Managing throughput for multiple processes in a materials handling facility

• US 9,129,247 B2
• Filed: 05/26/2010
• Issued: 09/08/2015
• Est. Priority Date: 05/26/2010
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Inventors: Hara, Yusuke, Alyea, Joseph M., Wong, Cherie G.
• Primary Examiner(s): Rines, David
• Assistant Examiner(s): Puri, Venay
• Application Number:
  US12/788,117
• Publication Number:
  US 20110295644A1
• Time in Patent Office: 1,931 Days
• Field of Search: 705/7.216
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/06315 Needs-based resource requirements planning or analysis
• CPC Class Codes: G06Q 10/0639 Performance analysis of employees; Performance analysis of enterprise or organisation operations
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

Various embodiments of a system and method for process management in a materials handling facility are described. Embodiments may include a process control component configured to generate a model of multiple unit handling processes of a materials handling facility. For each process, the model may indicate a measured throughput rate. The process control component may be configured to, based on at least one target output rate that is a goal for the output rate of a given unit handling process, evaluate the model to generate a particular target throughput rate that is a goal for the respective throughput rate of a particular unit handling process that is performed prior to the given unit handling process. The process control component may be configured to, based on the particular target throughput rate, generate one or more instructions to control the respective throughput rate of units processed by the particular unit handling process.

Claims

1. A computing system, comprising:

a memory; and

one or more processors coupled to the memory, wherein the memory comprises program instructions executable by the one or more processors to implement a process control component configured to;

generate within the memory a stored model of multiple unit handling processes of a materials handling facility, wherein for each unit handling process the model indicates a measured throughput rate at which that unit handling process processes units, wherein at least some of the multiple unit handling processes are different types of downstream unit handling processes that are downstream from a storage buffer and process units obtained from the storage buffer in order to prepare shipments of units to be shipped from the materials handling facility, wherein at least another one or more of the multiple unit handling processes is an upstream unit handling process that is upstream from the storage buffer and provides units to the storage buffer, wherein the upstream unit handling process provides units that are bound for the different types of downstream unit handling processes, and wherein each unit is bound for a particular one of the different types of downstream unit handling processes;

based on at least one target output rate that is a goal for the output rate of a given type of downstream unit handling process of the multiple unit handling processes, evaluate the model to generate a particular target throughput rate that is a goal for the respective throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process; and

based on the particular target throughput rate generated for the upstream unit handling process, generate one or more instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process.

2. The computing system of claim 1, wherein the one or more instructions that are generated include one or more instructions to control a rate at which units bound for the given type of downstream unit handling process are picked from inventory.

3. The computing system of claim 1, wherein the process control component is configured to:

for a first time period subsequent to the generation of said one or more instructions, evaluate the model to determine that the measured throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process during that first time period deviates from the particular target throughput rate; and

in response to that determination, generate a second target throughput rate for the upstream unit handling process for units bound for the given type of downstream unit handling process, the second target throughput rate to be utilized for one or more subsequent time periods after the first time period; and

based on the second target throughput rate, generate one or more additional instructions to control the throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process during said one or more subsequent time periods.

4. The computing system of claim 3, wherein the second target throughput rate is generated such that an average of the measured throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process during the first time period and the second target throughput rate utilized during said one or more subsequent time periods is equal to the particular target throughput rate for the upstream unit handling process for units bound for the given type of downstream unit handling process.

5. The computing system of claim 3, wherein after the one or more subsequent time periods, the process control component is configured to utilize the particular target throughput rate again to generate one or more instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process.

6. The computing system of claim 1, wherein the stored model further indicates units that are part of different collections of units, wherein at least some of said unit handling processes move items from one collection of units to another collection of units.

7. The computing system of claim 6, wherein the process control component is configured to:

evaluate the model to determine that a quantity of units within one of said collections of units has reached a threshold, wherein the units of the quantity of units are bound for the given type of downstream unit handling process; and

in response to that determination, modify the particular target throughput rate, and based on the modified target throughput rate, generate one or more additional instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process.

8. The computing system of claim 6, wherein the process control component is configured to:

evaluate the model to determine that a quantity of units within one of said collections of units has reached a threshold; and

in response to that determination, generate one or more of;

an alert message to alert an agent that the threshold has been reached, or a recommendation message to provide a recommendation for modifying the quantity of units within the respective collection of units.

9. The computing system of claim 8, wherein said recommendation indicates a change in a quantity of labor staffed on one or more of said unit handling processes.

10. The system of claim 6, wherein the storage buffer is a random access storage buffer, and wherein the units of at least one of said collections of units are stored within the random access storage buffer comprising multiple unit locations.

11. The computing system of claim 1, wherein the multiple unit handling processes include one or more of:

a picking process to pick units from one or more inventory locations;

a conveyance process to convey units from one location of the materials handling facility to another location of the materials handling facility;

an induction process for moving units into a random access storage buffer compressing multiple unit locations;

or

a packing process during which one or more units received from the random access storage buffer are packed into respective shipping containers to be shipped from the materials handling facility.

12. The computing system of claim 1, wherein the at least one target output rate for the given type of downstream unit handling process is based on:

a rate at which units are expected to be packed into shipments prior to being shipped from the materials handling facility or a rate at which shipments are expected to be processed within the materials handling facility.

13. A method, comprising:

performing, by one or more computing devices implementing a process control component for a materials handling facility;

generating within a memory accessible to the process control component a model of multiple unit handling processes of the materials handling facility, wherein for each unit handling process the model indicates a measured throughput rate at which that unit handling process processes units, wherein at least some of the multiple unit handling processes are different types of downstream unit handling processes that are downstream from a storage buffer and process units obtained from the storage buffer in order to prepare shipments of units to be shipped from the materials handling facility, wherein at least another one or more of the multiple unit handling processes is an upstream unit handling process that is upstream from the storage buffer and provides units to the storage buffer, wherein the upstream unit handling process provides units that are bound for the different types of downstream unit handling processes, and wherein each unit is bound for a particular one of the different types of downstream unit handling processes;

based on at least one target output rate that is a goal for the output rate of a given type of downstream unit handling process of the multiple unit handling processes, evaluating the model to generate a particular target throughput rate that is a goal for the respective throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process; and

based on the particular target throughput rate generated for the upstream unit handling process, generating one or more instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process.

14. The method of claim 13, wherein the one or more instructions include one or more instructions to control a rate at which units bound for the given type of downstream unit handling process are picked from inventory.

15. The method of claim 13, wherein the method comprises:

for a first time period subsequent to the generation of said one or more instructions, evaluating the model to determine that the measured throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process during that first time period deviates from the particular target throughput rate; and

in response to that determination, generating a second target throughput rate for the upstream unit handling process for units bound for the given type of downstream unit handling process, the second target throughput rate to be utilized for one or more subsequent time periods after the first time period; and

based on the second target throughput rate, generating one or more additional instructions to control the throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process during said one or more subsequent time periods.

16. The method of claim 15, wherein the second target throughput rate is generated such that an average of the measured throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process during the first time period and the second target throughput rate utilized during said one or more subsequent time periods is equal to the particular target throughput rate for the upstream unit handling process for units bound for the given type of downstream unit handling process.

17. The method of claim 15, wherein subsequent to the one or more subsequent time periods, the method comprises utilizing the particular target throughput rate again to generate one or more instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process processed by the upstream unit handling process.

18. The method of claim 13, wherein the stored model further indicates units that are part of different collections of units, wherein at least some of said unit handling processes move items from one collection of units to another collection of units.

19. The method of claim 18, wherein the method comprises:

evaluating the model to determine that a quantity of units within one of said collections of units has reached a threshold, wherein the units of the quantity of units are bound for the given type of downstream unit handling process; and

in response to that determination, modifying the particular target throughput rate, and based on the modified target throughput rate, generating one or more additional instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process processed by the upstream unit handling process.

20. The method of claim 18, wherein the method comprises:

evaluating the model to determine that a quantity of units within one of said collections of units has reached a threshold; and

in response to that determination, generating one or more of;

an alert message to alert an agent that the threshold has been reached, or a recommendation message to provide a recommendation for modifying the quantity of units within the respective collection of units.

21. The method of claim 20, wherein said recommendation indicates a change in a quantity of labor staffed on one or more of said unit handling processes.

22. The method of claim 18, wherein the storage buffer is a random access storage buffer, and wherein the units of at least one of said collections of units are stored within the random access storage buffer comprising multiple unit locations.

23. The method of claim 13, wherein the multiple unit handling processes include one or more of:

a picking process to pick units from one or more inventory locations;

a conveyance process to convey units from one location of the materials handling facility to another location of the materials handling facility;

an induction process during which units are moved into a random access storage buffer compressing multiple unit locations;

or

a packing process during which one or more units received from the random access storage buffer are packed into respective shipping containers to be shipped from the materials handling facility.

24. The method of claim 13, wherein the at least one target output rate for the given type of downstream unit handling process is based on:

a rate at which units are expected to be packed into shipments prior to being shipped from the materials handling facility or a rate at which shipments are expected to be processed within the materials handling facility.

25. A non-transitory computer-readable storage medium, storing program instructions computer-executable on a computer system to implement a process control component configured to:

generate within a memory a stored model of multiple unit handling processes of a materials handling facility, wherein for each unit handling process the model indicates a measured throughput rate at which that unit handling process processes units, wherein at least some of the multiple unit handling processes are different types of downstream unit handling processes that are downstream from a storage buffer and process units obtained from the storage buffer in-order to prepare shipments of units to be shipped from the materials handling facility, wherein at least another one or more of the multiple unit handling processes is an upstream unit handling process that is upstream from the storage buffer and provides units to the storage buffer, wherein the upstream unit handling process provides units that are bound for the different types of downstream unit handling processes, and wherein each unit is bound for a particular one of the different types of downstream unit handling processes;

based on at least one target output rate that is a goal for the output rate of a given type of downstream unit handling process of the multiple unit handling processes, evaluate the model to generate a particular target throughput rate that is a goal for the respective throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process; and

based on the particular target throughput rate generated for the upstream unit handling process, generate one or more instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process.

26. The non-transitory computer-readable storage medium of claim 25, wherein the one or more instructions include one or more instructions to control a rate at which units bound for the given type of downstream unit handling process are picked from inventory.

27. The non-transitory computer-readable storage medium of claim 25, wherein the process control component is configured to:

for a first time period subsequent to the generation of said one or more instructions, evaluate the model to determine that the measured throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process during that first time period deviates from the particular target throughput rate; and

in response to that determination, generate a second target throughput rate for the upstream unit handling process for units bound for the given type of downstream unit handling process, the second target throughput rate to be utilized for one or more subsequent time periods after the first time period; and

based on the second target throughput rate, generate one or more additional instructions to control the throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process during said one or more subsequent time periods.

28. The non-transitory computer-readable storage medium of claim 27, wherein the second target throughput rate is generated such that an average of the measured throughput rate of the upstream unit handling process for units bound for the given type of downstream unit handling process during the first time period and the second target throughput rate utilized during said one or more subsequent time periods is equal to the particular target throughput rate for the upstream unit handling process for units bound for the given type of downstream unit handling process.

29. The non-transitory computer-readable storage medium of claim 27, wherein subsequent to the one or more subsequent time periods, the process control component is configured to utilize the particular target throughput rate again to generate one or more instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process.

30. The non-transitory computer-readable storage medium of claim 25, wherein the stored model further indicates units that are part of different collections of units, wherein at least some of said unit handling processes move items from one collection of units to another collection of units.

31. The non-transitory computer-readable storage medium of claim 30, wherein the process control component is configured to:

evaluate the model to determine that a quantity of units within one of said collections of units has reached a threshold, wherein the units of the quantity of units are bound for the given type of downstream unit handling process; and

in response to that determination, modify the particular target throughput rate, and based on the modified target throughput rate, generate one or more additional instructions to control the respective throughput rate of units bound for the given type of downstream unit handling process and processed by the upstream unit handling process.

32. The non-transitory computer-readable storage medium of claim 30, wherein the process control component is configured to:

evaluate the model to determine that a quantity of units within one of said collections of units has reached a threshold; and

in response to that determination, generate one or more of;

an alert message to alert an agent that the threshold has been reached, or a recommendation message to provide a recommendation for modifying the quantity of units within the respective collection of units.

33. The non-transitory computer-readable storage medium of claim 32, wherein said recommendation indicates a change in a quantity of labor staffed on one or more of said unit handling processes.

34. The non-transitory computer-readable storage medium of claim 30, wherein the storage buffer is a random access storage buffer, and wherein the units of at least one of said collections of units are stored within the random access storage buffer comprising multiple unit locations.

35. The non-transitory computer-readable storage medium of claim 25, wherein the multiple unit handling processes include one or more of:

a picking process to pick units from one or more inventory locations;

a conveyance process to convey units from one location of the materials handling facility to another location of the materials handling facility;

an induction process during which units are moved into a random access storage buffer compressing multiple unit locations;

or

a packing process during which one or more units received from the random access storage buffer are packed into respective shipping containers to be shipped from the materials handling facility.

36. The non-transitory computer-readable storage medium of claim 25, wherein the at least one target output rate for a given type of unit downstream handling process is based on:

a rate at which units are expected to be packed into shipments prior to being shipped from the materials handling facility or a rate at which shipments are expected to be processed within the materials handling facility.