Note: Descriptions are shown in the official language in which they were submitted.
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PERPETUAL BATCH ORDER FULFILLMENT
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No.
61/863,406 filed on August 7, 2013. This application is a continuation
application of
International Application No. PCT/U52013/024308 filed on February 1, 2013. The
contents
of each of these applications are incorporated by reference in their entirety
as if fully set forth
herein.
BACKGROUND
[0002] Many industries rely on warehouses and distribution centers to store
products
and fulfill customer orders. One example is the direct-to-consumer (DTC)
market in which
consumers submit individual purchases to a vendor, such as an e-commerce
website operator,
who then relies on a distribution center for order fulfillment by direct
shipment to the
customer. At the distribution center, workers ("pickers") may locate ("pick")
ordered
products from a storage system ("pick line"), such as a series of shelves,
boxes, containers, or
the like, and place the products in a cart. The products are then packaged,
labeled and
shipped directly to the consumer.
[0003] Batch picking generally involves picking multiple orders at a time. For
instance, a picker may push a mobile cart through a warehouse to pick products
associated
with multiple orders. The mobile cart may include certain automated features,
such as
wireless radio frequency (RF) comtnunication elements, that tnay direct the
picker where to
go and what to pick in a logical walk sequence. Multiple orders ("N") may be
assigned to a
cart. Each order may be assigned a designated location on the cart, for
exatnple, based on
size or other characteristics of the ordered product. A controller (for
example, a processor,
computer, or the like) may join the orders together, making them one large
order or "batch."
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[0004] A cart may be assigned "N" orders as a batch and a picker may walk a
pick
line from a start point to an end point picking items as directed by the cart
in a walk
sequence. After the length of the pick line is completed, "N" orders are
completed. The
picker may then empty the cart, which can reloaded with "N" new orders and the
picking
process may be repeated.
[0005] In a conventional order fulfillment system, a picker or cart is
assigned a finite
set of orders that may be received at a titne (1-1)r exatnple, a cart tnay
only be able to hold
three orders). For instance, a picker may be assigned a first, a second and a
third order (i.e.,
N=3), with each order including multiple units -to be picked. The picker
starts at the starting
point of the pick line and picks the units in the set of orders as they travel
along the pick path
toward the end point of the pick path. When the first, second and third orders
are complete,
the picker may proceed back to the start, unload the orders, and repeat the
process again, for
instance, for a fourth, a fifth and a sixth order. At the end of two complete
cycles of picking,
the picker has completed six orders after walking two times around the pick
line.
[0006] One limitation of such systems is that they become progressively less
efficient
as more orders are completed. For example, if a picker starts with "N" orders
and progresses
along a route eventually completing one of the orders, the batch now becomes a
batch of only
N-1 orders. This degradation of picker efficiency continues until the batch
has only 1 order
with the remaining units of the order to be picked. Thus, at the end of one
walk through the
pick path, the picker has only picked a maximum of "N" orders.
[0007] The efficiency of the picking process may be improved by locating
warehouse
items based on their pick volume. For example, placing the most commonly
picked items
near the beginning of the pick line may improve the potential that the "N"
orders are
completed prior to walking the entire pick path, thereby allowing the picker
to return to the
start point earlier. However, the process of locating high volume itetns at
the front of the
pick line is time consutning and labor intensive, and warehouse managers are
challenged by
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moving stock around to maintain a conforming product placement arrangement.
Accordingly, a system configured to effectively and efficiently manage the
time and effort
required to complete a dynamic set of orders would be highly beneficial.
SUMMARY
[0008] This disclosure is not limited to the particular systems, devices and
methods
described, as these may vary. The terminology used in the description is for
the purpose of
describing the particular versions or embodiments only, and is not intended to
limit the scope.
[0009] As used in this document, the singular forms "a," "an," and "the"
include
plural references unless the context clearly dictates otherwise. Unless
defined otherwise, all
technical and scientific terms used herein have the same meanings as commonly
understood
by one of ordinary skill in the art. Nothing in this disclosure is to be
construed as an
admission that the embodiments described in this disclosure are not entitled
to antedate such
disclosure by virtue of prior invention. As used in this document, the term
"comprising"
means "including, but not limited to."
100101 In an embodiment, a computer-implemented method for fulfilling batch
orders
may comprise, by a processor, receiving order information associated with a
plurality of
orders, receiving order completion information from an order procuring device
responsive to
completion of an order, and assigning a new order from the plurality of orders
to the order
procurement component responsive to receiving the order completion information
[0011] In an embodiment, a batch order fulfillment system may comprise a
processor
and a non-transitory, computer-readable storage medium in operable
communication with the
processor. The computer-readable storage medium may contains one or more
programming
instructions that, when executed, cause the processor to receive order
information associated
with a plurality of orders, receive order completion information from the
order procuring
component responsive to completion of an order, and assign a new order from
the plurality of
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orders to the order procurement component responsive to receiving the order
completion
information.
100121 In an embodiment, an order procurement device may comprise a processor
and
a non-transitory, computer-readable storage medium in operable communication
with the
processor. The computer-readable storage medium may contain one or more
programming
instructions that, when executed, cause the processor to receive order
information associated
with a plurality of orders assigned to the order procurement device from an
order
management device, transmit order completion information to the order
management device
responsive to completing an order from the plurality of orders, and receive a
new order from
the order management device.
100131 In an embodiment, a computer-readable storage medium may have computer-
readable program code configured to implement an order fulfilment process. The
computer-
readable program code may comprise computer-readable program code configured
to receive
order information associated with a plurality of orders, receive order
completion information
from the order procuring component responsive to completion of an order, and
assign a new
order from the plurality of orders to the order procurement component
responsive to
receiving the order completion information
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1A-1E illustrate a method of batch order fulfillment according to
some
embodiments.
[0015] FIG. 2 illustrates various embodiments of a computing device for
implementing the various methods and processes described herein.
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DETAILED DESCRIPTION
[0016] This disclosure is not limited to the particular systems, devices and
methods
described, as these may vary. The terminology used in the description is for
the purpose of
describing the particular versions or embodiments only, and is not intended to
limit the scope.
[0017] As used in this docutnent, the singular forms "a," "an," and "the"
include
plural references unless the context clearly dictates otherwise. Unless
defined otherwise, all
-technical and scientific terms used herein have -the same meanings as
commonly understood
by one of ordinary skill in the art. Nothing in this disclosure is to be
construed as an
admission that the embodiments described in this disclosure are not entitled
to antedate such
disclosure by virtue of prior invention. As used in this document, the term
"comprising"
means "including, but not limited to."
[0018] FIGS. 1A-IE depict an illustrative order fulfillment system according
to some
embodiments. As shown in FIG. 1A, the order fulfillment system (the "system")
may incl.ude
an order management device 10 configured to manage order information
associated with a
plurality of orders having one or more units orders for the order fulfillment
system. The
system may also include an order procurement device or pick order device 20
configured to
receive order information, for example, from the order management device 10.
For example,
an order may include an order of media product units, such as books, DVDs, or
the like. In
another example, an order may include a clothing unit, such as a shirt.
Embodiments are not
limited to any particular orders and/or units, as any type of product, unit
and/or order that
may operate according to some embodiments is contemplated herein.
[0019] In an embodiment, the order management device 10 and/or the order
procurement device or pick order device 20 may include a logic device which
may generally
include a processor, a non-transitory memory or other storage device for
housing
programming instructions, data or information regarding one or more
applications, and other
hardware, including, for example, the central processing unit (CPU) 205, read
only memory
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(ROM) 210, random access memory 215, communication ports 240, controller 220,
and/or
memory device 225 depicted in FIG. 2 and described below in reference thereto.
The order
management device 10 and/or the pick order device 20 may include, without
limitation, a
server computing device, a personal computer (PC), a kiosk computing device, a
wall-
mounted computing device, a mobile computing device, such as a laptop
computer,
smartphone, personal digital assistant (PDA), tablet computing device, or any
other logic
and/or computing device now known or developed in the future. Although the
order
management device 10 and the pick order device 20 are described as separate
devices herein,
embodiments are not so limited. For example, in some embodiments, the order
management
device 10 and the pick order device 20 may be a single device, such as a
single computing
device. In such embodiments, the order management device 10 and the pick order
device 20
may include separate elements and/or hardware/software functionality of a
single device. In
another example, the order management device 10 may be a computing device
installed in or
otherwise connected to the pick order device 20.
[0020] The order management device 10 and/or the order procurement device or
pick
order device 20 (refeued to hereinafter as the "pick order device") may be
configured to
communicate using various communication protocols known to those having
ordinary skill in
the art. Illustrative and non-restrictive examples of communication protocols
include wired
and wireless communication protocols, Ethernet. infrared, Bluetooth,
universal serial
bus (USB), local area network (LAN), wide area network (WAN), and/or over the
Internet
[0021] In an embodiment, the order management device 10 may execute an order
management application configured to generate order information associated
with orders
received by the system. The order management application may be configured to
assign
orders to the pick order device 20 and to receive status information
therefrom, such as which
units and/or orders have been picked by the pick order device. The order
management
application may be configured to access unit or order information associated
with the units or
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orders (for instance, products) available within the system, such as stock
keeping units
(SKUs), radio-frequency identification (RFID) information, bar code
information, location,
number, distance between different unit locations, or the like. In this
manner, the order
management application may be configured to assign orders to the pick order
device 20 based
on the order information. For example, the order management application may
assign orders
to the pick order device 20 to minimize the distance the pick order device has
to travel to
complete an order based on the current orders assigned to the pick order
device.
[0022] The order management application may assign orders to the pick order
device
20 based on various factors (the "order assignment factors"), including,
without limitation,
travel distance and/or time ("travel costs"), random assignment, order ranking
(for example,
which orders need to be completed first), first-in-first-out, unit
characteristics (for example,
common SKU numbers), order characteristics (for example, larger orders last,
single orders
first, or the like), customer characteristics (for example, large volume
customers first, longest
shipping distance first, or the like), any other factor that may have an
effect on selecting an
order, and/or any combination thereof In some embodiments, the order
assignment factors
may include the fullness level of the pick order device 20. For example, if
the order
procurement device is full or substantially full (for instance, cannot hold
any more units or a
threshold number of units), an order may be assigned adjacent to and/or along
the path of a
completed order queue.
[0023] In some embodiments, the order management application may be configured
to assign weights or a priority to the order assignment factors. In some
embodiments, the
order management application may be configured to dynamically evaluate each
new order or
batch, for example, in view of the current set of orders and/or batches, based
on the order
assignment factors and any weighting or prioritizing thereof and assign orders
accordingly.
[0024] In some embodiments, the pick order device 20 may include a device used
by
a picker as they walk around the pick line 25 to complete orders. For example,
the pick order
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device 20 may include a mobile computing device configured to display order
information on
a display component. In some embodiments, the pick order device 20 may include
an
automated device configured to move around the pick line 25 on a track,
conveyor, on
wheels, or the like. In some embodiments, the pick order device 20 may include
an
automated cart or other device configured to automatically move through a pick
line 25 and
access units for assigned orders, with or without employee assistance (an
"automated pick
order device" or "automated order procurement device"). In some embodiments,
the pick
order device 20 may include a cart configured to be pushed by an employee
having a display
device for displaying orders. In some embodiments, the pick order device 20
may include
various elements configured to reach and grasp units to place the units in the
cart or to make
them accessible to a worker. In some embodiments, the pick order device 20 may
include
various containers, bins, or the like for storing units associated with
orders. As such, a pick
order device 20 according to some embodiments may be limited to storing a
finite number of
orders at a time.
[0025] The pick order device 20 may be configured to execute an order picking
application configured to receive order information associated with a
plurality of orders, for
example, from the order management device 10. In some embodiments, the order
picking
application may be a client application, module, routine, or other component
of the order
management application. In an embodiment, the order picking application may be
configured
to display order information, such as units associated with the order, the
sequence of the
order in relation to other orders, order identification information, or the
like. In another
embodiment, the order picking application may be configured to move or
otherwise operate
the order picking device 20 to locate a unit and/or to place a unit for
storage by the order
picking device.
[0026] As shown in FIG. IA, a pick order device 20 may be assigned a first
order 40,
a second order 45 and a third order 50. Each order 40, 45, 50 may include
multiple units to
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be picked from bins 11, 12, 13, 21, 22, 23, 31, 32, 33, 41, 42, 43, 51, 52,
53, 61, 62, 63
located within a pick line 25. From the starting point 30 to an end point 35,
the pick order
device 20 may locate units to be picked by travelling along the pick path 80,
for instance,
automatically or with the assistance of a worker, until one of the orders is
completed. In this
case, the third order 50 may be completed when an item is picked from bin 53.
Although the
pick line 25 is depicted as having a starting point 30 and an end point 35,
embodiments are
not so limited, as the pick line may not include a starting point and an end
point.
[0027] According to some embodiments, completed orders may be deposited into a
completed order queue 15, which may be located in various locations within the
system. The
completed order queue 15 include a conveyer belt, containers, platforms, or
other
components that may receive and/or process units for shipping, labelling,
processing,
inspection, packaging, or the like. As such, completed orders may be deposited
onto the
completed order queue 15 as the pick order device 20 moves about the system.
In an
embodiment, the completed order queue 15 may be accessible from various
locations from
within the system, including, without limitation, at the end of each aisle of
the pick line 25, at
the start of the pick line, at the end of the pick line, in the middle of the
pick line, or any
combination thereof
[0028] As shown in FIG. 1B, the pick order device 20 may receive order
information
assigning a new order, for example, a fourth order 65, to the pick order
device. The order
picking application may be configured to communicate order completion
information to the
order management device 10. For example, the pick order device 20 may include
or may
present on a display component buttons that may be selected by a worker to
indicate that a
unit and/or an order has been located and/or completed. For example, the
worker may select
an "order complete" or "unit complete" button, along with the entry of any
required
information when a unit is selected or an order is complete. In another
example, the pick
order device 20 may be configured to automatically detect and/or transmit the
order
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completion information to the order management device 10. For example, the
pick order
device 20 may include a component configured to manually and/or automatically
receive
information about the order, such as a bar code scanner, an RFID reader, or
the like. The
order completion information may include an order identifier, a unit
identifier, location
information (for example, a location of the pick order device 20), or the
like. The order
management application may use the order completion information to determine
that the pick
order device 20 may be able to accept a new order and may assign a new order
based on the
order information and/or the order completion information.
[0029] The pick order device 20 may continue travelling along the pick path 80
while
picking the first order 40, the second order 45 and the fourth order 55.
References herein to
the pick order device 20 may generally refer to a pick order device (such as a
cart or other
movable equipment) moving through the system (automatically or manually) or to
a worker
associated with a pick order device (such as a mobile computing device) who is
moving
within the system based on information provided by the pick order device and
may be
carrying the pick order device. In this case, the first order 40 may be
completed when an
item is picked from bin 63. Referring now to FIG. 1C, the picker 20 may be
assigned another
new order, a fifth order 70. The picker 20 may continue to travel along the
pick path 80
while picking the second order 45, the fourth order 55, and the fifth order 60
until one of the
orders is completed. The second order 45 may be completed when an item is
picked from bin
62. As shown in FIG. 1D, the picker 20 may be assigned a sixth order 65 and
may continue
travelling along the pick path 80 while picking the fourth order 55, the fifth
order 60, and the
sixth order 65 until one of the orders is completed. The fourth order 55 may
be completed
when an item is picked from bin 12. The picker 20 may be assigned a seventh
order 70
responsive to completion of the fourth order 55 as depicted in FIG. 1E. The
picker 20 may
continue travelling along the pick path 80 while picking the fifth order 60,
the sixth order 65
and the seventh order 70. At the end of two complete cycles through the pick
line 25
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according to some embodiments as depicted in FIGS. 1A-1E, the picker 20 may be
able to
complete at least seven orders 40, 45, 50, 55, 60, 65, 70 after walking two
times around the
pick path.
[0030] According to some embodiments, units may be selected by the pick order
device 20 in any sequence, such as a sequence that minimizes the travel costs
associated with
picking the orders. For example, the pick order device 20 may pick the units
for one order to
the exclusion of units for other orders, that is, working on one order at a
time before moving
on to the next order). In another example, the pick order device 20 may be
configured to
select the next available unit regardless of the order.
[0031] The order management application may be configured to use the order
information (for example, the location of each unit), the order information
(for example,
which units are in each order, which orders are assigned to the pick order
device 20), and/or
the location of the pick order device to determine which order to assign to
the pick order
device 20. The order management application may calculate travel costs for
each order
dynamically at any point in time based on the order information, the order
information, and
the location of the pick order device 20. In some embodiments, the order
management
application may assign new orders based on the next available order with the
lowest travel
costs (for example, the lowest travel distance and/or travel time). In some
embodiments, the
order management application may assign new orders based on the lowest travel
costs and the
order assignment factors.
[0032] In an embodiment, the order management application may receive
information
associated with the load of the pick order device 20, including any single
unit compartments
as described below, having a finite number of storage locations for units. In
such an
embodiment, the order management application and/or the order picking
application may
monitor the load of the pick order device 20. As such, the order management
application
may assign an order based on the pick order device 20 proximity to a completed
order queue
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15. As such, the order management application may assign an order such that
the order
picking device 20 may travel toward the unit on the way to a completed order
queue 15 to
unload completed orders. In an embodiment, the order management application
may handle
orders in which the number of units for the order is greater than the number
of available
compartments for the order picking device 20. In such an embodiment, the order
management application may configure the order such that the order picking
device 20 is in
proximity to a completed order queue 15 when the available compartments are
full of the
units so that the order picking device 20 may efficiently handle the order.
[0033] The "perpetual batch" system depicted in FIGS. 1A-1E provides for order
completion and new order assignment at varying points along the pick line 25
such that the
pick order device 20 and the overall order fulfillment process maintains
efficiency as orders
are completed. As such, a pick order device 20 or a worker with a pick order
device may
complete more orders than a conventional system while traversing the same
distance. In
addition, a pick order device 20 or a worker with a pick order device may be
able to move
through the system with a continuous supply of orders.
[0034] It will be understood that the above described method is one embodiment
and
that the systems and methods of batch order fulfillment described herein may
include
variations from the above description as well as additional features, some of
which are
described below.
[0035] Although the system depicted in FIGS. 1A-1E shows a pick line 20 having
bins 11, 12, 13, 21, 22, 23, 31, 32, 33, 41, 42, 43, 51, 52, 53, 61, 62, 63
arranged in aisles
having a start point 30 and an end point 35, embodiments are not so limited as
any other type
of arrangement that may operate according to some embodiments is contemplated
herein. In
some embodiments, a physical pick line 20 consisting of aisles may be
conceptualized by the
order picking application and/or the order management application as other
types of
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configurations, such as circles, squares, or the like. In some embodiments,
the pick line 20
may not have a designated start point 30 and/or end point 35.
[0036] For example, the pick line 20 depicted in FIGS. 1A-1E may be
conceptualized
as a virtual "circle". The pick line 20 represents a pick path 80 that ends
where it begins, and
thus the pick line can be exploded into a theoretical circle. Each pick
location in the pick line
may be represented in degrees or radians on a circle of circumference 'C,
where "C"
represents the distance required to travel the entire pick path. Each location
may represent a
specific angle on this circle. The distance between pick locations may then be
represented by
the difference between the current location angle on the circle and the angle
of the pick
location(s).
[0037] When no orders are assigned to a batch, the system, through the order
management device 10, may review every order in a queue of pending orders and
determine a
distance factor based on the current location of the pick order device 20. The
distance factor
may represent the distance along the pick path 20 required to complete the
order from the
current location of the pick order device 20 on the pick path. According to
some
embodiments, the order with the lowest distance factor may be added to the
batch.
[0038] In the case of a pick order device 20 with no orders configured to
handle "N"
orders, the "N" orders with the smallest distance factor may be added to the
batch, for
example, based on their rankings from shortest to longest. Thus, the first
order 40 would be
the order with the smallest distance to travel from the current location and
thus would be the
first order to be completed. Accordingly, the third order 50 would not be
completed before
first order, as was described in the description of FIGS. 1A-1E above. In an
embodiment, the
direction of movement around the pick circle may be in the same direction. In
such an
embodiment, orders are selected such that the pick order device 20 does not
move backward
on the pick line 25. In another embodiment, the pick order device 20 may move
in more than
one direction around the pick circle.
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[0039] In an embodiment in which the system includes a start point 30 and an
end
point 35, the pick order device 20 may be configured or instructed (for
example, by the order
picking application) to move from the start point forward toward the end
point. In an
embodiment, when the pick order device 20 reaches the end point 35 or the last
unit in the
pick line 25 before the end point the pick order device may reverse direction
and move in a
direction toward the start point 30. In such an embodiment, the start point 30
and the end
point 35 effectively switch with each pass through the pick line 25. In
another embodiment,
when the pick order device 20 reaches the end point 35 or the last unit in the
pick line 25
before the end point, the pick order device may return to the start point and
traverse the pick
line again in a direction toward the end point.
[0040] The order management application may be configured to assign orders to
the
pick order device 20 in order to minimize travel costs based on the travel
pattern of the pick
order device through the pick line, such as the two travel patterns described
above. Referring
to FIG. 1A, if the pick order device 20 has reached the end point 35, the
order management
application may assign an order having a unit at bin 11 if the pick order
device is configured
or instructed to return to the start point 30 and move in a direction toward
the end point. In
contrast, if the pick order device is configured or instructed to move in a
direction toward the
start point 30 from the end point 35, the order management application may be
configured to
assign an order with a unit in bin 51.
[0041] Once the pick order device 20 is in operation and new orders are being
assigned to the batch, it is possible for newly added orders to be completed
before older
orders. According to some embodiments, the set of assigned orders is
dynamically changing
based on orders being received from customers throughout the day and, as such,
the pending
pool of orders is dynamic and not a fixed order queue.
[0042] According to some embodiments, the pick order device 20 may be
configured
as a radio frequency (RF) device and/or cart ("RF cart"). In an embodiment,
the RF cart may
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be a paperless order fulfillment system that utilizes hardware mounted to a
mobile cart. An
RF cart may provide a method of picking multiple orders at a time on a single
pass through
the warehouse, making order pickers more accurate and productive. An RF cart
may be
computer controlled and communicate with a centralized computer system, such
as the order
management device 10, via an RF network, providing real-time response and
reporting. The
system may be configured to direct pickers to warehouse pick locations in the
most efficient
route, minimizing walk distance while fulfilling multiple orders at once.
However, as
described above, embodiments are not limited to RF carts, as any type of pick
order device
configured to opeate according to some embodiments is contemplated herein,
including RF
terminals, voice recognition systems, or pick sleds that travel on tracks or
conveyer systems.
[0043] The pick order device 20 may operate as a guidance system that directs
the
picker to units in a logical travel sequence that generally minimizes a travel
time and/or
distance of the pick order device 20. The guidance system may include a system
for directing
the pick order device 20 or a worker associated with the pick order device,
for example,
audibly or visually. In an embodiment, the pick order device 20 may include a
system for
controlling the movement of a vehicle or cart associated with a the pick order
device or a
worker associated with the pick order device may control the movement of the
pick order
device.
[0044] In an embodiment, the order management application may control the
picking
process to create batches of orders for the pick order device 20. In an
embodiment, the orders
may be assigned randomly or by using commonality algorithms. In another
embodiment, the
orders may be assigned based on, among other things, an increase in the travel
time resulting
from assigning the new order to the picker, the minimum travel distance and/or
time from the
current point on the pick path, or a combination thereof Accordingly, the
order management
application may assign orders to the pick order device 20 based on finding
orders that can be
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completed with a minimum amount of travel from the current pick order device
position or
from the last picked item position.
[0045] In an embodiment, the pick line 25 may not include a dedicated start
point 30
and/or end point 35. In such an embodiment, a plurality of pick order devices
20 may be
scattered at various locations throughout a pick line 25. The order management
application
may be configured to assign orders with such a distribution of pick order
devices 20 to avoid
collision and passing requirements necessitated when multiple pickers are
traversing a pick
line simultaneously. In the case of multiple pick order devices 20, at the
beginning of the
picking process, for each cart in the system, the order management application
may select
"N" orders corresponding to the number of order locations on the cart and/or
on the "N"
orders that can be completed in the shortest travel distance or shortest
travel time ("travel
costs"). The pick order device 20 may procure units until an order is
complete. The order
may be removed and placed in a completed order queue, either on the cart, or
on a conveyor
that transports the order to a shipping area. The order management application
may then
determine, from all available orders, the order which may be completed in the
least travel
distance or least travel time ("lowest travel cost order"). The lowest travel
cost order may be
assigned to the freed location and picking continues. The process of replacing
completed
orders with new orders that can be picked with the lowest travel costs may
continue, for
example, until all orders are completed. Accordingly, "M" pick order devices
20 are always
picking "N" orders at a time
[0046] According to some embodiments, the system may be configured to handle
"single unit orders." In many direct-to-consumer (DTC) order fulfillment
operations, the
order quantity is often a single unit. In an embodiment, a single storage
location on the pick
order device 20 and/or cart, sled, or the like associated with the pick order
device may be
dedicated to receiving single orders. Any order in the system that is a single
unit may be
dynamically assigned to each individual batch if that item resides between the
current
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location on the pick line 25 and the next batch pick location. In an
embodiment, single unit
orders may be added to any pick order device 20 and/or cart, sled, or the like
associated with
the pick order device that is passing or is within a threshold distance from
passing pick line
25 location where the single unit is being stored. In an embodiment, when the
single unit
order location on the pick order device 20 and/or cart, sled, or the like
associated with the
pick order device fills, the single unit orders may be removed and sent to a
secondary
processing station where each item is removed and assigned to an order
dynamically. As
each of these orders is completed as a single unit, no order integrity is
required until it arrives
at the secondary processing (shipping) station.
[0047] In an example of single unit order shipping, a bin, box, or other
storage
medium containing batch picked single unit orders may be removed from a pick
order device
20 and/or cart, sled, or the like associated with the pick order device and
delivered to a
shipping station. This station may include a computer, monitor (often touch
screen), bar code
scanner, label printer, and a scale. Since every item in the storage medium
represents a
unique and individual order, each item is a shipment in itself An operator
and/or automated
equipment at the shipping station may remove a unit from the container, scan
the unit with an
identifying bar code, places the unit into a shipping container or envelope,
and places the
item on a scale. A shipping application, which may include or may communicate
with the
order management application, may find a pending (queued) order that required
only that
item (for example, based on the SKU) from its database, calculate shipping
costs, and print
both a shipping label and a packing slip for that order.
[0048] The term "walking" or "walk" as used herein may generally refer to
picking
operations, for example, because picking operations often include carts that
are pushed
through a pick line manually, and hence, the picker is walking. Embodiments
are not limited
to circumstances where carts are used or where walking is required as
embodiments apply to
any situation that utilizes any form of batch picking, whether automated or
manual. Also,
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embodiments are not limited to the use of batch pick carts, as any other type
of component or
device may be used according to some embodiments provided herein, for example,
a
conveyor, automatic guided vehicle, conveyed sled, or other suitable
transportation device.
[0049] According to some embodiments, a batch fulfillment system may include a
loop sorter including a component for moving units for placement in a set of
boxes. In a
conventional loop sorter, the boxes are removed from the loop sorting area
responsive to a
threshold number of the boxes being filled. Typically, the boxes are not
removed until all of
them are full. As such, there are transaction costs when the number of boxes
available
descends toward the threshold and, in many cases, the system must stop or slow
down to
allow for the removal of the boxes. In an embodiment, as each box and/or each
set of boxes
associated with an order is filled a signal is sent to the order management
application to
remove the box. In this manner, a "perpetual" loop sorter may be configured in
which there
are a number of available boxes that equals or substantially equals the number
of boxes in the
set.
[0050] FIG. 2 depicts a block diagram of exemplary internal hardware that may
be
used to contain or implement the various computer processes and systems as
discussed above.
A bus 200 serves as the main information highway interconnecting the other
illustrated
components of the hardware. CPU 205 is the central processing unit of the
system,
performing calculations and logic operations required to execute a program.
CPU 205, alone
or in conjunction with one or more of the other elements disclosed in FIG. 2,
is an exemplary
processing device, computing device or processor as such terms are used within
this
disclosure. Read only memory (ROM) 230 and random access memory (RAM) 235
constitute exemplary memory devices.
[0051] A controller 220 interfaces with one or more optional memory devices
225 to
the system bus 200. These memory devices 225 may include, for example, an
external or
internal DVD drive, a CD ROM drive, a hard drive, flash memory, a USB drive or
the like.
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As indicated previously, these various drives and controllers are optional
devices.
Additionally, the memory devices 225 may be configured to include individual
files for
storing any software modules or instructions, auxiliary data, common files for
storing groups
of results or auxiliary, or one or more databases for storing the result
information, auxiliary
data, and related information as discussed above. For example, the memory
devices 225 may
be configured to store judicial information source 215.
[0052] Program instructions, software or interactive modules for performing
any of
the functional steps associated with the steps, applications, or the like
described above may
be stored in the ROM 230 and/or the RAM 235. Optionally, the program
instructions may be
stored on a tangible computer-readable medium such as a compact disk, a
digital disk, flash
memory, a memory card, a USB drive, an optical disc storage medium, such as a
Blu-rayTM
disc, and/or other recording medium.
[0053] An optional display interface 230 may permit information from the bus
200 to
be displayed on the display 235 in audio, visual, graphic or alphanumeric
format. The
information may include information related to a current job ticket and
associated tasks.
Communication with external devices may occur using various communication
ports 240.
An exemplary communication port 240 may be attached to a communications
network, such
as the Internet or a local area network.
[0054] The hardware may also include an interface 245 which allows for receipt
of
data from input devices such as a keyboard 250 or other input device 255 such
as a mouse, a
joystick, a touch screen, a remote control, a pointing device, a video input
device and/or an
audio input device.
[0055] In the above detailed description, reference is made to the
accompanying
drawings, which form a part hereof In the drawings, similar symbols typically
identify
similar components, unless context dictates otherwise. The illustrative
embodiments
described in the detailed description, drawings, and claims are not meant to
be limiting.
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Other embodiments may be used, and other changes may be made, without
departing from
the spirit or scope of the subject matter presented herein. It will be readily
understood that
the aspects of the present disclosure, as generally described herein, and
illustrated in the
Figures, can be arranged, substituted, combined, separated, and designed in a
wide variety of
different configurations, all of which are explicitly contemplated herein.
[0056] The present disclosure is not to be limited in terms of the particular
embodiments described in this application, which are intended as illustrations
of various
aspects. Many modifications and variations can be made without departing from
its spirit and
scope, as will be apparent to those skilled in the art. Functionally
equivalent methods and
apparatuses within the scope of the disclosure, in addition to those
enumerated herein, will be
apparent to those skilled in the art from the foregoing descriptions. Such
modifications and
variations are intended to fall within the scope of the appended claims. The
present
disclosure is to be limited only by the terms of the appended claims, along
with the full scope
of equivalents to which such claims are entitled. It is to be understood that
this disclosure is
not limited to particular methods, reagents, compounds, compositions or
biological systems,
which can, of course, vary. It is also to be understood that the terminology
used herein is for
the purpose of describing particular embodiments only, and is not intended to
be limiting.
[0057] With respect to the use of substantially any plural and/or singular
terms herein,
those having skill in the art can translate from the plural to the singular
and/or from the
singular to the plural as is appropriate to the context and/or application.
The various
singular/plural permutations may be expressly set forth herein for sake of
clarity.
[0058] It will be understood by those within the art that, in general, terms
used herein,
and especially in the appended claims (for example, bodies of the appended
claims) are
generally intended as "open" terms (for example, the term "including" should
be interpreted
as "including but not limited to," the term "having" should be interpreted as
"having at least,"
the term "includes" should be interpreted as "includes but is not limited
to"). While various
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compositions, methods, and devices are described in terms of "comprising"
various
components or steps (interpreted as meaning "including, but not limited to"),
the
compositions, methods, and devices can also "consist essentially of" or
"consist of" the
various components and steps, and such terminology should be interpreted as
defining
essentially closed-member groups. It will be further understood by those
within the art that if
a specific number of an introduced claim recitation is intended, such an
intent will be
explicitly recited in the claim, and in the absence of such recitation no such
intent is present.
For example, as an aid to understanding, the following appended claims may
contain usage of
the introductory phrases "at least one" and "one or more" to introduce claim
recitations.
However, the use of such phrases should not be construed to imply that the
introduction of a
claim recitation by the indefinite articles "a" or "an" limits any particular
claim containing
such introduced claim recitation to embodiments containing only one such
recitation, even
when the same claim includes the introductory phrases "one or more" or "at
least one" and
indefinite articles such as "a" or "an" (for example, "a" and/or "an" should
be interpreted to
mean "at least one" or "one or more"); the same holds true for the use of
definite articles used
to introduce claim recitations. In addition, even if a specific number of an
introduced claim
recitation is explicitly recited, those skilled in the art will recognize that
such recitation
should be interpreted to mean at least the recited number (for example), the
bare recitation of
"two recitations," without other modifiers, means at least two recitations, or
two or more
recitations). Furthermore, in those instances where a convention analogous to
"at least one of
A, B, and C, et cetera" is used, in general such a construction is intended in
the sense one
having skill in the art would understand the convention (for example, "a
system having at
least one of A, B, and C" would include but not be limited to systems that
have A alone, B
alone, C alone, A and B together, A and C together, B and C together, and/or
A, B, and C
together, et cetera). In those instances where a convention analogous to "at
least one of A, B,
or C, et cetera" is used, in general such a construction is intended in the
sense one having
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skill in the art would understand the convention (for example, "a system
having at least one
of A, B, or C" would include but not be limited to systems that have A alone,
B alone, C
alone, A and B together, A and C together, B and C together, and/or A, B, and
C together, et
cetera). It will be further understood by those within the art that virtually
any disjunctive
word and/or phrase presenting two or more alternative terms, whether in the
description,
claims, or drawings, should be understood to contemplate the possibilities of
including one of
the terms, either of the terms, or both terms. For example, the phrase "A or
B" will be
understood to include the possibilities of "A" or "B" or "A and B."
[0059] In addition, where features or aspects of the disclosure are described
in terms
of Markush groups, those skilled in the art will recognize that the disclosure
is also thereby
described in terms of any individual member or subgroup of members of the
Markush group.
[0060] As will be understood by one skilled in the art, for any and all
purposes, such
as in terms of providing a written description, all ranges disclosed herein
also encompass any
and all possible subranges and combinations of subranges thereof Any listed
range can be
easily recognized as sufficiently describing and enabling the same range being
broken down
into at least equal halves, thirds, quarters, fifths, tenths, or the like. As
a non-limiting
example, each range discussed herein can be readily broken down into a lower
third, a middle
third, and an upper third. As will also be understood by one skilled in the
art all language
such as "up to," "at least," and the like include the number recited and refer
to ranges which
can be subsequently broken down into subranges as discussed above. Finally, as
will be
understood by one skilled in the art, a range includes each individual member.
Thus, for
example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells.
Similarly, a group
having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.
[0061] Various of the above-disclosed and other features and functions, or
alternatives thereof, may be combined into many other different systems or
applications.
Various presently unforeseen or unanticipated alternatives, modifications,
variations or
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improvements therein may be subsequently made by those skilled in the art,
each of which is
also intended to be encompassed by the disclosed embodiments.
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