Method and system for assembling pallets for stock orders

• US 20080199297A1
• Filed: 07/25/2007
• Published: 08/21/2008
• Est. Priority Date: 02/16/2007
• Status: Active Grant

• Current Assignee: Dematic Corporation
• Original Assignee: Dematic Corporation
• Inventors: Ferrigni, Max Francis, Grunbach, Adrian Alexander
• Granted Patent: US 7,877,164 B2
• Time in Patent Office: Days
• US Class Current: 414/802
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

A method of assembling pallets 14, 20, 28 containing first stock units 50 for use in the fulfilment of stock orders, the method comprising the steps of providing a plurality of first pallets 14 each containing a quantity of the first stock units 50 and moving a portion of the first stock units 50 from at least one of the first pallets 14 onto one or more second pallets 20 in establishing desired quantities of the first stock units 50 in the first and second pallets 14, 20 for use in the fulfilment of the stock orders. In one form, the sequence of order fulfilment is controlled to increase the quantity of first stock units on the first pallets used in fulfilling the stock orders. A distribution system and control system is also disclosed.

Claims

1. A method of assembling pallets containing first stock units for use in the fulfilment of stock orders, the method comprising the steps of:

(a) providing a plurality of first pallets each containing a quantity of the first stock units; and

(b) moving a portion of the first stock units from at least one of the first pallets onto one or more second pallets in establishing desired quantities of the first stock units in the first and second pallets for use in the fulfilment of the stock orders.

2. A method according to claim 1, further comprising the steps of:

(c) using a plurality of said first pallets in assembling said stock pallets and;

(d) moving a portion of the first stock units from a plurality of the first pallets onto at least one of the second pallets.

3. A method according to claim 1, wherein the desired quantity of the first stock units is established in the first and second pallets in a predetermined sequence.

4. A method according to claim 3, further comprising the step of controlling the predetermined sequence to increase the quantity of first stock units on the first pallets used in fulfilling the stock orders.

5. A method according to claim 3, wherein the predetermined sequence is controlled by arranging the stock orders into sub groups where the combined quantity of the first stock units in the sub groups is close to a predetermined value.

6. A method according to claim 5, wherein the predetermined value is the initial quantity of first stock units on the first pallets.

7. A method according to claim 1, wherein the orders are in respect of pallets containing mixed stock and the method further comprises the step of loading at least one second stock unit onto both the first and second pallets to form a plurality of assembled mixed stock unit pallets.

8. A method according to claim 7, wherein the assembled mixed stock unit pallets each have a required quantity of first and second stock units.

9. A method according to claim 8, wherein the required quantities of first stock units are substantially greater than any one of the required quantities of the at least one second stock units.

10. A method according to claim 1, wherein the first pallets are provided as full pallets.

11. A method according to claim 1, wherein at least one of the second pallet is provided initially in an empty state.

12. A distribution system comprising:

a plurality of first pallets each containing a quantity of first stock units;

a plurality of second pallets arranged to receive the first stock units; and

a control system operative to issue instructions on the transfer of first stock units from the first pallets to the second pallets so as to establish desired quantities of the first stock units in the first and second pallets for use in the fulfilment of stock orders.

13. A distribution system according to claim 12, wherein the control system is arranged to issue instructions by any one or more of paper pick slips, voice commands and/or by indicators.

14. A distribution system according to claim 12, wherein the control system creates a predetermined sequence to establish the desired quantity of the first stock units in the first and second pallets.

15. A distribution system according to claim 12, wherein the predetermined sequence is created to increase the quantity of first stock units on the first pallets used in fulfilling the stock orders.

16. A distribution system according to claim 13, wherein the predetermined sequence is created by arranging the stock orders into sub groups where the combined quantity of the first stock units in the sub groups is close to a predetermined value.

17. A distribution system according to claim 16, wherein the predetermined value is the initial quantity of first stock units on the first pallets.

18. A control system for use in a distribution system according to claim 12.

19. A method of controlling the sequence of assembly of a batch of orders for a plurality of pallets containing a desired quantity of a first stock unit;

the method comprising the steps of;

(a) arranging the stock orders into sub groups where the combined quantity of the first stock units in the sub groups is close to a predetermined value; and

(b) sequencing the assembly of the pallets based on those sub groups.

20. A method according to claim 19, wherein, the predetermined value is equal to the initial quantity of the first stock units on a first pallet.