Method and system for order fulfillment in a distribution center

• US 8,140,183 B2
• Filed: 05/06/2009
• Issued: 03/20/2012
• Est. Priority Date: 05/11/1999
• Status: Expired due to Term

• Current Assignee: JUNE RAY LIMITED
• Original Assignee: IpVenture, Inc.
• Inventors: Ham, Peter, Klots, Boris, Waddington, William Henry, Grewell, Patricia C.
• Primary Examiner(s): BURGESS, RAMYA PRAKASAM
• Application Number:
  US12/387,801
• Publication Number:
  US 20090222129A1
• Time in Patent Office: 1,049 Days
• Field of Search: 700/216
• US Class Current: 700/216
• CPC Class Codes: G06F 16/9574 of access to content, e.g. by caching
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/06311 Scheduling, planning or task assignment for a person or group
• CPC Class Codes: G06Q 10/06312 Adjustment or analysis of established resource schedule, e.g. resource or task levelling, or dynamic rescheduling
• CPC Class Codes: G06Q 10/06315 Needs-based resource requirements planning or analysis
• CPC Class Codes: G06Q 10/06316 Sequencing of tasks or work
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06Q 10/08355 Routing methods
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 20/203 Inventory monitoring
• CPC Class Codes: G06Q 30/0201 Market modelling; Market analysis; Collecting market data
• CPC Class Codes: G06Q 30/06 Buying, selling or leasing transactions
• CPC Class Codes: G06Q 30/0601 Electronic shopping [e-shopping]
• CPC Class Codes: G06Q 30/0633 Lists, e.g. purchase orders, compilation or processing
• CPC Class Codes: G06Q 30/0641 Shopping interfaces
• CPC Class Codes: H04L 67/1097 for distributed storage of data in networks, e.g. transport arrangements for network file system [NFS], storage area networks [SAN] or network attached storage [NAS]

Abstract

Order allocation techniques that reduce the number of stops that a container makes in the process of fulfilling a customer order is disclosed. In one embodiment, this is accomplished by first identifying a pod that stocks the largest number of different items in a customer order. Then, a second pod is identified that stocks the largest number of remaining items in the customer order. Ultimately, all items in the customer order are assigned a pod. The collection of pods defines a container path through the distribution center.

Claims

1. A system for a distribution center with a plurality of sites, each site having a collection of storage areas to store a plurality of items, the system comprising:

a management system configured to (a) receive and analyze at least a first customer order and a second customer order, each of the first and second customer orders indicating a plurality of items, with a quantity for each item;

(b) identify a first site with the highest number of items in the first customer order available from the first site, and a second site with the highest number of items in the second customer order available from the second site;

(c) determine the items remaining in the first end second customer orders after removing those corresponding items identified as being available from the first and the second sites;

(d) thereafter for each of the first and second customer orders, identify another site with the highest number of the items remaining in the corresponding order available from the another site; and

(e) determine the items remaining in the first and second customer orders, if any, after removing those corresponding items identified as being available from the corresponding another site; and

wherein the system for the distribution center is configured to control a plurality of conveyors in the distribution center to at least route the identified items for fulfilling the customer orders,

wherein based on the identified sites, the system determines at least a first route to fulfill the first customer order and a second route to fulfill the second customer order, with the first route going to the first site before going to the corresponding another site, and with the second route going to the second site before going to the corresponding anther site.

2. A system as recited in claim 1, wherein the management system is further configured to identify any sites that collectively provide the items remaining in the first customer order after removing all the items previously identified as being available from the plurality of sites.

3. A system as recited in claim 1, wherein the management system is further configured to repeat the operations (d) and (e) once after the operation (e).

4. A system as recited in claim 1, wherein the management system is further configured to repeat the operations (d) and (e) a plurality of times, after the operation (e).

5. A system as recited in claim 4, wherein the management system is further configured to identify any sites that collectively provide the items remaining in the first customer order after removing all the items identified as being available from the plurality of sites.

6. A system as recited in claim 1, wherein the management system is further configured to provide an indication as to the location in the first site of an item identified in the first site, so as to help manually retrieve the identified item from the first site for fulfilling the first customer order.

7. A system as recited in claim 6, wherein the indication is provided audibly to a person to manually retrieve the identified item.

8. A system as recited in claim 6, wherein the indication is provided visually to a person to manually retrieve the identified item.

9. A system as recited in claim 1, wherein the system is configured to use information from a handheld computing device via a wireless interface, with the handheld computing device being used by a person regarding movement of an identified item in the distribution center.

10. A system as recited in claim 9, wherein the handheld computing device includes a scanner to allow a person to scan information regarding the identified item.

11. A system as recited in claim 9, wherein the handheld computing device communicates via the wireless interface with another computing device regarding movement of the identified item in the distribution center.

12. A system as recited in claim 1, wherein the first route is configured for a container to follow, with the first route including a stop at the first site to have an identified item at the first site picked and placed into the container to fulfill the first customer order.

13. A system as recited in claim 12, wherein the system is configured to direct a person to manually pick the identified item to be placed into the container for fulfilling the first customer order.

14. A system as recited in claim 13, wherein the system is configured to have the container loaded onto a truck for delivering the first customer order to the customer.

15. A system as recited in claim 12, wherein the management system is further configured to alter the first route in view of a problem detected in the distribution center while the container is on its way to the first site.

16. A system as recited in claim 1,

wherein at least one site includes a carousel with a collection of storage areas to store a plurality of items, and

wherein the controller is further configured to control the carousel.

17. A system as recited in claim 16, wherein the controller is further configured to use a scanner for routing an identified item through the distribution center for fulfilling the first customer order.

18. A system as recited in claim 1,

wherein at least one site includes a carousel with a collection of storage areas to store a plurality of items, and

wherein at least one other site includes mechanical storage mechanisms to store bulkier and heavier items than items stored in the storage areas of the carousel.

19. A computer-implemented method to manage a distribution center with a plurality of sites, each site having a collection of storage areas to store a plurality of items, the method comprising:

receiving and analyzing at least a first customer order and a second customer order, each of the first an the second customer orders indicating a plurality of items, with a quantity for each item;

identifying a first site with the highest number of items in the first customer order available from the first site, and a second site with the highest number of items in the second customer order available from the second site;

determining the items remaining in the first and second customer orders after removing those corresponding items identified as being available from the first and the second sites;

thereafter for each of the first and second customer orders, identifying another site with the highest number of the items remaining in the corresponding order available from the another site;

determining the items remaining in the first and second customer orders, if any, after removing those corresponding items identified as being available from the corresponding another site; and

controlling a plurality of conveyors in the distribution center to route the identified items for fulfilling the customer orders,

wherein based on the identified sites, the method further determines at least a first route to fulfill the first customer order and a second route to fulfill the second order, with the first route going to the first site before going to the corresponding another site, and with the second route going to the second site before going to the corresponding another site.

20. A system for a distribution center with a plurality of sites, each site having a collection of storage areas to store a plurality of items, the system comprising:

a management system configured to (a) receive and analyze at least a first customer order and a second customer order, each of the first and second customer orders indicating a plurality of items, with a quantity for each item;

(b) identify a first site with the highest number of items in the first customer order available from the first site, and a second site with the highest number of items in the second customer order available from the second site;

(c) determine the items remaining in the first and second customer orders after removing those corresponding items identified as being available from the first and the second sites;

(d) thereafter for each of the first and second customer orders, identify another site with the highest number of the items remaining in the corresponding order available from the another site; and

(e) determine the items remaining in the first and second customer orders, if any, after removing those corresponding items identified as being available from the corresponding another site; and

wherein based on the identified sites, the system determines at least a first route to fulfill the first customer order and a second route to fulfill the second customer order, with the first route going to the first site before going to the corresponding another site, and with the second route going to the second site before going to the corresponding another site.