Cross-dock management system, method and apparatus

• US 9,367,827 B1
• Filed: 12/14/2015
• Issued: 06/14/2016
• Est. Priority Date: 12/15/2014
• Status: Active Grant

• Current Assignee: Innovative Logistics, Inc.
• Original Assignee: Innovative Logistics, Inc.
• Inventors: Lively, Gary Shannon, Bradley, Mark, Sullivan, Patrick
• Primary Examiner(s): Cumbess, Yolanda
• Application Number:
  US14/968,144
• Publication Number:
  US 20160171441A1
• Time in Patent Office: 183 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/08355 Routing methods

Abstract

Disclosed herein is a cross-dock management system comprises: a plurality of movable platforms configured to hold one or more pallets or parcels; at least one barcode or RFID tag positioned on each of said movable platforms, pallets, or parcels, wherein the barcode readers are configured to read the barcodes and RFID readers are configured to read the RFID tags. The data scanned by the barcode readers and RFID readers is stored in a local warehouse database and is used to determine an optimized placement and load for each movable platform in the warehouse.

Claims

1. A cross-dock management system comprising:

a cross-dock having a plurality of doors for accommodating trailers,

wherein the cross-dock comprises a plurality of separated spaces arranged in a grid pattern comprising at least three rows and at least three columns;

a plurality of doors at opposing ends of the cross-dock for receiving inbound trailers and outbound trailers;

a plurality of movable platforms arranged on the cross-dock in the separated spaces,

wherein an area of the movable platforms is substantially the same as an area of the separated spaces;

a plurality of cargo arranged on at least one of the movable platforms,

wherein the cargo, the movable platforms, and the spaces are assigned at least one unique identifier;

at least one conveyance vehicle for moving the cargo and the movable platforms,

wherein the at least one conveyance vehicle comprises a reader for reading the unique identifiers;

a local database for storing received manifest data; and

an initial setup optimization server for determining a plurality of ordered move instructions for moving the cargo and the movable platforms on the cross-dock based upon the manifest data,

wherein the ordered move instructions are stored in an instructions database,

wherein the ordered move instructions are performed by the at least one conveyance vehicle, and

wherein, the reader is utilized to verify that each ordered move instruction is performed correctly.

2. The cross-dock management system according to claim 1, further comprising:

an radio frequency identification (RFID) tag located on each movable platform and each cargo,

wherein each RFID tag stores the unique identifier;

a plurality of (RFID) readers arranged in an RFID array on the cross-dock for scanning the RFID chips in real-time;

a RFID server for receiving location information of each RFID tag from the plurality of RFID readers.

3. The cross-dock management system according to claim 2, further comprising:

a real-time instruction server that utilizes the location information to verify that each ordered move instruction is performed correctly,

and, if the real-time instruction server determines that location information of the cargo or the movable platforms is incorrect, the real-time instruction server

determines corrected moving instructions and

transmits the corrected moving instructions to the instructions database.

4. The cross-dock management system according to claim 3, further comprising:

a plurality of dimensioners arranged in a dimensioner array for monitoring dimension information of cargo placed on each movable platform real-time; and

a dimensioner server for receiving the dimension information from the dimensioner array.

5. The cross-dock management system according to claim 4,

wherein the real-time instruction server utilizes the dimension information to determine that the cargo placed on each movable platform is less than a predetermined threshold, and

if the real-time instruction server determines that the predetermined threshold is exceeded, the real-time instruction server

determines corrected moving instructions and

transmits the corrected moving instructions to the instructions database.

6. The cross-dock management system according to claim 1, further comprising:

a tablet having a display associated with the at least one conveyance vehicle,

wherein the display displays the ordered move instructions to a user in a list; and

the tablet removes the ordered move instructions from the list as they are performed and updates the instruction database.

7. The cross-dock management system according to claim 1, wherein the initial setup optimization server utilizes initial setup optimization algorithms for determining the ordered move instructions,

wherein the initial setup optimization algorithms minimize unloading and loading times of trailers;

minimizes movable platform, cargo, and conveyance vehicle movement distance;

minimizes empty carries by the conveyance vehicle; and

optimizes the number of conveyance vehicles needed based upon a total number of ordered move instructions.

8. The cross-dock management system according to claim 1,

wherein the unique identifiers are barcode labels;

and

wherein the reader is a barcode reader.

9. The cross-dock management system according to claim 8, wherein each of the ordered move instructions is an instruction for moving a piece of cargo or an instruction for moving a movable platform;

wherein, if the ordered move instruction is an instruction for moving the piece of cargo, the ordered move instruction is performed by;

a) scanning the unique identifier associated with the piece of cargo and scanning the unique identifier associated with a movable platform containing the piece of cargo;

b) conveying the piece of cargo to another movable platform specified by the instruction for moving the piece of cargo using the conveyance vehicle; and

c) scanning the unique identifier associated with the piece of cargo and scanning the unique identifier associated with the another movable platform.

10. A method for performing transfer of a movable platform and cargo across a cross-dock from an inbound trailer to an outbound trailer, the method comprising:

a. calculating a plurality of moving instructions based upon inbound manifest data;

b. directing the inbound trailer to a door in accordance with moving instructions received from an instruction database;

c. unloading the movable platform from the inbound trailer using a conveyance vehicle and moving the movable platform to an assigned space on the cross-dock in accordance with moving instructions received from the instruction database;

d. loading and unloading cargo from the movable platform using conveyance vehicles in accordance with moving instructions received from the instruction database, wherein at least a portion of the cargo is not removed from the movable platform;

e. verifying that all moving instructions have been completed for the movable platform;

f. conveying the movable platform to the outbound trailer in accordance with the moving instructions; and

g. loading the movable platform in the inbound trailer.

11. The method according to claim 10, wherein the moving instructions are calculated by:

a. receiving the inbound manifest data, wherein the inbound manifest data includes a number of inbound trailers, an identification of a movable platform located on each inbound trailer, and an identification of the cargo located on each movable platform;

b. identifying a number of outbound load points;

c. determining a number of outbound load points needed for each inbound trailer;

d. determining which cargo needs to be moved;

e. determining a number of movable platforms needed to be added to the cross-dock;

f. assigning spaces on the cross-dock to each inbound movable platform;

g. determining required staffing levels;

h. assigning moving instructions to each staff member; and

i. storing the moving instructions in the instructions database.

12. The method according to claim 10, wherein steps a-g are performed for all inbound trailers.

13. The method according to claim 10, wherein the verification in step e. is accomplished utilizing an RFID array located on the cross-dock.

14. The method according to claim 13, wherein, if it is detected that any operating instructions are performed incorrectly, corrected operating instructions are determined and the corrected operating instructions are stored in the instructions database.

15. The method according to claim 13, wherein the RFID array determines real-time location information about a location of each movable platform and piece of cargo on the cross-dock.