WO2021054916A1

WO2021054916A1 - A method for fast and faultless collecting of products in warehouses

Info

Publication number: WO2021054916A1
Application number: PCT/TR2020/050827
Authority: WO
Inventors: Erdinc COMERT
Original assignee: Borusan Lojistik Dagitim Depolama Tasimacilik Ve Ticaret Anonim Sirketi
Priority date: 2019-09-20
Filing date: 2020-09-11
Publication date: 2021-03-25
Also published as: TR201914284A1

Abstract

The present invention relates to a weight-controlled collection method in logistics systems that allows the order data sent by a customer system server (10) to a warehouse management system module (20) to be collected on the basis of shipment, and by means of the tour algorithms created on the algorithm server (22), orders from the customer system server (10) can be collected in the fastest time and the shortest route within the warehouse by performing 4/12/48 order weight control at the same time.

Description

A METHOD FOR FAST AND FAULTLESS COLLECTING OF PRODUCTS IN WAREHOUSES Technical Field

The present invention relates to a weight-controlled collecting method that allows the active order information given by the customers in a logistics system to be separated on the basis of shipment, and that the collection orders of each shipment can be consolidated in the storage area in a way that does not involve human error. The technical benefits provided by the method are master data arrangement, making faultless measurements of width, height, height, weight and collecting error- free products with weight control.

More specifically, the present invention relates to a weight-controlled collecting method that allows the orders received from the customer system to be collected in the fastest time and the shortest route within the warehouse and without errors by means of tour algorithms created by separating the order data sent by the customer system to a warehouse management system on the basis of shipment.

Prior Art

The fast and error-free collecting of products in the warehouses is very important in order to keep up with recent conditions. Solutions to increase collecting speeds in logistics operations are still insufficient.

The most common present system is the form of collecting where an order is collected at one time. Although there are no scheduled orders in the order collecting method at issue, the orders are collected at any time during the day depending on the request of the person. Products in warehouses are stored in fixed positions on warehouse shelves or pallet shelves. To collect an order, the person who collects the order follows a route until it completes the entire order in the corridor. Because this method requires a lot of travel time for collection, it is not an effective method that results in a short time.

Another common method is to collect multiple orders at the same time in the same product location. It is used in cases where there is a concentration of a certain stock in the warehouse. Multiple orders are grouped into small lots. The order collector collects all orders within the lot in one pass using a consolidated collection list. The need for fast and error-free shipping of products is increasing day by day. During the mixed pallet, full pallet, original parcel and piece collection process, a process that depends on manpower and control of logistics operations causes errors and delays. The most common problems are low transaction speed and personnel cost, product delivery rate and not dispatching the correct product, resulting in increased customer complaints and loss of customers, and contractual KPI punishment. Thus instead of ensuring human initiative in the collection process, it should be reduced on a system basis.

This situation made it necessary to develop a method for collecting orders coming from the customer system in the fastest time and the shortest route within the warehouse by means of the tour algorithms created by separating the order data on the basis of shipment.

The document US7139637 mentions an order allocation method to minimize container stops at the distribution center. The order allocation algorithm used in the mentioned method is related to maximizing efficiency by reducing the number of stops that a container makes during the process of performing a customer order. However, there is no mention of a weight-controlled collection method that allows the orders from the customer system to be collected in the fastest time and the shortest route within the warehouse, by means of the tour algorithms created by separating the order data sent to a warehouse management system on the basis of shipment.

The document US20050149226A1 mentions a storage system and method. The document in point relates to the minimization of walking distance when collecting products in a collection and shelf area within a warehouse. Therefore, it is not mentioned that a weight-controlled collection method that allows the orders from the customer system to be collected in the fastest time and the shortest route within the warehouse, by means of the tour algorithms created by separating the order data sent to a warehouse management system on the basis of shipment.

The document JP2001301930A mentions an automatic storage and order filling for the processing of a minimum amount of product and product with human intervention. Therefore, there is no mention of a weight-controlled collection method that allows the active order information given by the customers in a logistics system to be separated on the basis of shipment, and that the collection orders of each shipment can be consolidated in a storage area in a way that does not involve human error.

Consequently, the need for an approach that allows the active order information given by the customers to be separated on the basis of shipment and that the collection orders of each shipment can be collected in a consolidated storage area in a way that does not include human error required the emergence of the solution according to the present invention. Objectives of the Invention

The aim of the invention is to provide a weight-controlled collection method that allows the active order information given by the customers in a logistics system to be separated on the basis of shipment, and that the collection orders of each shipment can be consolidated in the storage area in a way that does not involve human error.

Another aim of the invention is to provide a weight-controlled collection method that allows the orders from the customer system to be collected in the fastest time and the shortest route within the warehouse, by means of the tour algorithms created by separating the order data sent by the customer system to a warehouse management system on the basis of shipment.

One another aim of the invention is to present an order collecting method takes place by means of a customer system server that contains customer orders, warehouse management server in which information about the products is kept, algorithm server (a warehouse management system module that covers its components), where the planning is carried out, which ensures that the incoming orders are collected in the fastest time and the shortest route within the warehouse, an information processing device that enables collection trolleys to be directed to collect orders through the application running on it, a collection trolley used to collect orders and a parcel collection trolley used for collecting parcels in which orders are placed.

Another aim of the invention is master data arrangement, making the width, length, height, weight measurements without any errors and saving them to the system and error-free product collection.

Brief Description of the Figures

In Figure 1, system components of the method subject to the invention and interaction between them are shown.

In Figure 2, process steps for determining parcel while collecting orders from customers are shown.

In Figure 3, process steps for creating a tour while collecting orders from customers are shown.

Reference Numbers

10. Customer System Server

20. Warehouse Management System Module

21. Warehouse Management Server 22. Algorithm Server 30. Information processing device 40. Piece Collection Trolley 50. Parcel Collection Trolley

100. Collecting orders for each order are aligned from largest to smallest according to their location priorities.

105. Unless the total volume is larger than the largest parcel volume, order volumes are aggregated from the beginning of the list.

110. If the largest parcel size is exceeded, the aggregation in the list will be stopped.

115. If the list is over, the smallest volume parcel greater than the volume collected so far is selected and the locations are assigned to that parcel. It is proceeded to the next order.

120. The ones up to the previous location are assigned to the smallest volume parcel larger than the total volume and these locations are removed from the list.

200. The parcels assigned to the parcel determination section of each order are aligned from largest to smallest according to the priorities of the first location. Parcels with the same first location are arranged in the list, with the last location having a higher priority.

205. The first four parcels of the list arranged in the first step are selected and assigned as first four parcels to be filled by the collection trolley.

210. The parcel, which is greater than or equal to the last location of our first parcel from the remaining parcels of the list, is matched as a trolley backup of the first parcel.

215. If there is no other parcel left in the list, the new trolley tour will start.

Detailed Description of the Invention

The present invention relates to the fact that the active order information given by the customers in a logistics system can be separated on the basis of shipment and that the collection orders of each shipment can be consolidated in a storage area in a way that does not involve human error. In the present invention, a weight-controlled collection method is provided that allows the orders received from the customer system server (10) to be collected in the fastest time and the shortest route within the warehouse by means of the tour algorithms created on the algorithm server (22) by separating the order data sent by the customer system server (10) to a warehouse management system module (20).

The components of a system where the method of the invention is applied and the interaction between them are shown in Figure 1. According to the figure, the system comprises a customer system server (10) keeping orders related with customers; a warehouse management system module (20) comprising warehouse management server (21) in which information about products is kept and algorithm server (22) where planning is carried out to ensure incoming orders are collected in the fastest time and the shortest route within the warehouse; information processing device (30) that enables collection trolleys to be directed for collecting orders through the application running on it; a collection trolley (40) used for collecting orders; and a parcel collection trolley (50) used for collecting parcels in which orders are placed.

In the invention, besides the barcode information of the products, the product is measured in different sizes to ensure that the correct product is collected in the right amount. Width, length, height and weight variables are measured for each product. It is calculated upon determining the original parcel weight in pieces in order to determine the mentioned variables for each product. In order to determine the deviation rate of the weight measurement, it is measured repeatedly by using different samples from a certain number of the same product.

Within scope of the invention, it is ensured that the orders from the customer are collected in the fastest time and the shortest route within the warehouse. The products are stored in warehouse areas. Each work order from the customer is called an order. These orders are stored on the customer system server (10). Orders are prepared to be sent to the stores, suppliers and similar addresses specified by the customer. Products are collected from shelves based on orders, packed or placed on pallets. The products are placed in the warehouse by classifying them on the basis of product categories. As part of piece collection, the orders are collected in boxes according to their size and type, manually and individually.

When an order requested for forwarding is send by the customer system server (10), the products requested within the order are classified on the basis of their location in the warehouse on the warehouse management server (21). In the warehouse, the locations are numbered according to their proximity to the exit. These numbers ensure that they are aligned from largest to smallest and the closest location to be collected first before starting the collection. In order to decide which type of box to place the grouped orders, the orders grouped in the algorithm server (22) are provided with a tour algorithm so that the operator collects the order with minimal steps and without turn back.

Collecting orders are divided into two separate groups as parcel and number. For tasks with collecting orders based on parcel, the total volumes of all parcels of each order are calculated. If the total volumes of orders with collection orders based on parcels are greater than 40% of the defined pallet volume, 1 round is created for each order corresponding to one round. Parcels are aligned from smallest to largest in the first location of the products in order not to allow walking back in the collection corridors. In cases where the total volumes of orders received as parcel orders are parcels are less than 40% of the defined pallet volume, orders are aligned from largest to smallest according to location priorities. Tours are created so that 4/12/48 orders can be collected on a pallet at the same time according to the most suitable walking path.

Collection orders based on piece are divided into groups for piece collection trolley (40).

By means of the data received from the warehouse management system (20) to the computing device (30) on which the collection trolley application is running, the piece collection trolleys (40) and parcel collection trolleys (50) are directed to collect in the warehouses.

In the present invention, at first, the order data on the customer system server (10) is sent to the warehouse management system module (20). Herein, through the warehouse management system (21) server, order data is classified on the basis of their location in the warehouse. By enabling the warehouse management server (21) to interact with the algorithm server (22), planning is made to collect the classified orders with a tour algorithm with minimal steps and without return. The planning result developed in the warehouse management system module (20) is sent to the collection trolley application working on the computing device (30). The piece collection trolley (40) and parcel collection trolley (50) start collecting orders according to the collection trolley application working on the information processing device (30).

The steps for determining the parcel on the algorithm server (22) while collecting orders from customers are shown in figure 2. Firstly, collecting orders for each order are aligned from largest to smallest according to location priorities (100). Then, as long as the total volume is not larger than the largest parcel volume, order volumes are proceeded from the top of the list (105). If the largest parcel size is exceeded, the progress of the collection is stopped in the list (110). The ones up to the previous location are assigned to the smallest volume parcel larger than the total volume, these locations are removed from the list and again, unless the total volume is larger than the largest parcel volume, order volumes are collected from the top of the list and proceeded. (105). If the list is over, the smallest volume parcel greater than the volume collected so far is selected and the locations are assigned to that parcel. Then, by proceeding to the next order (115), collecting orders for each order are aligned from largest to smallest according to their location priorities, again (100). Process steps which occurs on algorithm server (22) for creating a tour while collecting orders from customers are shown in figure 3. Firstly, the parcels that are assigned in the parcel determination section of each order are aligned from largest to smallest according to the priorities of the first location. Parcels with the same first location are arranged in the list, with the last location having a higher priority (200). Thereafter, the first four parcels of the list in the first step are selected and it is assigned as the four parcels that the parcel collection trolley will fill first (205). After this process, the parcel, which is greater than or equal to the last location of our first parcel from the remaining parcels of the list, is matched as a trolley backup of the first parcel (210) and if there is no other parcel left in the list, the new trolley tour will start (215).

Claims

1. An order collecting method that allows consolidation of collection orders of each shipment fast and without human error in storage area by separating the active order information given by the customers in a logistics system on the basis of shipment characterized in that by means of a system comprising a customer system server (10) keeping orders related with customers; a warehouse management system module (20) comprising warehouse management server (21) in which information about products is kept and algorithm server (22) where planning is carried out to ensure incoming orders are collected in the fastest time and the shortest route within the warehouse; information processing device (30) that enables collection trolleys to be directed for collecting orders through the application running on it; a collection trolley (40) used for collecting orders; and a parcel collection trolley (50) used for collecting parcels in which orders are placed the method comprises the steps of sending the order data on the customer system server (10) to the warehouse management system module (20), classification of order data on the basis of their location in the warehouse through the warehouse management system server (21), planning to collect orders classified by the warehouse management server (21) interacting with the algorithm server (22) with minimal steps and without turn back via a tour algorithm, sending the planning result developed in the warehouse management system module (20) to the collection trolley application working on the information processing device (30), starting of the piece collection trolley (40) and parcel collection trolley (50) to collection of orders according to the collection trolley application working on the information processing device (30).

2. An order collecting method that allows consolidation of collection orders of each shipment fast and without human error in storage area by separating the active order information given by the customers in a logistics system on the basis of shipment according to claim 1 characterized in that the process steps for parcel determination occurring in the mentioned algorithm server (22) are alignment of collection orders from largest to smallest according to location priorities for each orders (100), progressing by collecting of order volumes from the beginning of the list unless the total volume is larger than the largest parcel volume (105), stopping the aggregation process in the list if the largest parcel size is exceeded (110) assignment of the ones up to the previous location to the smallest volume parcel larger than the total volume, removing these locations from the list and again progressing by collecting the order volumes from the top of the list unless the total volume is larger than the largest box volume (105), if the list is over, selecting the smallest volume parcel that is larger than the volume collected so far, assigning locations to this parcel and moving to the next order (115), again alignment of collection orders from largest to smallest according to the location priorities for each orders (100).

3. An order collecting method that allows consolidation of collection orders of each shipment fast and without human error in storage area by separating the active order information given by the customers in a logistics system on the basis of shipment according to claim 1 characterized in that the process steps for tour creation occurring in the mentioned algorithm server (22) are; aligning the parcels assigned to the parcel determination section of each of the orders according to the first location priorities from largest to smallest and arranging the parcels with the same first location in the list with a higher priority than the last location priority (200), selecting the first four parcels of the list ordered in the first step and assigning the collecting trolley as the first parcel to fill (205), matching of the parcel, which is greater than or equal to the last location of our first parcel from the remaining parcels of the list as a trolley back up of the first parcel (210), if there is no other parcel left in the list, the new trolley tour starts (215).

4. An order collecting method according to claim 1 characterized in that total volumes of all parcels of each order for tasks with parcel orders are calculated by means of mentioned tour algorithm.

5. An order collecting method according to one of the preceding claims characterized in that if the total volumes of orders with collection orders based on parcels are greater than 40% of the defined pallet volume, for each order, a tour is created corresponding to 1 turn.

6. An order collecting method according to one of the preceding claims characterized in that the parcels are aligned from smallest to largest in the first location of the products in order not to allow walking back in the collection corridors.

7. An order collecting method according to one of the preceding claims characterized in that the total volumes of orders with collection orders based on parcels is less than 40% of the defined pallet volume, the orders are aligned from largest to smallest according to location priorities.

8. An order collecting method according to one of the preceding claims characterized in that tours are created so that maximum 4 orders can be collected on a pallet at the same time according to the most suitable walking path.