the flow rack 5 or the step 51.

  The stopper may be a protrusion or projection at the tip of the flow rack 5 or the step 51, or may be a non-slip member having a high coefficient of friction attached to the bottom surface of the flow rack 5 or the step 51.

  In addition, for the convenience of the sorting operation by the operator, which will be described later, it is also preferable that at least one of the flow rack 5 and the stage 51 further includes a display unit that indicates the merchandise item 100 to be sorted. For example, an LED lamp that can be visually recognized by the operator is provided at a location corresponding to the position of the commodity item 100, such as the tip of the flow rack 5 and the step 51. Alternatively, a character display unit for displaying a delivery destination (which delivery case is shown) may be provided. By providing such a display unit, the operator's sorting work becomes easy and reliable.

  FIG. 6 is a front view and a plan view of the automatic warehouse in the embodiment of the present invention. The upper half of FIG. 6 is a plan view showing a state in which the automatic warehouse 2 is viewed from above. Since the automatic warehouse 2 also has a depth, the arrangement shelf 3 is arranged in a state including the depth. Moreover, the lower half of FIG. 6 is a front view, and it can be seen that a plurality of arrangement shelves 3 are provided. The flow rack 5 shown in FIG. 5 is mounted so as to protrude in front of any of the placement shelves 3 at any location in front of the automatic warehouse 2.

(Step ST4: Delivery case input)
Next, in step ST <b> 4, the product sorting system 1 inputs the delivery case 200 from the input unit 8 into the transport lane 7. In the loading unit 8, an operator different from the sorting operator may manually load the delivery case 200, or a conveyor line or the like is connected to the loading unit 8, and the delivery case 200 is automatically set. It may be input to the input unit 8.

The delivery case 200 is also preferably different in size, type, color, mark, etc. according to the final delivery destination. This is because the worker who works in the work area 10 in front of the flow rack 5 can identify the delivery case 200 and can prevent an error in sorting.
Here, the delivery case 200 may be thrown into the transport lane 7 continuously or intermittently.

  The conveyance lane 7 extends slightly straight (or obliquely) in a direction away from the automatic warehouse 2 from the input unit 8, and is bent or bent at the bending portion 7A when extended a certain amount. After this bending or bending, it extends substantially parallel to the automatic warehouse 2 and reaches the discharge part 9 as it is. For this reason, the delivery case 200 thrown in from the throwing-in part 8 advances on the conveyance lane 7 according to this curve and straight advance.

(Step ST5: Delivery case arrival)
In step ST <b> 5, the delivery case 200 put into the transport lane 7 from the loading unit 8 is moved by the transport force of the transport lane 7. The transfer lane 7 is configured by a belt conveyor or the like, and moves from the input unit 8 toward the work area 10. By this movement, the transport lane 7 transports the delivery case 200 loaded from the loading unit 8 to the work area 10. If transported, the delivery case 200 reaches the work area 10.

  When the delivery case 200 reaches the position corresponding to the work area 10 in the transport lane 7, the transport lane 7 reduces the transport speed or stops the transport. As a result, the worker can have time to pack the product items 100 to be sorted selected from the flow rack 5 into the delivery case 200 that has reached the position corresponding to the work area 10.

  Of course, if the transport speed of the transport lane 7 is slow from the beginning, the time for the delivery case 200 to pass through the corresponding front and rear of the work area 10 is also delayed, so the operator can pack the product item 100 into the delivery case 200. Can be done in sufficient time.

  In particular, the conveyance lane 7 extends substantially straight at a position facing the work area 10 as shown in FIG. For this reason, the delivery case 200 has a state parallel to the worker. Since the delivery case 200 is parallel to the worker, the worker can easily pack the product item 200 selected from the flow rack 5 into the delivery case 200.

(Step ST6; sorting of product items by worker)
Next, in step ST <b> 6, the product sorting system 1 selects a product item 200 to be packed in the corresponding delivery case 200 from among the product items 100 installed in the flow rack 5, and sorts the product by the operator. To implement.

  The delivery case 200 has reached the worker in the work area 10 in step ST5. The worker selects and packs products to be packed in the delivery case 200 that has arrived in front of him / her from the back flow rack 5 (sorting operation). At this time, in FIG. 1 and the like, the flow rack 5 is on the back side of the worker, but depending on the structure of the flow rack 5, it may be on the side of the worker.

  FIG. 7 is an explanatory diagram showing the working state of the worker in the implementation of the present invention. The right side of FIG. 7 shows a state where the flow rack 5 is viewed from the side with the worker 60 as a reference, and the left side of FIG. 7 shows the flow rack 5 as viewed from the front with the worker 60 as a reference. Indicates the state. That is, when the worker 60 is used as a reference, the state of the flow rack 5 is collectively shown on the left and right in FIG.

  As shown in FIGS. 1 and 4, merchandise items 100 to be sorted are arranged in the flow rack 5 (or the stage 51). As shown in FIG. 7 and the like, the flow rack 5 has a plurality of stages and widths, and thus the flow rack 5 has a plurality of product items 100 installed therein. Here, the flow rack 5 has a display unit at that stage, and it is also preferable to inform the display unit of products to be sorted into the delivery case 200 that has arrived before the worker 60.

  The operator 60 looks at the display unit (for example, lamp display, character display, etc.) and takes out the merchandise item 100 to be sorted from the flow rack 5. Of course, the ID number and the like of the delivery case 200 is displayed on the display unit. When a plurality of delivery cases 200 are transported in the transport lane 7 by looking at them, the product is matched with the corresponding delivery case 200. Item 100 is selected.

(Step ST7: Packing the selected product into the delivery case)
Next, in step ST <b> 7, the product sorting system 1 packs the product selected as the sorting target into the delivery case 200 through the work of the worker 60. In this way, the worker can combine a combination of the product items 100 to be delivered to a specific store or a specific factory from various miscellaneous and many product items 100 received in the automatic warehouse 2 into the specific store or the specific factory. The delivery case 200 to be delivered can be packed.

  When the worker 60 finishes packing the product items 100 to be sorted into the delivery case 200, the transport lane 7 transports the delivery case 200 packed with the product in the direction opposite to the input unit 8 as it is. Normally, all necessary product items 100 are packed in the delivery case 200 by the sorting operation of the worker 60. This is transferred to a specific store or distribution center in the next stage, for example. As described above, when the sorting operation is finished and all necessary product items 100 are packed, the sorting operation is completed. That is, the completed delivery case shown in the flowchart of FIG.

  In the case of a completed delivery case, the extended transport lane 7 discharges the completed product delivery case from the discharge unit 9. The discharged completed delivery case is transferred to the next stage where it is delivered to a specific store or delivery center as it is. If it moves to this next stage, the sorted goods will be delivered to the necessary place.

  As described above, the product sorting system 1 according to the first embodiment includes the configuration and the characteristics of each element, the characteristics of the overall combination, the elements and the overall shape, the positional relationship of the elements, the position of the work procedure and the elements, Combining the arrangement on the arrangement shelf 3 and the installation position of the flow rack 5 can be combined to form a very compact configuration. As a result, the problems with the conventional product sorting system 1, such as the increase in size, the difficulty of being suitable for small quantities of various products, and the problem that multiple types of product sorting systems cannot be laid out at one factory or distribution center, etc. Can be solved by the product sorting system 1 of the first embodiment.

  These are suitable not only for Japan but also for Japanese companies that have factories overseas. Japanese companies expanding overseas do not need to set up a large product sorting system to balance high initial costs and business maintenance risks. By reducing initial costs, overseas companies with high turnability and mobility This is because it is possible to expand the factory.

  Here, as shown in FIG. 3, after step ST <b> 7, a completed delivery case in which all the product items 100 to be packed in a certain delivery case 200 are packed, and all the product items 100 are not packed. A completed in-process delivery case occurs. Even in the completed delivery case, there are a case where it is discharged as it is from the discharge unit 9 and a case where it is re-stocked in the automatic warehouse 2. Hereinafter, these three cases will be described.

(Pattern PT1: Discharge of completed delivery case)
As described above, when an operator packs all necessary product items 100 to be packed in a certain delivery case 200, the completed delivery case 200 is handled as a completed delivery case. The product sorting system 1 normally moves the completed delivery case as it is through the transport lane 7 and discharges it from the discharge unit 9. At this time, the conveyance lane 7 moves at a constant speed from the input unit 8 to the discharge unit 9, and when the product item 100 is packed in the delivery case 200, the transfer lane 7 may be discharged from the discharge unit 9 as it is.

  Alternatively, the transport lane 7 may discharge the completed delivery case from the discharge unit 9 by confirming that the worker 60 has reached the completed delivery case and performing a certain operation. In this case, for example, the transport speed of the transport lane 7 is increased until the delivery case 200 is input to the input unit 8 and reaches the front of the worker 60, and the transport speed is increased in front of the worker 60. The conveyance speed may be increased later (because of the sorting work) and after the sorting work (detected by the operator, or when a completed delivery case has been reached by image processing or weight detection).

  In any case, in the case of the pattern PT1 in FIG. 3, when the completed delivery case is reached, the discharge unit 9 discharges the completed delivery case as in the pattern PT1. The discharged and completed delivery case is directly delivered to the next process.

(Pattern PT2: In-process delivery case)
In some cases, not all the merchandise items 100 that need to be packed in a predetermined delivery case 200 that has been transported in front of the worker 60 may be installed in the flow rack 5. In this case, stopping the conveyance of the conveyance lane 7 and operating the crane 6 to move the missing item item 100 from the arrangement shelf 3 to the flow rack 5 stops the sorting operation. Not preferable. This is an unacceptable response in most factories and distribution centers.

  Thus, not all the merchandise items 100 to be packed in the predetermined delivery case 200 are collected in the flow rack 5, and sorting and packing (sorting work) may not be completed. As described above, a delivery case 200 in which all necessary product items 100 are not packed (hereinafter, referred to as “in-process delivery case”) may occur in the sorting operation in the transport lane 7.

  In the prior art, such an in-process delivery case is discharged from the discharge unit 9 as it is. The discharged in-process delivery case is discharged from the discharge unit 9 by human power or a machine, and then temporarily stored in a dedicated warehouse for in-process delivery cases or a shelf, or placed in a dedicated arrangement area. It was. After that, it is thrown into the transfer lane 7 again in an in-process state by human power or a machine (by a dedicated warehouse, an arrangement area, and a conveyor connected to the loading unit 8 for loading the delivery case 200). The merchandise item 100 is taken out from the flow rack 5 and packed to complete sorting and packing.

  In such a conventional technique, a dedicated warehouse or a dedicated arrangement area for an in-process delivery case, or a conveyor connecting the input unit 8 and the power source, and a power source and a control opportunity therefor are required. Of course, the cost increases and the area required for product sorting also increases. As a result, the area and cost required for the product sorting system and its surroundings increase, and there is a problem that the product sorting system cannot be installed in a factory or distribution center with a highly flexible layout.

  As shown in FIG. 1, the product sorting system 1 according to Embodiment 1 has a branch 31 in the middle of the transport lane 7 and before the discharge unit 9. The transport lane 7 has a branch lane 30 from the branch 31 toward the automatic warehouse 2. The branch lane 30 does not carry the delivery case 200 to the discharge unit 9 but carries the delivery case 200 to the automatic warehouse 2 (that is, the arrangement shelf 3). This branch lane 30 is connected to a re-entry line 50 for re-entry into the automatic warehouse 2.

  For this reason, the in-process delivery case described above passes through the branch lane 30 at this branch 31 and is returned from the re-entry line 50 to the arrangement shelf 3 provided in the automatic warehouse 2. The automatic warehouse 2 provided with the arrangement shelf 3 is prepared from the beginning as the product sorting system 1 and is not a dedicated warehouse or dedicated area for in-process delivery cases as in the prior art. For this reason, an extra apparatus, a warehouse, and an area are not required outside the commodity sorting system 1.

  The control unit that controls the transport lane 7 (of course, the crane 6 and the flow rack 5 as a whole) receives the weight of the delivery case 200, image processing, or instructions from the operator, and the delivery case is an in-process delivery case. Can be grasped. As a result, the control unit branches the in-process delivery case to the branch lane 30 so as not to be discharged from the discharge unit 9.

  In this way, the in-process delivery case re-introduced from the re-introduction line 50 to the automatic warehouse 2 is moved and arranged on the arrangement shelf 3 of the automatic warehouse 2 by the crane 6.

  FIG. 8 is a drawing showing the positional relationship between the automatic warehouse and the crane according to Embodiment 3 of the present invention. FIG. 8 shows a state viewed from the side of the automatic warehouse. A plurality of arrangement shelves 3 are provided on both sides of the automatic warehouse 2, and a crane 6 is installed between them. The crane 6 includes a drive control unit 62 and an arm 61. The drive control unit 62 operates the arm 61 to arrange the above-described in-process delivery case on the arrangement shelf 3, or described in the first embodiment. The product item 100 is arranged on the arrangement shelf 3 as described above.

  The in-process delivery case returned to the arrangement shelf 3 is moved by the crane 6 to the input unit 8 at a predetermined timing. As a result, the in-process delivery case is again input from the input unit 8 to the transport lane 7. If it is put into the transport lane 7, an in-process delivery case that is incomplete but packed with certain product items 100 moves through the transport lane 7 and reaches the worker 60.

  The worker 60 takes out the product item 100 that is installed in the flow rack 5 and is insufficient in the in-process delivery case, and packs the product item 100 in the in-process delivery case to complete sorting and stuffing. Thus, the completed delivery case 200 proceeds as it is as a completed delivery case (as judged by the control unit) as it is in the transport lane 7 and is discharged from the discharge unit 9. As a result, the sorting operation is completed without requiring an extra dedicated warehouse and dedicated area.

  Of course, if the sorting and stuffing is not completed even in the second sorting operation, it is judged again as an in-process delivery case and returned to the placement shelf 3 via the branch lane 30 and the re-injection line 50. Thereafter, the sheet is returned from the arrangement shelf 3 to the transport lane 7 via the input unit 8 for the third sorting operation.

  As described above, in-process delivery cases are also processed in the product sorting system 1 shown in FIG. 1 (by the decision of the branch lane 30 and the control unit). Therefore, it is possible to achieve compactness, ease of layout, and low cost (including work cost) as a whole without requiring an extra device, area, and work.

(Pattern PT3: Re-entry of completed delivery case)
Further, the branch lane 30 and the re-entry line 50 may return not only in-process delivery cases in which sorting is incomplete but also completed delivery cases in which sorting and packing have been completed to the arrangement shelf 3 in a predetermined condition. Is preferred.

  The completed delivery case is originally discharged as it is from the discharge unit 9 and is carried to a temporary storage warehouse or truck for transportation. However, the completed delivery case may have various destination shops and destination factories, or may have a combination of various packed product items 100. In such a case, if various different completed delivery cases are discharged from the discharge unit 9, the efficiency of the work of moving to a temporary storage warehouse or truck is poor.

  For example, it may be better to move to a temporary storage warehouse or truck after a certain amount of finished product delivery cases at the same destination store or destination factory have accumulated. Alternatively, it may be better to move to a temporary storage warehouse or truck after a certain amount of completed delivery cases having the same product combination have accumulated.

  In such a case, it is better for the product sorting system 1 to discharge after having accumulated to some extent than to discharge the completed delivery cases one after another from the discharge unit 9.

  Alternatively, when completed delivery cases are discharged from the discharge unit 9 one after another, there are cases where preparations such as unloading by truck and ordering for unloading are not complete. As described above, when preparation for the next stage is not completed, there is a problem that the completed delivery case is scattered in the space ahead of the discharge unit 9 or occupies the space. As described above, it is not preferable that the discharging unit 9 discharges the completed delivery case when preparation for the next stage processing for processing the completed delivery case is not completed in a state where even the delivery is considered.

  For this reason, as predetermined conditions, when the completed delivery cases in which the same combination of product items 100 are packed under the same sorting conditions are continuous for a predetermined number or more, when they are continuous for a predetermined time, or more than a predetermined number within a predetermined period, and In at least one case where preparation for the next process for handling the completed delivery case after discharge has not been completed, the control unit managing the transfer lane 7 and the like sends the completed delivery case to the automatic warehouse 2 via the branch lane 30. It is preferable to return to.

  In this way, after a certain amount of finished product delivery cases of the same destination store or destination factory have accumulated or a certain amount of finished delivery cases having the same product combination have accumulated (these are the shelves of the automatic warehouse 2) 3) and is again put into the transport lane 7 and discharged together from the discharge unit 9. Of course, at this time, the sorting operation is not performed on the completed delivery case that moves from the arrangement shelf 3 to the transport lane 7 via the input unit 8.

  Further, after a certain amount of completed delivery cases have been accumulated, they may be delivered together from the collective delivery line 40 instead of being entered from the input unit 8. The collective delivery line 40 is connected to the transport lane 7 and exits from the arrangement shelf 3 toward the transport lane 7 as represented by the arrow in FIG. The completed delivery case that has been temporarily stored and arrives at the transfer lane 7 is discharged through the discharge unit 9 as it is. At this time, a plurality of completed delivery cases that have been temporarily stored may be superposed and delivered, or may be delivered sequentially. Thus, when the collective delivery line 40 is used, it is not necessary to input again from the input unit 8, so that the completed delivery case does not pass in front of the operator 60, and the operator 60 is bothered. In addition, the efficiency of the sorting operation is improved without hindering the conveyance of the new delivery case 200.

  Conversely, in cases other than the above conditions, the transport lane 7 discharges the completed delivery case as it is from the discharge unit 9. This is because special problems are unlikely to occur.

  As described above, the completed delivery cases are also temporarily stored in the automatic warehouse 2, so that it is possible to reduce labor, work, storage location, etc. until actual transportation. As a result, the compactness around the product sorting system 1 and the ease of layout can be improved.

  As described above, in the case of the pattern PT3, the completed delivery case is returned again to the arrangement shelf 3 through the re-entry line 50, and processing according to the convenience of delivery and insufficient preparation for delivery, etc. is performed. it can.

  As described above, the product sorting system 1 according to the first embodiment is downsized and installed in a flexible factory or the like by combining hardware and software (including human work) and by designing the product sorting device. Can do. In addition, various devices can be made compact including the work area, and the product sorting system 1 can be easily applied to various places.

  The product sorting system 1 can also be grasped as a product sorting method based on hardware as devices such as the automatic warehouse 2 and the transport lane 7.

  That is, what is necessary is just to grasp | ascertain as a goods classification method including each of the following step.

(1) A warehousing step of warehousing a plurality of product items 100 in an automatic warehouse 2 having a plurality of arrangement shelves 3 partitioned by a plurality of rows and stages.
(2) An arrangement step of arranging and storing each of the plurality of product items 100 received in the storage step by using the crane 6 in any of the plurality of arrangement shelves 3.
(3) An installation step in which among the product items 100 stored on the arrangement shelf 3, the product items 100 that are candidates for sorting are installed on the flow rack 5 that is mounted to face a part of the automatic warehouse 2.
(4) A loading step of loading the delivery case 200 from one end of the transportation lane 7 for transporting the delivery case 200 in which the product items 100 sorted from the flow rack 5 are packed.
(5) A sorting step of selecting and packing the product items 100 to be packed in the delivery case 200 transported to the front surface of the worker 60 in the transport lane 7 from the flow rack 5.
(6) A discharging step in which the delivery case 200 in which the sorting step has been completed is discharged to the discharging unit 9 provided on the opposite side of the loading unit 8 from the transport lane 7.

  Here, as described above, the work area 10 as shown in FIG. 1 is secured by the structure of the transfer lane 7 and the positional relationship between the transfer lane 7 and the automatic warehouse 2 (flow rack 5). is there. In addition, in this work area 10, the delivery case 200 transported in the transport lane 7 reaches the front surface of the worker 60, and the flow rack 5 in which the product items 100 to be sorted are installed on the back surface of the worker 60. The worker 60 can perform the sorting step by the flow line in the change of the body direction before and after the predetermined range.

  Thus, it is also suitable to be grasped as a product sorting method. In addition, as described above, it is possible to add an option to which additional processing such as re-entry of an in-process delivery case and re-entry of a completed delivery case is added in the product sorting method.

  (Embodiment 2)

  Next, a second embodiment will be described. In the second embodiment, further downsizing of the product sorting system 1 and sharing of the role to be processed by the product sorting system 1 to devices and structures other than the product sorting system 1 shown in FIG. 1 can be reduced as much as possible. A device (as a result, naturally, the product sorting system 1 can be reduced in size and the degree of freedom and ease of layout in a factory or a distribution center is increased) will be described.

(Corresponding to product surplus in flow rack)
The crane 6 moves the merchandise item 100 stored in the arrangement shelf 3 to the flow rack 5 and installs it. At this time, the crane 6 selects the commodity item 100 corresponding to the delivery case 200 transported in the transport lane 7 as much as possible, moves it to the flow rack 5 and installs it.

  However, the delivery case 200 is inserted in various ways, and the storage positions of the merchandise item 100 on the arrangement shelf 3 are also various. For this reason, the product item 100 that is to be sorted immediately (target to be packed in the delivery case 200) is not necessarily installed in the flow rack 5. Even if the worker 60 performs a plurality of sorting operations on the plurality of product items 100 installed in the flow rack 5 (for example, the product item 100 having a display as a sorting target), the sorting is not performed ( The merchandise item 100 may remain (not left in the delivery case 200 and left).

  That is, in the plurality of product items 100 arranged in the flow rack 5, the product item 100 remaining until a period exceeding at least one of the predetermined time and the predetermined number of sorting operations is not required for the sorting operation for a certain period of time. Product item 100 (hereinafter, defined as “remaining product item”). In other words, there is a high possibility that the remaining product items will not be sorted for a while after that.

  If such remaining commodity items remain in the flow rack 5 forever, the usage efficiency of the flow rack 5 is reduced. In order to prevent this decrease in usage efficiency, for example, it is conceivable to enlarge the flow rack 5. However, considering the work of the worker 60, it is impossible to make the height direction of the flow rack 5 too large, so the lateral direction is increased. When this happens, the flow line of the worker becomes large, and the sorting work efficiency of the worker decreases. Alternatively, it is necessary for a plurality of workers to work in the work area 10, and in the latter case, a sorting error may occur depending on the role sharing and skill level of the workers.

  In addition, if the horizontal direction of the flow rack 5 is increased, there is a problem that the product sorting system 1 is naturally increased. This cannot solve the problem of the prior art, that is, a product sorting system that can handle a small variety of products and a product sorting system that can be installed compactly according to various layouts.

  Therefore, the crane 6 returns the remaining product items classified according to the above conditions from the flow rack 5 to the arrangement shelf 3. By doing so, the merchandise item 100 that is not used for the sorting work for a while does not occupy the limited space of the flow rack 5 over a long period of time. As a result, the merchandise items 100 installed in the flow rack 5 are sorted one after another and packed in the delivery case 200. For this reason, the flow rack 5 can be made smaller in the lateral direction, and of course, the product sorting system 1 can be reduced in size. The product sorting system 1 according to the second embodiment can solve the problems of the conventional product sorting system described above.

  The crane 6 may use a predetermined rule to determine a product item remaining until a period exceeding at least one of the predetermined time and the predetermined number of sorting operations as the remaining product item. The predetermined rule may be determined by a control unit provided in the commodity sorting system 1 including the crane 6 using a computer program or LSI. For this reason, it is also preferable that this predetermined rule can be changed.

  That is, the time until it is determined as the remaining product item can be changed according to the characteristics of the product item 100, the characteristics of the sorting, and the characteristics of the factory where the product sorting system 1 is installed. Such a high flexibility has an advantage that the application range of the product sorting system 1 can be further expanded because the product sorting system 1 can be easily applied to various uses.

(Ingenuity when returning the remaining product items to the shelf)
In addition, the flow rack 5 records the history of the product item 100 that is likely to be a remaining product item. The plurality of merchandise items 100 have various types, and depending on the merchandise item 100, there may be a merchandise item 100 that is rarely sorted into the delivery case 200 (that is, rarely delivered to a store or a factory). Product item). The flow rack 5 includes an electronic control unit, and the electronic control unit includes a processor, a memory, and the like, and the memory records the product items 100 that are likely to become the remaining product items.

  For example, in a predetermined period, the memory records the product item 100 that is the remaining product item more than a predetermined number of times as a history. It is determined that the product item 100 that has been recorded is a product item 100 that is likely to be a remaining product item.

  It is also preferable that the crane 6 returns and arranges the merchandise item determined to be the merchandise item 100 that is likely to become a remaining merchandise item according to the history on the arrangement shelf 3 far from the position of the flow rack 5. Such a product item 100 that is likely to be a remaining product item is determined to have a low number of times and possibility of being moved to the flow rack 5 and installed. When such a commodity item 100 is stored in the arrangement shelf 3 near the flow rack 5, the commodity item 100 that is frequently moved to the flow rack 5 is easily stored in a position far from the flow rack 5. End up.

  In this case, the moving distance of the crane 6 tends to be large, which is not preferable for work efficiency and energy consumption. For this reason, when returning the product item 100 that is likely to become a remaining product item from the flow rack 5 to the placement shelf 3, the crane 6 is appropriately returned to the placement shelf 3 far from the flow rack 5. The distant from the flow rack 5 is, for example, an arrangement shelf 3 that does not overlap with the mounting area of the flow rack 5 or an arrangement that does not overlap with the mounting area of the flow rack 5 and that is separated by a predetermined distance or more. Shelf 3 Or in the automatic warehouse 2, the arrangement | positioning shelf 3 of both ends and its vicinity is said. Alternatively, it refers to the arrangement shelf 3 that the crane 6 must move over a predetermined distance with the flow rack 5 as a reference.

  As a result, the product item 100 that is likely to be a remaining product item is less likely to occupy the placement shelf 3 near the flow rack 5, and the product item 100 that is to be sorted more frequently is placed near the flow rack 5. Arranged on the shelf 3. As a result, the efficiency of the entire sorting operation is improved and the energy efficiency is also improved.

  Further, there is a merit that the flow rack 5 can be downsized, and the product sorting system 1 can be made compact, easy to install in various places, wide application range, and easy to spread.

(Cleat)
A large number of product items 100 are arranged and stored in the arrangement shelf 3 as shown in FIGS. Although the arrangement shelf 3 temporarily stores the merchandise item 100 to be sorted, it may be necessary to store for a long time depending on the case. For example, when the sorting operation does not end in one day, or as described above, the remaining product items may remain on the arrangement shelf 3 indefinitely.

  In such a case, even if the automatic warehouse 2 and the arrangement shelf 3 are formed with strong and sufficient durability, the product item 100 may slide off the arrangement shelf 3 due to an earthquake or a sudden accident. It is possible. In particular, Japan has a vivid memory of the earthquake disaster, and there is a need for a quick recovery when factories and distribution centers are damaged by the earthquake.

  For this reason, it is also preferable that at least a part (or all of them) of the plurality of arrangement shelves 3 provided in the automatic warehouse 2 have a slip stopper that contacts at least a part of the bottom surface of the commodity item 100. Since the slip prevention is applied, even if an earthquake or a sudden accident occurs, it is possible to prevent a large number of product items 100 stored in the arrangement shelf 3 from falling. This is because if the fall is prevented, human and physical damage will be reduced and recovery will be accelerated.

  Further, the presence of the slip prevention makes it difficult for the product item 100 to be displaced in the arrangement shelf 3 even if an earthquake or sudden accident occurs, and is also suitable for the crane 6 that operates according to the position of the product item 100. It is. When the crane 6 does not grip the product item 100 placed on the placement shelf 3 by image processing but grips the product item 100 based on the set coordinate value, the product item 100 is placed It is preferable that the position on the shelf 3 is not shifted.

  By providing the anti-slip, the position of the commodity item 100 is less likely to be shifted in the arrangement shelf 3, and the work by the crane 6 can be immediately restored.

  FIG. 9 is a perspective view showing a state in which the arrangement shelf in the second embodiment of the present invention is slip-prevented. As described above, the anti-slip (a member having a high coefficient of friction) is attached to a part (or all) of the bottom surface of the arrangement shelf 3, so that the above-mentioned earthquake disaster countermeasures and recovery countermeasures are possible.

  As described above, the product sorting system 1 according to the second embodiment can further reduce the size of the product, and can realize high installation ease, wide application range, and widespread use in various places.

(Embodiment 3)
Next, Embodiment 3 will be described.

  In the third embodiment, a product sorting system that combines a plurality of the product sorting systems 1 described in the first and second embodiments will be described.

  FIG. 10 is a schematic diagram of a product sorting system according to Embodiment 3 of the present invention. FIG. 10 shows the product sorting system 300 as viewed from above. As described in the first to third embodiments, the commodity sorting system 1 includes an automatic warehouse, a transportation lane, a flow rack, and a crane as main elements. Here, the transportation lanes are connected to each other so as to share the transportation lanes, or the transportation lanes are shared, so that a plurality of automatic warehouses 2 (the associated flow rack 5, crane 6, etc.) are provided. It is also suitable to be configured to face each other.

  For example, when there are a plurality of automatic warehouses 2, the plurality of automatic warehouses 2 are configured to face each other with the conveyance lane 7 interposed therebetween. Further, when the plurality of automatic warehouses 2 sandwich the transport lane 7, the workers 60 working in the work area 10 in front of the transport lane 7 and the flow rank 5 face each other.

  FIG. 10 shows such a configuration, and a plurality of automatic warehouses 2 (or a plurality of product sorting systems 1) are combined so as to face each other. As described above, the product sorting system 1 described in the first to third embodiments can be combined so as to face each other as shown in FIG. As a result, it can be installed in a highly flexible layout in a factory or distribution center that needs to handle various product items 100. Naturally, the individual product sorting system 1 is small in size, and the worker 60A and the worker 60B face each other because of structural features.

  As described above, when the workers 60A and 50B face each other, it is possible to work while confirming each other, so that a work mistake can be prevented. In addition, each of the two work areas can be surely secured by the configuration facing each other, and the overall size can be reduced.

  Further, the input lines 4A and 4B of the product item 100 face each other, and the input work of the product item 100 is aggregated, and each of the product items 100 is necessary for each of the product sorting system 1A and the product sorting system 1B. Product item 100 is inserted.

  Similarly, since the input portions 8A and 8B of the delivery case 200 are close to each other, the operations necessary to input the delivery case 200 are easily collected. After being easily collected, a delivery case 200 necessary for each of the product sorting system 1A and the product sorting system 1B is loaded.

  Furthermore, the discharge unit 9A and the discharge unit 9B are easily integrated, and in particular, the delivery case 200 sorted in the same direction at substantially the same position can be discharged. In this regard, whether the delivery case 200 is discharged from the product sorting system 1A or from the product sorting system 1B is discharged to almost the same place. Therefore, the efficiency of moving work and the like is improved.

  As described above, by combining the product sorting system 1 having the configuration shown in FIG. 1 so as to face each other, it becomes easy to collect other operations required for each of the product sorting systems 1A and 1B. . This naturally increases the efficiency of the product sorting operation, and further, various product sorting systems can be constructed according to the product quantity, type, characteristics, etc. of the product sorting target.

  Of course, there are various combinations as well as the two combinations shown in FIG. 10, and a highly flexible product sorting system suitable for the convenience of the factory or distribution center can be constructed in the factory or distribution center. As a matter of course, the work efficiency of product sorting increases, and it is easy to change the combination in response to changes in product items, etc., so the application range is expanded.

  As a result, the product sorting system 1 according to the present invention can promote technological advancement and globalization in various industries, particularly in a variety of small-lot and foreign developments, in manufacturing and distribution sites.

  Note that the product sorting system described in the first to third embodiments is an example for explaining the gist of the present invention, and includes modifications and alterations without departing from the gist of the present invention.

DESCRIPTION OF SYMBOLS 1 Commodity sorting system 2 Automatic warehouse 3 Arrangement shelf 4 Receiving line 5 Flow rack 6 Crane 7 Transport lane 7A Curved part 8 Input part 9 Discharge part 10 Work area 30 Branch lane 40 Collecting line 50 Re-entry line 60 Worker 100 Product item 200 delivery cases

Claims (21)

An automatic warehouse having a plurality of arrangement shelves partitioned by a plurality of rows and stages;
A warehousing line for warehousing a plurality of types of merchandise items in the automatic warehouse;
Among the plurality of types of merchandise items stored in the plurality of arrangement shelves, a flow rack that installs a predetermined type of merchandise item for sorting of workers;
A crane that arranges the product items to be received from the warehousing line on the placement shelf, and moves and sets the product items stored on the placement shelf to the flow rack;
A transport lane for transporting a delivery case for stuffing the commodity items sorted from the flow rack, wherein one of the transport lanes has an input unit for loading the delivery case, and the other ejects the delivery case Having a discharge part to
The transport lane is provided with a work area of the worker provided at a position facing the automatic warehouse across the flow rack,
The warehousing line allows the merchandise item to be conveyed to the automatic warehouse by transporting the merchandise item,
The crane moves the commodity item received from the warehousing line and arranges it on one of the arrangement shelves,
The crane is installed in the flow rack by moving the candidate product items to be sorted among the product items stored on the shelf.
In the work area, the worker selects and packs product items to be packed in the delivery case to be transported to the transport lane among the product items installed in the flow rack,
The flow rack includes a display unit that displays a target product item to be sorted into a predetermined delivery case that is a work target of the worker,
The worker takes out the product item displayed on the display unit as a sorting target from the flow rack, and performs a sorting operation to pack the product item into the delivery case.
The product item remaining until a period exceeding at least one of a predetermined time and a predetermined number of times of the sorting operation after the sorting operation is defined as a remaining product item and returned to the placement shelf from the flow rack. system. In the work area, the delivery case transported on the transport lane reaches the front of the worker, and the flow rack for placing the product items to be sorted is positioned behind the worker,
The said operator selects the goods item which should be packed in the said delivery case which has reached the front surface from the said merchandise item installed in the said flow rack located back, and packs in the said delivery case. Product sorting system described.   Since the delivery case is transported from one of the workers having the transport lane in front to the other, the worker is standing at a substantially constant range in the work area, with the front and the back as the center. The product sorting system according to claim 1 or 2, wherein the product items to be sorted are packed in the delivery case by a flow line.   The conveyance lane extends in a direction away from the automatic warehouse from the input unit, curves or bends when extending a predetermined distance, extends substantially parallel to the automatic warehouse, and reaches the discharge unit. The product sorting system according to any one of 1 to 3.   The commodity according to any one of claims 1 to 4, wherein the crane arranges one or a plurality of the commodity items arranged in at least one of the same type, the same shape, and the same size on each of the plurality of placement shelves. Sorting system.   The product sorting system according to claim 5, wherein when the plurality of product items are arranged on each of the plurality of arrangement shelves, the crane arranges the distances between the plurality of product items at substantially equal intervals. .   The said flow rack is mounted | worn corresponding to the said arrangement | positioning shelf of either the height direction of the said automatic warehouse, and a horizontal direction while facing a part of these arrangement | positioning shelves. Product sorting system described.   The worker, after the sorting operation, the delivery case is the delivery case in which all the commodity items necessary for the delivery case to be worked are packed (hereinafter referred to as “completed delivery case”). The product sorting system according to claim 1, wherein the product sorting system is divided into a delivery case in which the product items necessary for the delivery case to be worked are insufficient (hereinafter referred to as "in-process delivery case"). .   The flow rack records a history of the product items that are likely to become the remaining product items, and the crane arranges the product items received from the warehousing line on an arrangement shelf far from the position of the flow rack. Item 1. A product sorting system according to item 1. The transport lane has a branch lane that branches in front of the discharge unit, and a leading end that heads to the automatic warehouse,
9. The product sorting system according to claim 8, wherein the in-process delivery case is returned to the arrangement shelf of the automatic warehouse through the branch lane after the sorting operation.   The product sorting system according to claim 10, wherein the crane moves and arranges the in-process delivery case that has reached the tip of the branch lane to the placement shelf.   The in-process delivery case returned to the arrangement shelf is again input into the transport lane from the input unit, and in the re-sorting operation, the insufficient item items installed in the flow rack can be packed. The product sorting system according to claim 11.   The said branch lane is a goods sorting system of Claim 10 which returns the said completion delivery case to the arrangement | positioning shelf of the said automatic warehouse via the said branch lane in the case of predetermined conditions.   The predetermined condition is that if the completed delivery cases in which the product items of the same combination are packed under the same sorting conditions are continuous for a predetermined number or more, if the predetermined delivery period is continuous for a predetermined time, or more than a predetermined number within a predetermined period, discharge The product sorting system according to claim 13, comprising at least one of cases where preparation for the next process for handling the subsequent completed delivery case is not completed.   15. The product sorting system according to claim 13 or 14, wherein the transport lane sends the completed delivery case to the discharge unit when the predetermined condition is not met.   The product sorting system according to any one of claims 1 to 15, wherein at least a part of the plurality of arrangement shelves has a non-slip at a portion that contacts at least a part of a bottom surface of the product item. A warehousing step for warehousing a plurality of product items in an automatic warehouse having a plurality of arrangement shelves partitioned by a plurality of rows and stages;
An arrangement step of arranging and storing each of the plurality of product items received in the warehousing step on any of the plurality of arrangement shelves using a crane;
Of the product items stored in the arrangement shelf, an installation step of installing a product item that is a candidate for sorting on a flow rack mounted facing a part of the arrangement shelf;
A transport lane for transporting a delivery case for stuffing the commodity items sorted from the flow rack, and an input step for inserting the delivery case from one end thereof;
A sorting step of selecting and packing the product items to be packed in the delivery case to be transported to the front of the worker in the transport lane from the flow rack;
A discharge step of discharging the delivery case in which the sorting step is completed, to a discharge unit provided on the opposite side of the transfer unit from the input unit used in the input step,
The transport lane extends from the charging unit in a direction away from the automatic warehouse, and is bent or bent when extending a predetermined distance, and extends substantially parallel to the automatic warehouse with the flow rack interposed therebetween, and the discharge By having a configuration that reaches the part, forming the work area of the worker,
In the work area, a delivery case transported in the transport lane reaches the front of the worker, and the flow rack on which the commodity items to be sorted are placed is located on the back of the worker, In the flow line in the direction change of the body before and after the inside, the worker can perform the sorting step,
The flow rack includes a display unit that displays a target product item to be sorted into a predetermined delivery case that is a work target of the worker,
The worker performs the sorting step of taking out the product item displayed on the display unit as the sorting target from the flow rack and stuffing the delivery item into the delivery case to be worked,
After the sorting step, the product item remaining until a period exceeding at least one of a predetermined time and a predetermined number of sorting operations is defined as a remaining product item and returned from the flow rack to the placement shelf. Method. In the sorting step, the product items to be sorted into a predetermined delivery case are taken out from the flow rack and packed in the predetermined delivery case.
After completing the sorting step,
The delivery case is defined as the delivery case (hereinafter referred to as a “complete delivery case”) in a state in which all the commodity items necessary for the delivery case to be worked on by the worker are packed. ,
18. The case defined as the delivery case (hereinafter referred to as “in-process delivery case”) in a state where the product items necessary for the delivery case to be worked are insufficient is generated. The product sorting method described. After the sorting step is completed, when the delivery case is defined as the in-process delivery case,
The transport lane has a branch lane that branches in front of the discharge unit and has a leading end that is directed to the automatic warehouse. The in-process delivery case is returned to the arrangement shelf of the automatic warehouse through the branch lane. The product sorting method according to claim 18, further comprising a first return step. After the sorting step is completed, when the delivery case is defined as the completed delivery case and satisfies a predetermined condition,
A second return step, wherein the completed delivery case is returned to the placement shelf of the automatic warehouse through the branch lane;
The predetermined condition is that when the completed delivery cases in which the product items of the same combination are packed under the same sorting condition are continuous for a predetermined number or more, when they are continuous for a predetermined period of time, or when they are a predetermined number or more within a predetermined period, The product sorting method according to claim 19, including at least one of cases where preparation for a next process for handling the subsequent completed delivery case is not completed. When at least a part of the products installed in the flow rack is defined as the remaining product items after the sorting step is completed,
A third return step of returning the remaining merchandise item to the placement shelf by the crane;
The product sorting method according to claim 17, wherein in the third return step, the product item having a history that is likely to be the remaining product item is placed on a placement shelf far from the flow rack.