Method and apparatus for optimized shipping strategies accounting for endpoint requirements

• US 9,152,940 B2
• Filed: 05/24/2011
• Issued: 10/06/2015
• Est. Priority Date: 05/24/2011
• Status: Active Grant

• Current Assignee: Intelligrated Incorporated (Honeywell International Inc.)
• Original Assignee: Intelligrated Incorporated (Honeywell International Inc.)
• Inventors: Nashif, Hazem Nizar An, Brady, Thomas Frederick
• Primary Examiner(s): CUMBESS, YOLANDA RENEE
• Application Number:
  US13/068,940
• Publication Number:
  US 20120303156A1
• Time in Patent Office: 1,596 Days
• Field of Search: 700/216, 700/214, 700/213
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management

Abstract

The cartonization process in a distribution center can be modified to account for factors which influence the efficiency with which the products distributed from the distribution center can be stocked onto store shelves, such as layout (i.e., planogram) information indicating where the various products will actually be located in a store.

Claims

1. A machine for fulfillment of orders in a distribution center comprising:

a. a pick face, the pick face adapted to allow products to be taken from the pick face and placed into containers; and

b. a means for determining a plan for placing products into containers based on how the products will be used in store replenishment;

wherein the means for determining the plan for placing products into containers based on how the products will be used in store replenishment operates based on information grouping the products into a plurality of groups which treats a first group from the plurality of groups as an in scope group and a second group from the plurality of groups as an out of scope group.

2. The machine of claim 1, wherein:

a) the pick face is part of a pick to light system;

b) lights on the pick to light system are operated based on the means for determining the plan for placing products into containers based on how the products will be used in store replenishment; and

c) the machine comprises a voice directed picking system.

3. The machine of claim 2 wherein commands provided by the voice directed picking system are based on the means for determining the plan for placing products into containers based on how the products will be used in store replenishment.

4. The machine of claim 1, wherein the means for determining the plan for placing products into containers based on how the products will be used in store replenishment operates on a multiple container basis.

5. The machine of claim 1, wherein the second group is a subgroup of a third group from the plurality of groups.

6. The machine of claim 1, wherein the functions for the means comprise:

a) determining the plan for placing products into containers based on how the products will be used in store replenishment; and

b) determining the plan for placing products into containers based on how the products are situated in the distribution center.

7. A method comprising:

a) receiving a fulfillment order specifying a plurality of products to be used in store replenishment at one or more stores;

b) in a computer memory, determining a plan for placing products from the plurality of products into containers based on how the products will be used in store replenishment; and

c) outputting instructions to a picking system indicating products to be placed into containers based on the plan;

wherein store is defined as an establishment where products are sold.

8. The method of claim 7, comprising, in the computer memory, sorting the plurality of products according to one or more levels in a hierarchy, wherein:

a) the hierarchy comprises a plurality of levels;

b) a set of the plurality of levels in the hierarchy comprise groups;

c) each product from the plurality of products has a position in the hierarchy, the position in the hierarchy indicating that the product is grouped into a set of groups, the set of groups comprising;

i) one highest group which is not a subgroup of any other group in the set of groups; and

,

ii) one or more descendant groups, each of which is a subgroup of another group in the set of groups;

the set of groups the product is grouped into indicating how the product will be used in store replenishment; and

d) when a product is identified as grouped in an in scope group, the product is sorted according to any levels of the hierarchy which contain a group which is a direct subgroup of the in scope group.

9. The method of claim 8 wherein when a product is identified as grouped in an out of scope group, the product is not sorted according to any of the levels of the hierarchy which comprise one or more subgroups of the out of scope group.

10. The method of claim 7, wherein determining the plan for placing products from the plurality of products into containers based on how the products will be used in store replenishment comprises:

a) performing one or more determinations taken from a set of determinations consisting of;

i) determining whether a combination comprising

a set of products assigned to a container; and

a product to be assigned cannot fit in a maximum container size;

ii) determining whether the product to be assigned is the last product in a boundary group associated with the product to be assigned;

iii) determining whether the product to be assigned is the last product in a condition group associated with the product to be assigned, and, if the product to be assigned is the last product in the condition group associated with the product to be assigned, whether a condition associated with the condition group is violated by assigning an additional product after the product to be assigned to the container; and

b) if any of the determinations from the set of determinations is true, indicating that no additional products can be assigned to the container.

11. The method of claim 10 further comprising, if any of the determinations from the set of determinations is true, assigning a size to the container.

12. The method of claim 11, wherein assigning the size to the container comprises modifying data representing, in the computer memory, a container into which the products to be assigned a container are to be placed, to indicate the container into which the products to be assigned a container are to be placed has the assigned size.

13. The method of claim 7, wherein:

a) the method comprises sorting the plurality of products according to store replenishment location information comprising departments, aisles, and aisle sides where products from the plurality of products will be placed during store replenishment;

b) determining the plan for placing products from the plurality of products into containers based on how the products will be used in store replenishment comprises, for each product from the plurality of products which will be placed in an in scope department during store replenishment;

i) performing one or more determinations from a set of determinations consisting of;

A) determining whether a combination comprising the product and a set of already assigned products cannot fit in a container of maximum size;

B) determining whether the product is the last product in the aisle on which it will be placed during store replenishment; and

C) determining whether a rule associated with handling, safety or quality would be violated by assigning the product to a single container with the set of already assigned products;

ii) if any of the determinations from the set of determinations is true, performing acts comprising;

A) indicating that no additional products can be assigned to the container into which the set of already assigned products are to be placed; and

B) assigning a size to the container into which the set of already assigned products are to be placed.

14. A method, comprising:

a) receiving, at a warehouse control computer, a fulfillment order indicating a plurality of products;

b) identifying, at the warehouse control computer, a store to which each of the plurality of products is to be shipped;

c) determining, at the warehouse control computer, a plan for placing each of the plurality of products into a set of cartons based on layout information stored in a memory accessible by the warehouse control computer for each identified store to which each of the plurality of products is to be shipped;

d) generating, at the warehouse control computer, a set of instructions to control an operation of a cartonization system to control which of the plurality of products should be added to each carton of the set of cartons based at least in part on the determined plan; and

e) sending the set of instructions from the warehouse control computer to the cartonization system;

wherein the memory accessible by the warehouse control computer has stored therein unique layout information for each identified store; and

wherein determining, at the warehouse control computer, a plan for placing each of the plurality of products into a set of cartons based on layout information stored in a memory accessible by the warehouse control computer for each identified store to which each of the plurality of products is to be shipped comprises;

i) identifying, at the warehouse control computer, a location of each of the plurality of products in each identified store to which each of the plurality of products is to be shipped based on the layout information for each identified store; and

ii) assigning each of the plurality of products to the set of cartons in the plan such that locations of products in any one carton of the set of cartons in the plan do not violate an adjacency grouping rule.

15. The method of claim 14, wherein the layout information of each identified store is a planogram indicating a department, an aisle, an aisle side, a bay, a shelf, and a position that identifies the location of each of the plurality of products in that respective store.

16. The method of claim 15, wherein the adjacency grouping rule is a requirement that products have the same handling, safety, and quality restrictions.

17. The method of claim 15, wherein the adjacency grouping rule is a requirement that the locations of products in any one carton of the set of cartons have a same department and same aisle.

18. The method of claim 17, wherein the adjacency grouping rule is a requirement that the locations of products in any one carton of the set of cartons have the same department, the same aisle, and a same aisle side.

19. A method comprising:

a) receiving a fulfillment order specifying a plurality of products to be used in store replenishment at one or more stores;

b) in a computer memory;

i) sorting the plurality of products according to one or more levels in a hierarchy, wherein;

A) the hierarchy comprises a plurality of levels;

B) a set of the plurality of levels in the hierarchy comprise groups;

C) each product from the plurality of products has a position in the hierarchy, the position in the hierarchy indicating that the product is grouped into a set of groups, the set of groups comprising;

I) one highest group which is not a subgroup of any other group in the set of groups; and

,

II) one or more descendant groups, each of which is a subgroup of another group in the set of groups;

the set of groups the product is grouped into indicating how the product will be used in store replenishment; and

D) when a product is identified as grouped in an in scope group, the product is sorted according to any levels of the hierarchy which contain a group which is a direct subgroup of the in scope group; and

ii) determining a plan for placing products from the plurality of products into containers based on how the products will be used in store replenishment;

c) outputting instructions to a picking system indicating products to be placed into containers based on the plan.

20. The method of claim 19 wherein when a product is identified as grouped in an out of scope group, the product is not sorted according to any of the levels of the hierarchy which comprise one or more subgroups of the out of scope group.

21. A method comprising:

a) receiving a fulfillment order specifying a plurality of products to be used in store replenishment at one or more stores;

b) in a computer memory, determining a plan for placing products from the plurality of products into containers based on how the products will be used in store replenishment, wherein determining the plan for placing products from the plurality of products into containers based on how the products will be used in store replenishment comprises;

i) performing one or more determinations taken from a set of determinations consisting of;

A) determining whether a combination comprising

I) a set of products assigned to a container; and

II) a product to be assigned cannot fit in a maximum container size;

B) determining whether the product to be assigned is the last product in a boundary group associated with the product to be assigned;

C) determining whether the product to be assigned is the last product in a condition group associated with the product to be assigned, and, if the product to be assigned is the last product in the condition group associated with the product to be assigned, whether a condition associated with the condition group is violated by assigning an additional product after the product to be assigned to the container; and

ii) if any of the determinations from the set of determinations is true, indicating that no additional products can be assigned to the container; and

c) outputting instructions to a picking system indicating products to be placed into containers based on the plan.

22. The method of claim 21 further comprising, if any of the determinations from the set of determinations is true, assigning a size to the container.

23. The method of claim 22, wherein assigning the size to the container comprises modifying data representing, in the computer memory, a container into which the products to be assigned a container are to be placed, to indicate the container into which the products to be assigned a container are to be placed has the assigned size.