Order-filling distribution system and method

• US 20020124389A1
• Filed: 03/01/2002
• Published: 09/12/2002
• Est. Priority Date: 03/07/2001
• Status: Abandoned Application

• Current Assignee: Kenneth D. Matson
• Original Assignee: Kenneth D. Matson
• Inventors: Matson, Kenneth D.
• Application Number:
  US10/082,537
• Publication Number:
  US 20020124389A1
• Time in Patent Office: Days
• US Class Current: 29/700
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas
• CPC Class Codes: B65G 2209/10 Partial order forming
• CPC Class Codes: Y10T 29/53 Means to assemble or disassemble

Abstract

A system and method for filling orders and distributing products. Layer quantities of products are picked in bulk, and remaining quantities of less than a full layer quantity needed to fill orders are separately picked from a pick module. Products are distributed from the layer-picking cell and the pick module to selected assembly stations for assembly into orders.

Claims

1. An order-filling system comprising:

a pallet storage area for storing at least one pallet carrying product arranged in at least one layer;

a layer-picking cell for collecting product from a pallet in layer quantities;

a pick module for picking product in less than layer quantities; and

at least one assembly station for assembling orders comprising product received from at least one of said layer-picking cell and said pick module.

2. The order-filling system of claim 1, wherein said pick module comprises at least one pick face, each pick face containing not more than a layer quantity of product.

3. The order-filling system of claim 1, further comprising means for transporting product between said pallet storage area and said layer-picking cell.

4. The order-filling system of claim 1, further comprising means for transporting product between said pick module and said assembly station.

5. The order-filling system of claim 1, further comprising means for transporting product between said layer-picking cell and said assembly station.

6. The order-filling system of claim 1, further comprising an unscrambler for distributing product from said layer-picking cell to a plurality of assembly stations.

7. The order-filling system of claim 1, wherein product remaining on pallets after discharge from said layer-picking cell is returned to said pallet storage area or transferred to said pick module.

8. The order-filling system of claim 1, further comprising means for stocking said pick module from said layer-picking cell.

9. A method of filling an order, comprising:

providing a stock of product comprising at least one layer;

layer-picking at least a portion of the order from the stock of product; and

individually picking any remainder of the order.

10. The method of claim 9, wherein multiple orders are filled simultaneously.

11. The method of claim 10, further comprising transporting layer-picked product and individually picked product to a plurality of assembly stations and assembling each order at an assembly station.

12. The method of claim 9, further comprising distributing layer-picked product to a plurality of assembly stations.

13. The method of claim 9, wherein after the step of layer-picking at least a portion of the order from the stock of product, the method further comprises selecting between:

(i) returning remaining product to a storage area; and

(ii) delivering remaining product to a pick module.

15. The method of claim 14, further comprising delivering the assembled orders to remote locations.

16. The method of claim 14, further comprising stocking the pick module from the layer picking cell.

17. The method of claim 14, further comprising delivering a pallet of product from the pallet storage area to an assembly station.

19. The distribution facility of claim 18, wherein said pick module comprises at least one pick face, each pick face containing not more than a layer quantity of product.

20. The distribution facility of claim 18, further comprising means for stocking said pick module from said layer-picking cell.

14. A method of filling multiple orders simultaneously, said method comprising:

storing a plurality of pallets at a pallet storage area, each pallet having at least one layer of product supported thereon;

delivering pallets to a layer picking cell;

layer-picking product from a pallet in layer quantities at the layer picking cell;

distributing the layer-picked product from the layer picking cell to selected assembly stations;

picking product in less than layer quantity from a pick module;

distributing product picked from the pick module to selected assembly stations; and

assembling orders from the product delivered to the assembly stations.

18. A distribution facility for filling multiple orders simultaneously, said facility comprising:

a receiving bay for receiving products;

a pallet storage area for storing a plurality of pallets, each pallet carrying product arranged in at least one layer;

a layer-picking cell for collecting products from pallets in layer quantities;

a pick module for picking products in less than layer quantities;

a plurality of assembly stations for assembling orders from product received from said layer-picking cell and said pick module;

means for distributing product from said layer-picking cell to selected assembly stations;

means for distributing product from said pick module to selected assembly stations; and

a delivery bay for discharging assembled orders.