JP6182000B2 - Picking system - Google Patents

Description

  The present invention relates to a picking system for picking a designated product out of products on a rack and putting it into a collection box conveyed by a collection conveyor.

  In general, a line-type digital display picking system is used for assembling a wide variety of products in order (order) units. This type of picking system includes a collection conveyor that conveys a collection box, and the collection conveyor is divided into a plurality of zones along the conveyance direction, and stores products for each product type in each zone. A storage shelf is provided. An order indicator is attached to each product outlet of the storage shelf and the side of the collection conveyor.

  In such a picking system, an operator is arranged in each zone, and each worker takes out the instructed product from the storage shelf of the zone he is in charge of based on the picking instruction displayed on the order indicator. Thus, the container is stored in a collection box conveyed by a collection conveyor.

  Further, in the conventional general picking system, the collection box is continuously moved, and in order to put articles into such a moving collection box, for example, the picking system disclosed in Patent Document 1 below is widely used. Are known. In this picking system, a large number of tracking type guide lamps are arranged along the collection conveyor, and when a predetermined collection box passes through a zone where the goods to be picked are placed, the guide lamps are arranged in the collection box. By sequentially lighting in synchronization with the movement, the light travels with the collection box so that the worker can recognize the collection box to be thrown in.

Japanese Patent No. 2799445

  In the conventional picking system, the collection boxes flow in the order of shipment, that is, the order of loading into the truck. Therefore, the order of the collection order data input to the control device that controls the entire system is the flow of the collection boxes. They are arranged in order.

  For this reason, depending on the order tendency, products to be picked may be biased, and a worker may be in a waiting state in another zone even though he is busy in one zone. In particular, when work is concentrated in a certain zone, it is conceivable that a situation in which the collection conveyor is stopped due to inadequate time to take out the products from the storage shelves and put the products into the collection boxes. Thus, conventionally, there is a problem that the efficiency of picking work does not increase when the work load is biased.

  An object of the present invention is to provide a novel picking system capable of solving such problems in the prior art and improving the efficiency of picking work.

  In order to achieve the above-described object, the present invention provides a collection conveyor for transporting a collection box for storing products, and a plurality of types arranged in each of a plurality of zones set along the collection conveyor. A storage shelf for storing the product of the product, a plurality of product waiting stands for temporarily placing the product disposed in each of the zones, and a first display for displaying picking information provided on each of the storage shelves An order indicator, a second order indicator provided on each of the product waiting platforms for displaying picking information, the collection conveyor, the first order indicator, and the A picking system comprising a control means for controlling a second order indicator, wherein the control device is for (a) a product from the storage shelf with respect to a part of continuous or frequent picking operations. When the previous picking operation is not continuously performed, the product is taken out from the storage shelf and the product is temporarily placed on the product waiting stand. Rewrite the data of the collection order; (b) based on the rewritten data, take out the product from the storage shelf, put the product into the collection box, and store the product from the storage shelf. The removal and temporary placement of the product on the product waiting platform are displayed on the first order indicator, and the introduction of the product from the product waiting platform into the collection box is displayed on the second order indicator. It is characterized by being comprised.

  Moreover, it is preferable to arrange | position the goods waiting stand in the position along the collection conveyor.

  According to the configuration described above, when the picking work is performed continuously or frequently, a part of the picking work is performed when the previous picking work is not performed continuously. Then, the taken out product is temporarily placed on a product waiting stand along the collection conveyor, and when the target collection box arrives, the temporarily placed product is put into the collection box. As a result, a series of operations of taking out the products from the storage shelves and putting them into the collection box is distributed using a time zone with a margin, so that the picking operation is leveled. Further, when a product is put into the collection box from the product waiting stand, the labor for searching for the product is not required, and the work efficiency is improved.

1 is a schematic diagram of a picking system according to the present invention. It is a figure which shows roughly the structure of the control apparatus which controls the picking system by this invention. It is a flowchart of the program run by a control apparatus. It is a flowchart of the data rewriting process in FIG. It is a flowchart of the picking system control in FIG.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

  The picking system 10 shown in the figure basically has the same configuration as the conventional configuration disclosed in Patent Document 1 described above, and includes a collection conveyor 14 such as a belt conveyor that conveys the collection box 12. Yes. A plurality of zones Z are set along the collection conveyor 14, and a storage shelf 16 for storing products is provided in each zone Z. Each storage shelf 16 is composed of, for example, a flow rack. A plurality of types of products are stored, and the products can be taken out from the side facing the collection conveyor 14.

  An order indicator (first order indicator) 18 for displaying picking information is attached to the commodity outlet of the storage shelf 16. As the order indicator 18, a conventionally known one can be used, and there are various types such as a model and a mounting position thereof, but a digital order indicator is preferable. Further, in the present embodiment, the picking information to be displayed is the product to be taken out from the storage shelf, the quantity thereof, the position of the product waiting platform described below, and the like. As shown in FIG. 2, the order indicator 18 is connected to a control device 20 that controls the entire picking system 10, and lights up and displays predetermined picking information according to a command from the control device 20. .

  Each order indicator 18 is provided with a reset button 22. After the operator has taken out the merchandise according to the display on the order indicator 18, the control device 20 can recognize that the take-out of the merchandise has been completed by pressing the reset button 22.

  Further, the picking system 10 includes a guide device 24 that indicates the position of the collection box to be loaded. There are various types of guide devices 24, but the guide device 24 of the illustrated embodiment is a so-called tracking type described in the above-mentioned Patent Document 1, and is located on the side of the collection conveyor 14 along the conveying direction. It is composed of a large number of guide lamps 26 arranged at regular intervals. In the guide device 24, when a predetermined collection box 12 passes through the zone Z in which the picking target products are stored, the guide lamps 26 are sequentially turned on in synchronization with the movement of the collection box 12. . The operator puts the product into the collection box 12 moving beside the lit guide lamp 26.

  When the product is input, the operator can cause the control device 20 to recognize that the input of the product into the collection box 12 is completed by pressing the product input completion switch 28 provided in each zone Z. . Various types of the product insertion completion switch 28 are conceivable. However, a tape switch extending over the entire length of each zone Z is effective because the switch is turned on regardless of which portion is pressed.

  The main part of the present invention will be briefly described. When picking operations are performed continuously or frequently, some of the picking operations are performed when the previous picking operations are not performed continuously. That's what it meant. Then, the taken out product is temporarily placed, and when the target collection box 12 arrives, the temporarily placed product is put into the collection box 12. As a result, the work of taking out the products from the storage shelf 16 and putting them into the collection box 12 is dispersed using a time zone with a margin, so that the picking work is leveled.

  Based on the main part of the present invention, the picking system 10 according to the present embodiment is provided with a plurality of product waiting stands 30 for temporarily placing products, three in the illustrated embodiment, for each zone Z. The position where the product waiting table 30 is installed may be any position as long as the product temporarily placed on the product stand 30 can be quickly put into the collection box 12 on the collection conveyor 14. The waiting platform 30 is located on the side of the collection conveyor 14 opposite to the storage shelf 16 and higher than the upper edge of the collection box 12 on the collection conveyor 14. This is because the product temporarily placed at this position can be put into the collection box.

  The product waiting table 30 is provided with an order indicator (second order indicator) 32 and a reset button 34 similar to the order indicator 18 and the reset button 22 provided on the storage shelf 16. An order indicator 32 and a reset button 34 are also connected to the control device 20. In the present embodiment, since the picking information displayed on the order display 32 is only instruction information for instructing product entry, the order display 32 may simply be a lamp.

  Next, an example of operation | movement of the picking system 10 of the structure mentioned above is demonstrated.

  First, collection order data (order data) is input to the control device 20 in advance or sequentially during operation. When the picking system 10 starts operation, the control device 20 performs a process of sequentially rewriting the input collection order data (S1 in FIG. 3). This rewriting process forms the main part of the present invention, and FIG. 4 is a flowchart as an example.

なお、表のオーダＮｏの数字は集品箱１２の流れる順番であり、また、出荷の順番でもある。また、表中の「×」は、ピッキング作業が行われないこと、すなわち制御装置２０から保管棚１６及び商品待ち台３０のオーダ表示器１８，３２並びにガイド装置２４に指令が発せられないことを示している。「○」は、保管棚１６から商品を取り出した後、その商品を対象の集品箱１２に投入すること、すなわち制御装置２０から保管棚１６のオーダ表示器１８とガイド装置２４に所定の指令が発せられることを示している。「□」は、保管棚１６から商品を取り出した後、その商品を指定の商品待ち台３０に仮置きすること、すなわち制御装置２０から保管棚１６のオーダ表示器１８に指令が発せられることを示している。「△」は、商品待ち台３０の上の商品を対象の集品箱１２に投入すること、すなわち制御装置２０から商品待ち台３０のオーダ表示器３２及びガイド装置２４に指令が発せられることを示している。 Here, reference is made to the following Table 1. Table 1 is an example of a collection order for the zone Z1, and the first input data is a portion indicated by “order No” and “original” in the table. This data is sequentially rewritten by the processing of the flowchart of FIG. 4 according to the order of order numbers.

The number of the order No. in the table is the order in which the collection box 12 flows and also the order of shipment. In addition, “x” in the table indicates that no picking operation is performed, that is, no command is issued from the control device 20 to the order display units 18 and 32 of the storage shelf 16 and the product waiting table 30 and the guide device 24. Show. “○” indicates that after the product is taken out from the storage shelf 16, the product is put into the target collection box 12, that is, a predetermined command is sent from the control device 20 to the order indicator 18 and the guide device 24 of the storage shelf 16. Is emitted. “□” indicates that after a product is taken out from the storage shelf 16, the product is temporarily placed on the designated product waiting stand 30, that is, a command is issued from the control device 20 to the order indicator 18 of the storage shelf 16. Show. “△” indicates that the product on the product waiting table 30 is put into the target collection box 12, that is, the control device 20 issues a command to the order indicator 32 and the guide device 24 of the product waiting table 30. Show.

  In the data rewriting process, first, the picking work status in the order 1 is read by the control device 20. In order 1, since there is no picking work, the same processing is repeated for the next order 2 and order 3 assuming that it is not the target of rewriting (S102 to S105).

  Since order 4 is “picking”, the process proceeds to S106. Here, “A” indicates the number of consecutive picking operations, and A = 1. However, since A = 3 is not satisfied (because the picking operation is not performed three times), the process returns to S103.

  Since order 5 is “no picking”, the process returns to S102 and A is reset to zero. For orders 5 and 6, S102 to S105 are repeated.

  In orders 7 to 9, picking work is required. Therefore, S103 to S107 are repeated, and A = 3 (since picking work items are continued three times), the process proceeds to S108.

  In S108, M = 1, and data of order 1 is read (S109). “M” indicates an order (N−B) that is a predetermined number (B) after the last order (Nth) of three consecutive picking operations. Since subtraction of “N = 15” results in a minus value, the smallest number “1” is set to M here.

  Since there is no collection of order 1, the process returns to S109 via S111, S112, and S113. “C” in S111 indicates how many times the picking operation is not continuously performed. Further, when the data of order 3 is read, C = 3 (no picking continues three times), and the process proceeds to S114.

  In S114, the order obtained by subtracting 1 from the order M, that is, the data of the order 2 in this case, is rewritten so that the order indicator 18 of the storage shelf 16 is lit. The contents of rewriting are “lighted display of picked-up product and its quantity” and “position of the product waiting table 30 where the product is temporarily placed”. In Table 1, as the first rewrite, □ is marked in the rewrite 1 column.

  In S114, data of order N, that is, data of order 9 in this case, is rewritten. The rewriting content is “information to put the placed product” on the order display 32 of the product waiting table 30. Table 1 is shown with a Δ mark.

  If the rewriting of data is completed, the process returns to S102, and the same procedure as above is repeated from the data of the order 10. When the order 17 is reached, the second rewrite is performed. In Table 1, the rewrite state is shown in the rewrite 2 column. Furthermore, when the order 20 is reached, the third rewrite is performed, and in Table 1, the rewrite state is shown in the rewrite 3 column.

  If it is determined in S110 that picking is present, C is reset in S116, and then the process proceeds from S113 to S109. Further, since no picking may continue three times, when order M reaches three orders before order N in S115, the process returns to S102.

The above rewriting process is performed in the other zones in the same manner. The following Table 2 shows an example of data rewriting in the zone Z2, but it will be understood from this table that when the contents of the collection order are different, the number of times of rewriting is different.

  Note that the value of “B” in the flowchart of FIG. 4 is a value that determines how far back the picking operation is to be examined from the three consecutive picking operations. That is, as the value of “B” is increased, the state where there is no picking work is searched farther from the three consecutive picking work, and is appropriately determined according to the environment in which the picking system 10 is used. Can be determined.

For example, in the collection order shown in Table 3 below, picking work continues for a considerable number of times from the order 19. It will be understood from Table 3 that in such an environment in which such a case occurs, the picking work can be leveled more by setting the value of “B” to be large.

  As described above, the rewriting process of the collection order data proceeds, and when the rewriting process of a predetermined number of orders is completed, the rewritten data is sequentially read again by the control device 20 (FIG. 3). S2).

  And the control apparatus 20 controls the picking system 10 according to the flowchart shown in FIG. 5 in order of the rewritten data. First, the control device starts the collection conveyor 14 and starts flowing the collection box 12 (S301). Next, the control device 20 sets the order collection boxes 12 in the orders with lighting instructions, that is, in the orders 1 to 3 to which “O”, “□”, and “Δ” are attached, to the zone corresponding to the order. It is determined whether or not Z is entered (S302). This determination is performed by a known method, for example, by reading an identification means such as RFID attached to the collection box 12 with a sensor and sending the signal to the control device 20, or after the collection box 12 has started. This is done by calculating the time.

  Next, if the order content is “□” and the product is taken out from the storage shelf 16 and temporarily placed on the product waiting table 30, the order indicator 18 of the storage shelf 16 is turned on to prompt the operator. On the other hand, the position and number of the storage shelves 16 where the target product is located and the position of the product waiting table 30 to be temporarily placed are informed (S303, S304). Then, the operator takes out the product from the storage shelf 16 and places it on the product waiting table 30, and presses the reset button 22 of the storage shelf 16 (S305). As a result, the control device 20 recognizes that the temporary placement work for the product has been completed, and returns to S302.

  On the other hand, if it is determined in S303 that the order content is not temporary placement of the product, it is a case where the product is put into the collection box 12, and the process proceeds to S306, where the control device 20 performs the process based on the collection order data. It is determined whether the product is inserted from the product waiting stand 30 or the storage shelf 16. When the data is “◯”, that is, when a product is taken out from the storage shelf 16 and directly put into the collection box 12, first, the control device 20 controls the guide device 24 to set the guide lamp 26 to the target collection. Lights up in synchronization with the movement of the box 12 (S307). Then, the position display unit 18 of the storage shelf 16 displays the position and the number of the storage shelves 16 with the products to be thrown in (S308). The operator looks at the display on the order indicator 18, takes out the product from the storage shelf 16, presses the reset button 22 of the storage shelf 16, and stores the product in the collection box 12 next to the lit guide lamp 26. And press the tape switch 28 (S309, S310). If the tape switch 28 is pressed, the control device 20 determines that the picking operation for the product has been completed, turns off the order indicator 18 of the storage shelf 16 (S311), and returns to S302. If the tape switch 28 is not pressed even though the collection box 12 has passed through the zone Z, the control device determines that some abnormality has occurred and stops the collection conveyor. (S310, S312).

  In S306, when it is determined that the data is “Δ”, that is, the product is inserted from the product waiting platform 30, the control device 20 controls the guide device 24 in the same manner as the direct input of the product from the storage shelf 16. The guide lamp 26 is turned on in synchronization with the movement of the target collection box 12 (S313). Then, the order indicator 32 of the product waiting table 30 on which the target product is placed is turned on to instruct the operator to input (S314). If this instruction is issued, the operator only has to put all the products on the product waiting table 30 into the collection box 12. Then, the worker presses the reset button 34 and presses the tape switch 28 (S315, S316). If the tape switch 28 is pressed, the control device 20 determines that the picking operation for the product has been completed, turns off the order indicator 32 of the product waiting table 30 (S317), and returns to S302. If the tape switch 28 is not pressed even though the collection box 12 has passed through the zone Z, the control device 20 determines that some abnormality has occurred and stops the collection conveyor 14. The same as described above (S316, S318).

  Thus, the picking system 10 operates, but reference is again made to Tables 1 and 2. Looking at the originals in Tables 1 and 2 and the rewriting 3 in Table 1 and the rewriting 4 in Table 2, there is no state in which picking has not been performed after data rewriting, and this causes the worker to wait. It can be seen that wasted time has been reduced and work has been leveled. On the other hand, the portion indicated by “Δ” is increased, but this is not the operation of putting the product into the collection box 12 from the storage shelf 16 but the operation of putting the product into the collection box 12 from the product waiting stand 30. It has been replaced. When a product is put into the collection box 12 from the storage shelf 30, the operator changes the body direction by 180 degrees to take out and put in the product, but the product waiting platform 30 is positioned along the collection conveyor 14. Therefore, the physical burden is greatly reduced without having to change the direction of the body. In addition, since all the products on the product waiting stand 30 are targets for input, there is no need to select products or confirm the number of products, the time for product input is shortened, and the mental burden is reduced. become. Thus, according to the picking system of the present invention, the efficiency of the picking operation is greatly improved.

  As mentioned above, although preferred embodiment of this invention was described in detail, this invention is not limited to the said embodiment.

  For example, in the above-described embodiment, the collection conveyor is continuously operated. However, the present invention is also applicable when the collection conveyor is operated intermittently. Of course, in this case, the guide device is not a tracking type, but a type that turns on a guide lamp next to the stopped collection box is sufficient.

  Further, although the number of continuous picking operations and the number of continuous picking operations is 3 in the above embodiment, it can be 4 or more (in FIG. 4, the numerical values of X and Y are changed).

  Furthermore, the concept of the present invention includes a case where the picking operation is not performed continuously but is frequently performed. For example, if there are four consecutive orders, and there are three picking operations, the operation can be considered as a high frequency. Therefore, one of the three picking operations is not performed continuously. It may be moved to a place.

  Further, in the above embodiment, the last picking operation among the three consecutive picking operations is to be put into the product box from the product waiting platform. The picking operation may be performed.

  Furthermore, the main part of the present invention is that when picking work is continued, the picking work is arranged where there is no picking work. It goes without saying that the present invention is not limited to those described in the embodiments. For example, in the above-described embodiment, the collection order data is read according to the order of the order for each zone, and is rewritten sequentially.However, after all the collection order data is read for one day's work, the program is rewritten all at once. It is also possible to do.

DESCRIPTION OF SYMBOLS 10 ... Picking system, 12 ... Collection box, 14 ... Collection conveyor, 16 ... Storage shelf, 18 ... First order indicator, 20 ... Control device, 22 ... Reset button, 24 ... Guide device, 26 ... Guide lamp , 28 ... Product introduction completion switch (tape switch), 30 ... Product waiting table, 32 ... Second order indicator, 34 ... Reset button.

Claims (1)

A collection conveyor (14) for transporting a collection box (12) for storing products;
A storage shelf (16) for storing a plurality of types of merchandise disposed in each of a plurality of zones (Z) set along the collection conveyor (14);
A plurality of product waiting platforms (30) for temporarily placing products disposed in each of the zones (Z);
A first order indicator (18) provided on each of the storage shelves (16) for displaying picking information;
A second order indicator (32) for displaying picking information provided at each of the product waiting platforms (30);
Picking system comprising control means (20) for controlling the collection conveyor (14), the first order indicator (18) and the second order indicator (32) based on the data of the collection order ( 10)
The control means (20)
With regard to a part of continuous or high-frequency picking work, picking of the goods from the storage shelf (16) and loading of the goods into the collection box (12) are continuously performed. Rewrite the data of the collection order so as to take out the product from the storage shelf (16) and temporarily place the product on the product waiting stand (30),
Based on the rewritten data, the product is taken out from the storage shelf (16), the product is put into the collection box (12), and the product is taken out from the storage shelf (16). The temporary placement of the product on the waiting platform (30) is displayed on the first order indicator (18), and the loading of the product from the product waiting platform (30) into the collection box (12) is performed in the first order display (18). A picking system, characterized in that the picking system is configured to display on two order indicators (32).

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