U.S. patent application number 10/892500 was filed with the patent office on 2005-07-07 for warehousing system and method.
This patent application is currently assigned to eBox, Inc.. Invention is credited to Stevens, John, Vandenberg, Mike, Waterhouse, Paul.
Application Number | 20050149226 10/892500 |
Document ID | / |
Family ID | 46302356 |
Filed Date | 2005-07-07 |
United States Patent
Application |
20050149226 |
Kind Code |
A1 |
Stevens, John ; et
al. |
July 7, 2005 |
Warehousing system and method
Abstract
A warehousing system includes a container for storing at least
one item, a first electronic (e.g. radio frequency identification
(RFID)) module associated with the first container, and a
controller which wirelessly communicates with first electronic
module, for directing a transfer of said at least one item to
and/or from said first container. The inventive system may include,
for example, a hybrid retail/warehouse system which includes a
facility having a shelving area, and a picking area adjacent to the
shelving area, and a layout so as to minimize a picking area and a
walking distance between a picking area and a shelving area.
Inventors: |
Stevens, John; (Ontario,
CA) ; Waterhouse, Paul; (Ontario, CA) ;
Vandenberg, Mike; (Ontario, CA) |
Correspondence
Address: |
MCGINN & GIBB, PLLC
8321 OLD COURTHOUSE ROAD
SUITE 200
VIENNA
VA
22182-3817
US
|
Assignee: |
eBox, Inc.
Toronto
CA
|
Family ID: |
46302356 |
Appl. No.: |
10/892500 |
Filed: |
July 16, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10892500 |
Jul 16, 2004 |
|
|
|
10474353 |
Oct 9, 2003 |
|
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Current U.S.
Class: |
700/214 |
Current CPC
Class: |
B65G 2209/04 20130101;
B65G 2201/0261 20130101; B65G 1/1378 20130101; B65G 2203/046
20130101; B65G 2201/0258 20130101; B65G 1/1371 20130101 |
Class at
Publication: |
700/214 |
International
Class: |
G06F 007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 9, 2002 |
WO |
PCT/US02/10927 |
Claims
What is claimed is:
1. A warehousing system comprising: a first container for storing
at least one item, a first electronic module associated with said
first container; and a controller which wirelessly communicates
with said first electronic module, for directing a transfer of said
at least one item to and from said first container.
2. The warehousing system according to claim 1, further comprising:
a second container for receiving said at least one item from said
first container, wherein said controller directs a transfer of said
at least one item from said first container to said second
container.
3. The warehousing system according to claim 2, wherein said second
container is associated with a second electronic module which
wirelessly communicates with said controller, for facilitating a
transfer of said at least one item from said first container to
said second container.
4. The warehousing system according to claim 1, wherein said first
electronic module comprises a light emitting device which is
activated to indicate that said at least one item should be
transferred to and from said first container.
5. The warehousing system according to claim 1, wherein said first
electronic module comprises a display device for indicating a
content of said first container.
6. The warehousing system according to claim 1, wherein said first
container comprises a plastic tote.
7. A hybrid retail/warehouse system comprising: a retail/warehouse
facility comprising a shelving area and a picking area adjacent to
said shelving area, and having a layout so as to minimize a picking
area and a walking distance between a picking area and a shelving
area; a container associated with said retail/warehouse facility
for storing at least one item, an electronic module associated with
said container; and a controller which wirelessly communicates with
said module, for directing a transfer of said at least one item to
and from said container,
8. The hybrid retail/warehouse system according to claim 7, wherein
said item is personally selected by in-store customers and remotely
selected by out-of-store customers.
9. The warehousing system according to claim 7, wherein said
electronic module is affixed to said container.
10. A warehousing method comprising: storing at least one item in a
first container; and remotely directing a transfer of said at least
one item to and from said first container, using a first electronic
module which is associated with said first container.
11. The warehousing method according to claim 10, further
comprising: remotely assigning a second container to receive said
at least one item from said first container.
12. A hybrid retail/warehouse method comprising: storing at least
one item in a container which is associated with a retail/warehouse
facility, said facility comprising a shelving area and a picking
area adjacent to said shelving area, and having a layout so as to
minimize a picking area and a walking distance between a picking
area and a shelving area; and remotely directing a transfer of said
at least one item to and from said container, using an electronic
module which is associated with said container.
13. The hybrid retail/warehouse method according to claim 12,
wherein said item is at least one of personally selected by
in-store customers and remotely selected by out-of-store
customers.
14. The hybrid retail/warehouse method according to claim 12,
wherein said electronic module is affixed to said container.
15. The hybrid retail/warehouse method according to claim 12
wherein said container comprises a plastic tote.
16. A signal-bearing media tangibly embodying a program of
machine-readable instructions executable by a digital data
processor to perform a warehousing method, said method comprising:
storing at least one item in a first container; and remotely
directing a transfer of said at least one item to and from said
first container, using an electronic module which is associated
with said first container.
17. A signal-bearing media tangibly embodying a program of
machine-readable instructions executable by a digital data
processor to perform a hybrid retail/warehouse method, said method
comprising: storing at least one item in a container which is
associated with a retail/warehouse facility, said facility
comprising a shelving area and a picking area adjacent to said
shelving area, and having a layout so as to minimize a picking area
and a walking distance between a picking area and a shelving area;
and remotely directing a transfer of said at least one item to and
from said container, using an electronic module which is associated
with said container.
18. The warehousing system according to claim 1, wherein said
container comprises a pallet.
19. The warehousing system according to claim 1, wherein said
container comprises a plastic package.
20. The warehousing system according to claim 1, wherein said
container stores one item of merchandise.
21. The warehousing system according to claim 1, wherein said
controller wirelessly communicates with said first electronic
module via a low frequency signal.
22. A pallet for storing an item of merchandise, said pallet
comprising: a body which contains said item of merchandise; and an
electronic identification module attached to said body.
23. A package for storing an item of merchandise, said package
comprising: a body which contains said item of merchandise; and an
electronic identification module attached to said body.
24. The warehousing system according to claim 1, wherein said first
electronic module comprises an antenna for facilitating said
communication with said controller.
25. The warehousing system according to claim 1, wherein said first
electronic module is integrally formed with said first
container.
26. A container for containing an item, comprising: a body which
contains said item; and an electronic module integrally formed with
said body.
27. The container according to claim 23, wherein said body
comprises an antenna coupled to said electronic module for
facilitating wireless communication with said electronic
module.
28. The container according to claim 24, wherein said body
comprises a plurality of sides, said antenna being integrally
formed with at least one of said plurality of sides.
29. The container according to claim 24, wherein said antenna is
integrally formed with said plurality of sides.
30. A package for containing an item, comprising: a body which
contains said item; and an electronic module integrally formed with
said body.
31. A pallet for containing an item, comprising: a body which
contains said item; and an electronic module integrally formed with
said body.
32. The warehousing system according to claim 1, wherein said item
comprises a medical device.
33. A system for warehousing an item, comprising: an electronic
module associated with said item; and a controller which wirelessly
communicates with said electronic module, for controlling a
warehousing of said item.
34. The system of claim 33, wherein said controller controls a
warehousing of said item by controlling at least one of a location
of said item and a movement of said item.
35. An item to be warehoused, comprising: an electronic module
associated with said item for wirelessly communicating with a
controller which controls a warehousing of said item.
36. The item of claim 35, wherein said electronic module is one of
affixed to said item and integrally formed with said item.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part (CIP) Application
of U.S. patent application Ser. No. 10/474,353 which was filed on
Oct. 9, 2003, is assigned to the present assignee, and is
incorporated herein by reference, and this Application claims the
benefit of U.S. patent application Ser. No. 10/474,353.
[0002] U.S. patent application Ser. No. 10/474,353 claimed the
benefit of U.S. Provisional Application No. 60/282,150 which was
filed on Apr. 9, 2001 by John Stevens, and assigned to the present
assignee, and U.S. Provisional Application No. 60/359,350 which was
filed on Feb. 26, 2002 by John Stevens, et al. and assigned to the
present assignee, and which were incorporated therein by
reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention generally relates to a warehousing
system and method, and more particularly, a warehousing system and
method which may be used in a hybrid retail/warehouse facility.
[0005] 2. Description of the Related Art
[0006] Many inventory-based businesses rely exclusively or heavily
on the Internet. However, such businesses (e.g., dotcoms) have
often failed, primarily because there are simply too few customers
to carry costs. That is, the costs of fulfillment and operating
overhead could simply not be covered with the actual customer base.
However, the Internet customer base continues to grow by 25% each
year, and so the potential for future profits appears evident. For
instance, Amazon.com recently had its first profitable quarter
ever.
[0007] A major barrier to growth for any inventory-based business
is managing the physical warehouse, physical inventory, and
fulfillment from warehouse to customer. Many companies sell
"solutions" that include pick-to-light (PTL) or Dynamic Picking
Systems, batch picking with tilt tray sorting, automated crane
systems. A major problem with such conventional systems is that
volume and throughput commitments must be established before
capital and systems commitments are made. If the business plan is
wrong and a warehouse faces unexpected expansion, it becomes quite
expensive. If the business plan is wrong and the warehouse faces
below target throughput, it is a financial disaster. Finally, if
throughput is predictable, existing legacy systems are too
expensive to change.
[0008] Any new initiatives especially retail based ventures must
take a long hard look at fundamental economics, value chains and
operating costs. For instance, one of the major economic
inefficiencies in dotcom businesses is the Internet's dependency
upon expensive "old economy" fulfillment channels. In addition, the
dotcoms assume that any Internet retail business (i.e., "the
e-tailer") was just like mail order.
[0009] After the dotcom collapse none of the fulfillment companies
filed for Chapter 11. All claimed 10% to 20% annual growth in new
business as a result of the Internet and appear to have had
positive Internet cash flows from day one. However the high costs
and inefficiencies of these fulfillment channels cause conventional
systems to be expensive and inefficient and were directly
responsible for the demise of many dotcoms.
[0010] More specifically, three basic types of fulfillment systems
have been used for retail Internet-based businesses: Central High
Volume Automated Warehouse (National Fulfillment Channel), Regional
Medium Volume Warehouse (Regional Fulfillment Channel), and
Regional Low Volume Store/Warehouse (Regional Fulfillment Channel)
Many examples exist for the first type of system or mail-order
model, some successful and some not so successful. The best known
success of the second type of conventional system is Corporate
Express, with revenues of over $4 billion. In this second type of
system, inventive system 100 (e.g., the inventive fulfillment
chain) can cut fulfillment costs by as much as 50%.
[0011] The third type of system (e.g., Store/Warehouse approach)
has worked on a small scale and certainly minimizes capital
required to launch any Internet business. However, merely using
conventional retail store systems does not have the ability to
scale. In other words, merely utilizing a different fulfillment
channel without major modifications to the store does not make
economic sense for many reasons.
[0012] The major advantage of the third type of system (e.g., the
retail Store/Warehouse approach) is that the sunk costs associated
with inventory and inventory management can be shared by both the
Internet and direct in-store retail sales. However, this type of
system has two major shortcomings that make it not scalable.
[0013] First, the "value chain penalty". That is the product has
come from manufacture to a pallet based central warehouse, broken
down into "eaches" (e.g., single items), shipped to the store and
prepared for shelf-based in-store sales. It has been handled maybe
four or five times. The sunk cost for the product on the in-store
shelf may be as much as 12% higher than if it were in an optimized
"two touch" warehouse environment.
[0014] Second, inefficiencies created for the Internet business by
an in-store environment where picking eaches and management of
inventory is complicated and costly. For instance, many warehouse
systems involve placing products on shelves and picking the
products based on lights and displays attached to the shelf (e.g.,
a so-called "Pick and Put to Light" (PTL) system). These systems
typically require physical addresses for each item and also require
that a "picker" travel to the warehouse shelf to get an item.
[0015] Therefore, such conventional systems are inefficient and
time consuming. For example, lead to pick rates of 100 or less per
hour per employee are not uncommon. Indeed, the inventors believe
the warehouse picking penalty for the Internet business might be as
much as 4% on sales.
[0016] Thus, in the end the products will either cost more for the
Internet customer, in addition to the actual fulfillment costs, or
the products will cost more for in-store customer.
[0017] In addition, many warehousing systems, product distribution
systems, and methods for storing items (e.g., medical devices such
as heart valves, stents, endoscopes, sutures, shunts, etc.) are
currently very inefficient. For example, many such items have an
expiry date (e.g., a shelf life) after which the item is no longer
usable and is thus, discarded. Currently, many such items are not
used by their expiry date and are, therefore, discarded due to an
inability to efficiently and effectively track inventory, store or
warehouse these items.
SUMMARY OF THE INVENTION
[0018] In view of the foregoing and other problems, drawbacks, and
disadvantages of the conventional systems and methods, an object of
the present invention is to provide a cost and space efficient
warehousing system and method which optimizes each employee's time
and leads to highly efficient putting away" (e.g., re-shelving) of
products and highly efficient picking of products, and which may be
used in a hybrid retail/warehouse facility.
[0019] The inventive warehousing system includes a container (e.g.,
tote, package, packet, wrapper, envelope, pouch, crate, pallet,
bin, cylinder, box, carton, bag, can, etc.) for storing at least
one item (e.g., an item of merchandise), an electronic (e.g., radio
frequency identification (RFID)) module associated with the
container, and a controller which wirelessly communicates with the
module, for directing a transfer of the item(s) to and from the
container.
[0020] The inventive warehousing system may also include a second
container for receiving the item(s) from the first container. In
this case the controller may also direct a transfer of the item(s)
from the first container to the second container. In addition, the
second container may be associated with a second electronic (e.g.,
RFID) module which wirelessly communicates with the controller, for
facilitating a transfer of the item(s) from the first container to
the second container.
[0021] More specifically, the electronic module may include a light
emitting device which is activated to indicate that the item(s)
should be transferred to and from the first container. The module
may also include a display device for indicating a content of the
container (e.g., first container).
[0022] In another aspect, the present invention includes a hybrid
retail/warehouse system which includes a retail/warehouse facility
including a shelving area, and a picking area adjacent to said
shelving area, and having a layout so as to minimize a picking area
and a walking distance between a picking area and a shelving area.
The system also includes a container associated with the
retail/warehouse facility for storing at least one item (e.g., item
of merchandise) an electronic (e.g., RFID) module associated with
the container, and a controller which wirelessly communicates with
the module, for directing a transfer of the item(s) to and from the
container.
[0023] Further, the retail/warehouse facility may store item which
is personally selected by in-store customers and remotely selected
by out-of-store (e.g., Internet) customers.
[0024] In another aspect, a warehousing method according to the
present invention includes storing at least one item in a
container, and remotely directing a transfer of the item(s) to and
from the container, using a electronic (e.g., Radio Frequency
Identification Device (RFID) module) which is associated with the
container. The inventive method may also include remotely assigning
a bag (e.g., second container) to receive the item(s) from the
container.
[0025] In another aspect, a hybrid retail/warehouse method
according to the present invention includes storing at least one
item in a container which is associated with a retail/warehouse
facility, the facility including a shelving area, and a picking
area adjacent to said shelving area, and having a layout so as to
minimize a picking area and a walking distance between a picking
area and a shelving area. The method also includes remotely
directing a transfer of the item(s) to and from the container,
using an electronic (e.g., RFID) module which is associated with
the container. Further, the item may be personally selected by
in-store customers and/or remotely selected by out-of-store
customers.
[0026] The present invention may also include a signal-bearing
media tangibly embodying a program of machine-readable instructions
executable by a digital data processor to perform the inventive
warehousing method (e.g., hybrid retail/warehousing method).
[0027] Further, in the present invention, the container may include
a box, pallet, plastic package, or bag, etc. Further, the container
may store (e.g., house) a single item.
[0028] In addition, the controller can wirelessly communicate with
the first electronic module via a low frequency signal (e.g., radio
frequency signal).
[0029] In another aspect, the present invention includes a pallet
for storing an item, the pallet includes a body which contains the
item, and an electronic identification module attached to the
body.
[0030] In another aspect, the present invention includes a package
for storing an item. The package includes a body which contains the
item, and an electronic identification module attached to the
body.
[0031] Further, in the present invention the electronic module
(e.g., the first electronic module) may include an antenna for
facilitating the communication with the controller. The antenna may
be small or large relative to the size of the container.
Specifically, the antenna may be large and may be formed on at
least one side of the container.
[0032] Further, the electronic module (e.g., first electronic
module) may be integrally formed with the container (e.g., first
container). That is, the entire body of the container may be
available for including features of the electronic module. For
example, if the container is a plastic package having 6 sides
(e.g., a tetrahedron-shaped package) the antenna may be integrally
formed (e.g., embedded in) on one or more of the six sides of the
package.
[0033] In another aspect, the present invention includes a
container for containing an item. The container includes a body
which contains the item, and an electronic module integrally formed
with (e.g., embedded in) the body. For example, as noted above, the
body may include an antenna coupled to the electronic module for
facilitating wireless communication with the electronic module. For
example, the body may include a plurality of sides, the antenna
being integrally formed with at least one of the plurality of
sides. For example, the antenna may be integrally formed with all
of the plurality of sides.
[0034] In another aspect, the present invention includes a package
for containing an item. The package includes a body which contains
the item, and an electronic module integrally formed with the
body.
[0035] In another aspect, the present invention includes a pallet
for containing an item. The pallet includes a body which contains
the item, and an electronic module integrally formed with the
body.
[0036] With its unique and novel features, the present invention
optimizes each employee's time and leads to highly efficient put
away of products and highly efficient picking of products. The
invention, therefore, offers affordable, state-of-the-art
technology for managing and improving retail and warehouse
operations. The inventive system and method may also be
conveniently offered as an independent or integrated solution to
supply chain needs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The foregoing and other purposes, aspects and advantages
will be better understood from the following detailed description
of a preferred embodiment of the invention with reference to the
drawings, in which:
[0038] FIG. 1 is a schematic drawing illustrating an inventive
warehousing system 100;
[0039] FIG. 2A-2B illustrate a container that may be used in the
inventive system 100 according to the present invention;
[0040] FIG. 2C-2D illustrate examples of how containers may be
arranged on shelves according to the present invention;
[0041] FIG. 3A provides a detailed illustration of a container
which may be used in the inventive system 100;
[0042] FIG. 3B illustrates an electronic module which may be
associated with a container in the inventive system 100;
[0043] FIG. 4A provides a detailed illustration of a smart bag
(e.g., container) which may be used in the inventive system
100;
[0044] FIG. 4B illustrates an electronic module which may be
associated with a smart bag in the inventive system 100;
[0045] FIG. 5A-5B are schematic drawings illustrating a layout of
an inventive warehousing system 100 according to the present
invention;
[0046] FIG. 6 illustrates an inventive hybrid retail/warehouse
system 100 according to the present invention;
[0047] FIG. 7A illustrates a conventional warehouse system, and
FIG. 7B illustrates a comparably-sized warehouse utilizing the
inventive hybrid retail/warehouse system 600;
[0048] FIG. 7C illustrates a conventional warehouse system, and
FIG. 7D illustrates a comparably-sized warehouse utilizing the
inventive hybrid retail/warehouse system 600;
[0049] FIG. 8 is a flow chart illustrating an inventive warehousing
method 800 according to the present invention;
[0050] FIG. 9 illustrates an inventive hybrid retail/warehouse
method 900 according to the present invention;
[0051] FIG. 10 illustrates a typical hardware configuration which
may be used for implementing the system and method according to the
present invention;
[0052] FIG. 11 illustrates an example of a signal-bearing media
which may be used to implement the system and method according to
the present invention;
[0053] FIG. 12 illustrates the details of an electronic module
which may be associated with a container in the inventive system
100; and
[0054] FIG. 13 illustrates another aspect of the present invention
which includes an item 1305 to be warehoused, and a system 1300 for
warehousing the item 1305.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0055] Referring now to the drawings, and more particularly to
FIGS. 1-13, there are shown preferred embodiments of the system and
method according to the present invention.
[0056] As shown in FIG. 1, an inventive warehousing system 100
includes a container (e.g., tote, package, packet, wrapper,
envelope, pouch, crate, pallet, bin, cylinder, box, carton, bag,
can, etc.) 110 for storing at least one item of merchandise, an
electronic (e.g., first radio frequency identification (RFID))
module 120 which is associated with the first container, and a
controller 130 which wirelessly communicates with the module, for
directing a transfer of the item(s) to and from the first
container.
[0057] The inventive warehousing system 100 is especially useful
for storing an item (e.g., one or more items) in a container. The
system 100 may be especially efficient for warehousing (e.g.,
storing) items having an expiry date.
[0058] For example, in the inventive system, a medical device
(e.g., a single medical device) such as a heart valve, stent or
shunt may be stored in a package (e.g., container).
[0059] As described below, the inventive system 100 optimizes each
employee's time and leads to highly efficient "put away" (e.g.,
shelving) of items and highly efficient "picking" of items. The
inventive system 100 is based in part on a wireless container
system that may use display modules and short range low frequency
RF transmitted through loop antennas similar to those used for
grocery store pricing modules.
[0060] In addition, as shown in FIGS. 2A-2B, the container 110 may
include a tote for easily transferring items to and from the
container.
[0061] The container 110 used in the inventive system 100 may be
formed of varying dimensions and may be used to store several
items. For example, the container 110 may be small enough to hold
bolts and spices, or large enough to hold 50 lb bags of dog food.
In fact, for very large items the container 110 may resemble a
pallet in a pallet-based system.
[0062] For instance, the container 110 may have suitable dimensions
(e.g., approximately 18".times.18" by 24" in an exemplary
non-limiting embodiment) and may be made from conventional
materials (e.g., plastic). The container 110 may be smaller or
larger, and a warehouse may use a plurality of containers 110
having a variety of sizes. In addition, as shown in FIGS. 2C-2D,
the container 110 may be easily stored on store shelves to provide
for a very neat and organized presentation of the items.
[0063] In addition, as shown in FIG. 3A, associated with each
container is an electronic module 120 (e.g., radio frequency
identification module (RFID)). For example, the electronic module
120 may be affixed (e.g., attached) to the container 110. More
specifically, the module 120 may be a wireless battery operated
module capable of two-way communication.
[0064] As shown in FIG. 3B, each module 120 may include a memory
device 121 (e.g., semiconductor memory; random access memory (RAM)
for storing a unique identification (ID) number, two light emitting
devices 122 (e.g., light emitting diodes (LEDs)) which may have
different colors (e.g., red and green), a display device 123 (e.g.,
liquid crystal display (LCD)) which may include a five-digit
display, and at least one device 124 (e.g., button) for
activating/deactivating a feature of the module 110 (e.g., the LED,
display device, etc.).
[0065] Of course, many variations of the module 120 configuration
are possible. The module 120 may use a low power complementary
metal oxide semiconductor (CMOS) circuitry and, with a standard
lithium battery, will operate for a period of many years. The
memory device 121 may also store button pushes or other parameters
associated with the status of the container (e.g., weight,
temperature, etc.). The memory device 121 may also store
identification numbers (e.g., UPC) corresponding to items which are
contained in the container 110 or which are to be transferred to or
from the container 110.
[0066] The inventive warehousing system 100 also includes a
controller 130 which wirelessly communicates with the module 120.
The controller 130 directs a transfer of the item(s) to and from
the container 110.
[0067] For example, the controller 130 may include a processor
(e.g., microprocessor), memory device and two way radio device
(e.g., transmitter/receiver). For instance, the controller 130 may
include a computer system which is capable of directing a radio
transmitting/receiving function. For instance, the controller 130
may wirelessly communicate with the module 120 using low frequency
(e.g., 300 khz) two-way radio frequencies.
[0068] The inventive warehousing system 100 may also include an
antenna (e.g., antennas) (not shown) to facilitate communication
between the controller 130 and the module 120. The antenna may
include one or more antenna loops (e.g., wire loops) and
communication may be limited to the area within a loop. These
antenna loops can be placed in the floor, behind a shelf or in the
ceiling.
[0069] Thus, when a given loop is activated, it can poll for a
specific module 120 and if the module 120 is present, it can be
made to respond to the poll. In other words the controller 110
(e.g., a software system operated by the controller 130) can direct
a search of the entire warehouse, loop by loop polling for a
specific module 110, and locate the presence or absence of a module
120. When the software system establishes communication, the
inventive warehousing system 100 can bcause the module's display
device 123 to display a particular number, read whether a
particular button 124 has been pushed or not, turn an LED 122
(e.g., red, green, etc.) on or off, read back the identification
number of the module 120, read the contents of the memory device
121, etc.
[0070] As shown in FIG. 4A, the inventive warehousing system 100
may also include a smart bag 310 for receiving items from the
container 110. Generally, the features described above for the
container 110 can also be provided by the smart bag 310. For
example, the smart bag 310 may be made of conventional materials,
such as plastic or canvas.
[0071] Further, as shown in FIG. 4B, the smart bag 310 may also be
associated with an electronic module 320 similar to the module 110
discussed above. For instance, the module 320 may include a memory
device 321 (e.g., semiconductor memory; random access memory (RAM)
for storing a unique identification (ID) number, two light emitting
devices 322 (e.g., light emitting diodes (LEDs)) which may have
different colors (e.g., red and green), a display device 323 (e.g.,
liquid crystal display (LCD)) which may include a five-digit
display, and at least one device 324 (e.g., button) for
activating/deactivating a feature of the module 320 (e.g., the LED,
display device, etc.).
[0072] Further, the module 320 may be affixed to the smart bag 310.
For instance, the smart bag 300 may include a pocket 330 on the
front of the bag 310 for containing the module 320. Further, the
smart bag 310 may also contain an optional second bag (not shown)
that can be used to hold products for delivery.
[0073] The inventive warehousing system 100 provides a fast and
efficient tool for picking and putting away items and may be used
in virtually any setting (e.g., retail, warehouse, hybrid
retail/warehouse, etc.). For instance, FIGS. 5A and 5B illustrate
examples of how the inventive warehousing system 100 may be
implemented according to the present invention.
[0074] As shown in FIG. 5A, items may arrive at the facility (e.g.,
a warehouse) on pallets. As soon as the items are identified (from
bar codes or the invoice), it may be moved to a "pallet to
container put area" 410 (e.g., staging area). The number of
containers 110 required to hold all of the product from the pallet
may be calculated by the controller 130 (e.g., the system
software), and the required number of containers 110 may be
transferred into the put area 410 automatically.
[0075] A database (e.g., controller database) links the unique
identification number of each container 110 with the item and the
number of items that should be placed in the container 110. The
pallet may be manually unpacked item by item and placed in the
containers 110. Each container 110 may be weighed as a cross-check
that the number of items are correctly packed into the container
110.
[0076] Referring again to FIG. 5A, the packed containers 100 may be
moved into the shelf storage area 420 using, for example, a
conveyor or truck. Each container 110 may be placed on the shelf in
whatever order and in any available place the worker might find
empty. For example, the containers 100 may be placed randomly on
shelves. Further, the shelves may contain many thousands of
containers 100 on shelves.
[0077] The controller 130 may communicate with a module 120 on a
particular container 110 to indicate that an item contained in that
particular container 110 is to be transferred. For instance, the
controller 130 may cause the module 120 to activate an LED 122
which can be seen by operator to indicate that an item is to be
transferred from that particular container 110. (It should be noted
that the module 120 may include an audible signal (e.g., bell)
instead of the LED 122 as an indicating device).
[0078] The container 110 indicated by the controller 130 may be
transferred (e.g., by an operator or automatically) from the shelf
storage area 420 to a container to bag pick area 430. Here, the
item may be transferred from the container 110, for example, for
delivery to a purchaser. For example, the item may be transferred
from the container 110 to a smart bag 310. The smart bag 310
containing the item may be transferred from the container to bag
pick area 430 to a bag to truck put area 440 to await transfer out
of the facility.
[0079] Specifically, FIG. 5B provides a detailed illustration of a
container to bag pick area 430. As shown in FIG. 4B, the picking
area 430 may include a conveyor lane 436 and a picking lane
437.
[0080] When an operator (e.g., a "shelf picker") sees a light
flashing on a container 110 in the shelf storage area 420, he may
remove the container 110 from the shelf and place it in a conveyor
lane 436 (e.g., conveyor belt) that takes it to a picking area 430.
As the container 110 moves to the picking area 430, the red LED is
turned off. The container 110 arrives at the picking area 430 and
goes past several picking regions 431 until it comes to the region
that has a bag 310 assigned to the order.
[0081] When that particular container 110 reaches that region 431,
the controller 130 (e.g., software) causes the red light on the
module 120 on that particular container 110 to activate again. The
"packing picker" sees the light flashing an removes the item from
the container 110.
[0082] The operator may scan the item removed from the container
110 using a scanner 435 provided in the picking area 430. The
controller 130 (e.g., software system) detects that the correct
item has been scanned and turns off the container's LED.
[0083] The operator may transfer the item to the picking lane 437
where smart bags 310 may be assembled. The controller 130 may
(e.g., simultaneously with deactivating the container LED) activate
an LED on a smart bag 310 in the picking lane 437 that is supposed
to receive the item. The packing picker may place the item in the
bag 310 that is flashing.
[0084] The picking area 430 may also contain a weight detection
device (not shown) which allows the smart bag 310 to be weighed so
as to detect a change in the weight of the smart bag 310 when an
item is placed in the smart bag 310. For instance, when a
predetermined weight change is detected, the LED on that particular
smart bag 310 may be deactivated (e.g., by the weighing device or
by the controller 130 which communicates with the weighing
device).
[0085] After the item has been removed from the container 110, the
container 110 may continue on the conveyor belt and eventually
return to the shelf storage area 420. As the container 110 moves
towards the shelf storage area 420 the controller 130 may activate
an LED on the container module 120 (e.g., the green LED) to
indicate that the container 110 should be placed back on the shelf.
When the shelf picker may see the green flashing light on the
container 110 and remove the container 110 from the conveyor and
place it back on the shelf (e.g., in a random order).
[0086] Thus, for example, the shelf picker may simply pick red
light containers and place them on the conveyor towards the picking
area, and green flashing containers and put them back on the
shelves. Therefore, the packing pickers may, for example, work
within their region in the packing area 430 and simply take items
from a red flashing container in the conveyor lane 436, scan it and
place it in the bag 310 that has a flashing light in the picking
lane 437. A container 110, the items in which have not been picked,
may simply stay on the conveyor belt to return to the picking
regions 431. It may also be possible to keep high volume items
(e.g., items that are frequently picked) on a special conveyor
behind the pick lane 437 so that they may be easily moved to the
pick lane.
[0087] Hybrid Retail/Warehouse Facility
[0088] The inventive warehousing system and method may be
efficiently and effectively incorporated, for example, in a hybrid
retail/warehouse system.
[0089] As shown in FIG. 6, an inventive hybrid retail/warehouse
system 600 includes a retail/warehouse facility 605 for storing
items (e.g., items of merchandise). The retail/warehouse facility
605 may store items which may be either personally selected by
in-store customers and/or remotely selected by out-of-store
customers. For example, the retail/warehouse facility 605 may be
designed to handle both retail customers who are shopping in person
and personally taking items from the shelves for purchasing.
However, the facility 605 may also be designed to handle customers
that are remotely purchasing items such as over the Internet (e.g.,
the World Wide Web). Thus, the facility 605 may be equipped to
conveniently take orders over the Internet.
[0090] The inventive hybrid retail/warehouse system 600 also
includes a container 610 associated with the retail/warehouse
facility 605 for storing at least one item, an electronic module
620 (e.g., a radio frequency identification (RFID) module)
associated with the container 610, and a controller 630 which
wirelessly communicates with the module 620, for directing a
transfer an item to and from the container 610.
[0091] Specifically, the container 610, electronic module 620 and
controller 630 may have features comparable to those discussed
above with respect to the container 110, electronic module 120 and
controller 130 in the warehousing system 100 above. In addition,
the operation of the inventive hybrid retail/warehouse system 600
is comparable to the operation of the warehousing system 100
explained above with respect to FIGS. 5A-5B.
[0092] In short, the inventive system 600 provides a highly
efficient, low capital cost solution that also can be easily scaled
with throughput growth at low costs. The cost-effective scalability
feature makes the inventive system 600 an attractive component in
the Corporate Network product. Further, the inventive system 600 is
ideally suited to serve uncertain inventory requirements. The
system 600 can serve the full range and be quickly retrofitted at a
low cost to increase productivity or be used as a simple
pick-to-light in aisle system.
[0093] In other words, the inventive system 600 provides an
inventive "new economy" fulfillment channel, that can save as much
as 50% in regional fulfillment costs. The inventive channel may be
based, for example, on optimized un-attended night-time delivery to
a network of proprietary, secure drop boxes.
[0094] The inventive system 600 may be used, for example, for
business-to-business (B2B) corporate fulfillment (e.g., critical
parts, industry specific networks, wholesale fulfillment, and
private corporate networks). However, the inventors believe retail
fulfillment also offers a significant opportunity and can also
benefit from the inventive system 600 and its related
technology.
[0095] Unlike conventional systems, the inventive hybrid
retail/warehouse system 600 provides optimized high throughput for
each picking. The inventive system 600 relies in part on the
electronic module 620 associated with the container 610. However,
unlike many radio frequency (RF) tag devices in conventional
systems (and comparable to the features discussed above with
respect to module 120) the module 620 may include: two LEDs, an 8
Digit LCD, three operating switches (e.g., activating/deactivating
buttons), a two way 300 Khz 1200 baud RF link, programmable
functionality, and a prepro-grammed unique identification (e.g., ID
number). Further, each module 620 may be used to display retail
price and unit price, in addition to displaying all other warehouse
functions on demand for in-store pickers, including pick-to-light
LEDs.
[0096] Referring again to FIG. 6, the controller 630 wirelessly
communicates with the RFID module 620, in order to identify and
locate items. It should be noted that FIG. 6 is merely illustrative
and that the controller 630 may be located within or outside the
facility 605. Likewise, the RFID module may be located either
inside or outside the facility 605 and still be controlled by the
controller 630.
[0097] The inventive system 600 provides a low-cost,
small-footprint pick-to-light fulfillment system that can use the
controller 630 to "find" an item in a warehouse (e.g., a hybrid
retail/warehouse facility 605). Using a unique Radio Frequency
Identification (RFID) module, the controller 630 allows random,
dynamic placement of inventory for either pick or put-away. The
controller 630 can "find" and recognize the location of any
randomly placed inventory with periodic scans of the warehouse.
[0098] In addition, inventive system 600 is very flexible. Its
installation can be configured to as low as 2,000 containers or
modules, yet there is no practical limit on the size of facility or
number of SKUs.
[0099] The inventive system 600 further provides a wireless,
real-time fulfillment system using pick-to-light (PTL) and RFID
technology which may be coupled with a proprietary inventory
location and positioning software which may be executed, for
example, by the controller 630. The controller 630 allows for the
identification and placement of inventory anywhere in the warehouse
without the rigid structures of predetermined inventory locations
or addresses.
[0100] Further, the proprietary wireless display module 620 is
designed so as to allow the central controller 630 to selectively
"talk" to the module 620 when it is located anywhere in or around
the warehouse facility 605. In addition, the modules 620 can be
attached to any inventory unit (e.g., each/container/tote/pallet,
etc.). Once an SKU is identified to the module 620, an item may be
placed anywhere in or around the facility 605 and the controller
630 will "locate" it.
[0101] Further, the inventive system 600 is configurable to any
warehouse operation. Its basic functionality may include, for
example, receiving, dynamic or traditional addressed put-away,
dynamic picking, packing, shipping, cross docking, productivity
measurement, labor management, dynamic slotting, re-warehousing
(storage consolidation), RF communications for all functions,
automatic replenishment, expiration dating, batch/lot control,
report generation, order management, wave management, weight check,
cycle counting.
COMPARATIVE EXAMPLES
[0102] FIG. 7A illustrates a conventional warehouse system, and
FIG. 7B illustrates a comparably-sized warehouse utilizing the
inventive hybrid retail/warehouse system 600.
[0103] Specifically, FIG. 7A illustrates a conventional warehouse
which may include, for example, a typical 250,000 sq.ft.
distribution center (500'.times.500') in which all SKUs have
location addresses assigned to them, either random or fixed. All
locations within the facility are active, picking can occur
throughout the facility. It is assumed that 20 pickers are required
to pick 200 orders for this hypothetical operation.
[0104] Traditional pick-paths can span the entire warehouse to find
the "B" and "C" items in a pick list.
[0105] It may be assumed, for example, that within such a
conventional distribution operation, 75% of a picker's time will be
spent traveling, and an average multi-pick order will require the
picker to travel 60% of the total aisle distance within the picking
area. In this case there are 7 aisles, 300 feet each; at 60%
average order batch travel will be 1,260 feet and 200 batches will
require travel of 252,000 feet per day (7 aisles.times.300
feet.times.60%.times.200 order batches). Assuming 20 pickers are
required to fulfill, the average picker travel will be 12,600 feet
per day. Therefore the standard output per picker is 12,600 feet
per day.
[0106] FIG. 7B, on the other hand, illustrates a warehouse
utilizing the inventive system 600 and which includes a Dynamic
Pick Area A B C D F G. The inventive system 600 allows a much
smaller pick area. In addition, a limited number of people locate
the "B" and "C" containers and position them within the picking
area.
[0107] Specifically, FIG. 7B illustrates a distribution center with
25,000 sq.ft. picking area, with 825 feet of aisles (11
aisles.times.75 feet) and 225,000 sq.ft. for back stock. This
methodology may require two (2) full-time replenishers. However,
since the picking area is geographically smaller and travel
distances are shorter, there will be fewer pickers required. Using
the math from the first illustration: 200 order
batches.times.(825.times.60%)/12,600 feet/day/picker (performance
standard)=8 pickers required. 8 pickers+2 replenishers=10 total
headcount for a 10 headcount reduction. Paybacks of less than one
year can be attained using the presently disclosed inventive system
600.
[0108] Referring again to the drawings, FIG. 7C illustrates a
conventional warehouse system, and FIG. 7D illustrates a
comparably-sized warehouse utilizing the inventive hybrid
retail/warehouse system 600.
[0109] FIG. 7C illustrates second example of a conventional
warehouse system A B C D E F G Y. As shown here, conventional
pick-paths can span the entire warehouse to find the "B" and "C"
items in a pick list.
[0110] Specifically, FIG. 7C illustrates a typical 250,000 sq.ft.
distribution center (500'.times.5800') in which all SKUs have
location addresses assigned to them, either random or fixed. All
locations within the facility are active, picking can occur
throughout the facility.
[0111] It may be assumed, for example, that 20 pickers are required
to pick 200 orders for this hypothetical operation. It may also be
assumed that, within distribution operations, 75% of a picker's
time will be spent traveling, and an average multi-pick order will
require the picker to travel 60% of the total aisle distance within
the picking area.
[0112] In this case there are 7 aisles, 300 feet each; at 60%
average order batch travel will be 1,260 feet and 200 batches will
require travel of 252,000 feet per day (7 aisles.times.300
feet.times.60%.times.200 order batches). Assuming 20 pickers are
required to fulfill, the average picker travel will be 12,600 feet
per day. Therefore the standard output per picker is 12,600 feet
per day.
[0113] FIG. 7D, on the other hand, illustrates a facility using the
inventive system 100 as applied to a picking operation. As shown in
FIG. 7D, the inventive system 600 allows a much smaller pick area.
A limited number of people locate the "B" and "C" containers and
position them within the picking area (e.g., dynamic pick area A B
C D E F.
[0114] Specifically, FIG. 7D illustrates the a distribution center
with 25,000 sq.ft. picking area, with 825 feet of aisles (11
aisles.times.75 feet) and 225,000 sq.ft. for back stock. This
methodology will require two (2) full-time replenishers, however
since the picking area is geographically smaller and travel
distances are shorter, there will be fewer pickers required. Using
the math from the first illustration: 200 order
batches.times.(825.times.60%)/12,600 feet/day/picker (performance
standard)=8 pickers required. 8 pickers+2 replenishers=10 total
headcount for a 10 headcount reduction. Paybacks of less than one
year can be attained using the inventive system 600.
[0115] This example, assumes, for instance, that each
headcount=$15.00 US/hr including fringes, and that each
headcount=2080 hours/year (no overtime). It also assumes a 250,000
sq.ft. warehouse cost at $4.00 US per sq.ft. $1,000,000 US
inventory.
[0116] Therefore, the cost of the inventive system 600 may include
installation w/20,000 containers $250,000, employee retraining 8
hrs H 20 HC 2,400, maintenance agreement (15%) 37,500, and
contingency (10%) 25,000. Thus, the total cost is about
$314,900.
[0117] In other words, the inventive system 600 results in savings
over the conventional system. For instance, assuming a 10 headcount
reduction (10 H $15 H 2080) $312,000, space utilization improvement
15% 50,000, and inventory utilization improvement 5% 50,000, the
total savings is about $362,000.
[0118] Other Features
[0119] An important feature of the inventive system 600 is that
location of items does not need to be assigned. All movement
whether put-away, re-stocking, receiving or shipping can be random
and dynamic. The controller 630 will locate the SKU, container, or
pallet and update the system 600. All items within or around the
facility 605 may be identified with modules 620 which are
continuously interrogated by the controller 630 for quantity and
physical location of the items.
[0120] This unique attribute is invaluable in fast paced, dynamic
warehouse environments such as fashion, seasonal businesses, and
service parts. The ability to dynamically slot picking areas allows
the warehouse to keep a small picking footprint. The ability to
dynamically consolidate put-away areas keeps those storage areas
densified and opens empty slots for inbounds.
[0121] There are other important features of the inventive system
600 which make it more efficient than conventional systems. For
example, the receipt process ties a single unit of product (each,
container, pallet, etc) to a single module 620 which may be
automatically tracked by the controller 630. Further, Received
product is simply put into the next available picking or storage
slot anywhere in the warehouse (e.g., dynamic put-away). The
controller 630 takes care of the tracking. This user-friendly
approach allows operators more freedom to manage the flow of
inbound inventory.
[0122] In addition, the system 600 provides for dynamic picking.
For instance, occasionally, a "B" item becomes an "A for a day" and
these items can be moved forward in real-time by the pickers, while
slower moving items "B for a day" can be moved back using the same
methodology. The system 600 also provides for cross-docking. For
instance, during the receiving process, the controller 630 will
automatically identify product to be cross docked and will notify
receiving personnel through the display on the module 620. The
product is then directed to the appropriate packing or shipping
area. The system 600 also helps to facilitate productivity
measurement. That is, the controller 630 may contain productivity
reporting capabilities and interface with all conventional
warehouse productivity software.
[0123] The system 600 also provides for dynamic slotting. For
example, as the velocity of products change, the controller 630 may
direct the movement of product to specific aisles or slots.
Replenishers may be directed to move fast movers to the front of
the picking area, slower movers back, and "C" items will be removed
to storage if there is no future picking requirement. It should be
noted that there is no requirement to return the "C" item to a
fixed address, because it can be replaced anywhere in storage and
the controller 630 will find it. The controller 630 updates the new
location of the product automatically, and directs pickers or
replenishers to the "new" location.
[0124] Further, the system 600 provides for pick path optimization.
Specifically, pickers and replenishers may be directed through the
most efficient pick paths to optimize productivity (e.g., a picking
area may be minimized and a walking distance between a shelving
(e.g., storage) area and a picking area may be minimized).
[0125] The system 600 also facilitates re-warehousing (storage
consolidation). In other words, partially depleted containers may
be moved to half-container locations to densify the storage area.
Again the controller 630 may automatically update the new location
of the product.
[0126] Further, wireless (e.g., radio frequency) communications may
be used for all functions, thereby providing for automatic
replenishment. In other words, since the controller dynamically
tracks the location and quantity of all products in the warehouse,
replenishment signals may be triggered to keep the right product in
the pick area, just in time.
[0127] The system 600 can be incorporated at receipt to so as to
facilitate expiry dating. In other words, the controller 630 can be
configured to "find" the oldest product to reduce expiry dating
write-downs. The system 600 may also aide in batch/lot control. The
system 600 is completely variable and operator controllable to
assure that the right mix or match of products is sent to the right
customer. Last in first out (LIFO), first in first out (FIFO),
least costly first, most costly first, expired product flash, and
more are available in the controller 630.
[0128] The system 600 also facilitates cycle counting. In other
words, the system 600 is configurable to meet the audit
requirements of any company. Pickers may transmit (e.g., directly
transmit) inventory discrepancies or replenishers to the controller
630 to trigger full scale cycle counts by SKU, container,
expiration date, batch, etc.
[0129] In addition, the inventive system 600 is consistent and
compatible with many current warehouse operations and systems. This
is a significant benefit to organizations that have invested
heavily in a traditional warehouse management system (WMS) and
desire to add the module 620 and controller 630 functionality to
their existing systems.
[0130] Economic Analysis
[0131] The inventors carried out preliminary economic analysis and
marketing interviews and concluded that a retail store which
utilizes the inventive hybrid retail/warehouse system 600 will
overcome the major disadvantages of value chain issues and in-store
picking of items. The store would effectively be able to sell "two
touch" items at a retail level.
[0132] Additionally, such retail stores with the inventive system
600 will have low costs associated with item shelf maintenance, and
provide the consumer with a neat orderly appearance. Such stores
would also have very low planogram requirements, product
maintenance inventory management costs, and the ability to modify
and re-set store layout in a matter of only a few hours. Such a
store would also have many inventory maintenance advantages, and
the ability to optimize pricing to consumers.
[0133] In addition, such stores using the inventive system 600 may
overcome one of the major consumer objections to bulk discount
stores, namely "that it costs too much to shop because your forced
to buy in large quantities". In other words, a store using the
inventive system 600 will permit the store to sell individual items
at discount bulk prices, for both in-store and out-of-store (e.g.,
internet/catalog) sales.
[0134] Advantages
[0135] The advantages of the inventive system 600 over a
conventional shelf-based system with a traditional warehouse
management system (WMS) are numerous. For example, the system 600
provides for captive customers, and strong customer conversion.
Most in-store customers would make use of Internet and visa-versa.
The system 600 also makes it possible to sell individual items
in-store at prices competitive to discount bulk in competition.
This is considered a consumer barrier to current bulk stores. In
addition, the system 600 provides strong economic and value chain
justification.
[0136] Further, the containers provide enormous savings in software
and systems complexity, and product handling and space management
efficiencies. Totes have a long history of success in Europe, where
many manufactures are required to deliver all back-door products
packed in containers. The containers can also provide a neat
orderly looking store.
[0137] In addition, the system 600 provides electronic pricing and
price optimization which is essentially free, and has stand-alone
economic advantages. Further, the electronic management of item
location or planogram has a low cost and is easy to implement.
Moreover, store re-set can be carried out at much lower cost. In
addition, the software systems and product inventory management
software in the system 600 are not complex compared to conventional
in-store systems.
[0138] In addition, the modules 620 are relatively inexpensive
(e.g., less than $5.00 per module). Further, the software used to
manage item picks and inventory that replaces current warehouse
management system (WMS) software is simple. This is at least in
part because the system 600 may be based on containers not SKUs.
Moreover, physical location of the items can be managed and
detected by the software in the warehouse, and items can be re-set
based on whatever optimization might be required.
[0139] By flashing light-emitting devices (e.g., light-emitting
diodes (LEDs)) on items to be picked, the pick rates may be
doubled, put costs reduced, inventory management simplified,
particularly with same SKUs that have different cost basis or
expiration dates. Furthermore, physical inventory is simple,
warehouse re-sets can be carried in matter of only few hours, and
item location in warehouse can be optimized on almost a daily
basis.
[0140] Conventional paper based operations can retain their
existing warehouse storage philosophy and simply implement the
inventive system 600 in a picking area. This is an excellent use of
capital and the inventive system's capabilities. Improving picking
productivity by 20-40% will justify the capital expenditure for the
system 600, due to the system's low investment. For instance, if a
company employs 20 or more warehouse personnel, an improvement in
performance of only 4-6 headcount will justify the cost of the
system 600. In addition, the system 600 is expandable and scalable,
allowing warehouse operations to grow with their expanding
businesses and markets.
[0141] Further, documentation and support of the controller 630 may
include operations manuals, training documentation and support,
installation manual, installation technical support, technical help
desk, and full release and documentation of the controller 630
source code. Maintenance agreements in one (1) to five (5) year
increments may also be available at 15% of installation annually,
which will include all upgrades and modifications.
[0142] In short, the inventive system 600 provides fast paced
quickly changing distribution operations the accuracy and
efficiency of a conventional pick-to-light system without the high
cost and static positions of hard-wired displays.
[0143] Further, the open code structure allows the inventive system
600 to easily interface with existing legacy business systems,
enterprise resource planning systems (ERP) or existing
inventory/warehouse management systems.
[0144] Specifically, the modules 620 may include a proprietary
design. Briefly, though, each module 120 may contain a custom
communication chip. A typical warehouse utilizing the inventive
system 600 may include, for example, approximately ten (10) base
stations for communication, a central controller, and approximately
20,000 containers for a total cost of under $250,000 installed.
This is relatively inexpensive, compared to conventional WMS and
PTL which cost approximately $100 to $250US per location.
[0145] Other benefits of the inventive system 600 may include:
installation costs 50-75% below traditional WMS-based PTL systems,
improved picker accuracy to 99%+, improved picker productivity of
20-40% compared to non PTL installations, Space reductions up to
25% due to more effective space utilization, dynamic ABC, dynamic
storage consolidations, Inventory reductions due to improved
accuracy, consolidation, real-time, and cross-dock capabilities,
Operator accountability, Real-time transaction capture, Paperless
warehouse environment, 24.times.7 customer service/help desk, and
Installation support.
[0146] Referring to FIG. 8, another aspect of the present invention
includes an inventive warehousing method 800. As shown in FIG. 8,
the inventive method includes storing (810) at least one item in a
first container, and remotely directing (820) a transfer of the
item(s) to and from the first container, using a Radio Frequency
Identification Device which is associated with the first
container.
[0147] In addition, FIG. 9 is a flowchart an inventive hybrid
retail/warehouse method 900. As shown in FIG. 9, the inventive
method 900 includes storing (910) at least one item in a first
container which is associated with a retail/warehouse facility, and
remotely directing (920) a transfer of the item(s) to and from the
first container, using a Radio Frequency Identification Device
which is associated with the first container.
[0148] Referring again to the drawings, FIG. 10, illustrates a
typical hardware configuration which may be used for implementing
the inventive system 100, 600 and method 800, 900. The
configuration has preferably at least one processor or central
processing unit (CPU) 1011. The CPUs 1011 are interconnected via a
system bus 1012 to a random access memory (RAM) 1014, read-only
memory (ROM) 1016, input/output (I/O) adapter 1018 (for connecting
peripheral devices such as disk units 1021 and tape drives 1040 to
the bus 1012), user interface adapter 1022 (for connecting a
keyboard 1024, mouse 1026, speaker 1028, microphone 1032, and/or
other user interface device to the bus 1012), a communication
adapter 1034 for connecting an information handling system to a
data processing network, the Internet, and Intranet, a personal
area network (PAN), etc., and a display adapter 1036 for connecting
the bus 1012 to a display device 1038 and/or printer 1039. Further,
an automated reader/scanner 1041 may be included. Such
readers/scanners are commercially available from many sources.
[0149] In addition to the system described above, a different
aspect of the invention includes a computer-implemented method for
performing the above method. As an example, this method may be
implemented in the particular environment discussed above.
[0150] Such a method may be implemented, for example, by operating
a computer, as embodied by a digital data processing apparatus, to
execute a sequence of machine-readable instructions. These
instructions may reside in various types of signal-bearing
media.
[0151] Thus, this aspect of the present invention is directed to a
programmed product, including signal-bearing media tangibly
embodying a program of machine-readable instructions executable by
a digital data processor to perform the above method.
[0152] Such a method may be implemented, for example, by operating
the CPU 1011 to execute a sequence of machine-readable
instructions. These instructions may reside in various types of
signal bearing media.
[0153] Thus, this aspect of the present invention is directed to a
programmed product, comprising signal-bearing media tangibly
embodying a program of machine-readable instructions executable by
a digital data processor incorporating the CPU 1011 and hardware
above, to perform the method of the invention.
[0154] This signal-bearing media may include, for example, a RAM
contained within the CPU 1011, as represented by the fast-access
storage for example. Alternatively, the instructions may be
contained in another signal-bearing media, such as a magnetic data
storage diskette 1100 (FIG. 11), directly or indirectly accessible
by the CPU 1011.
[0155] Whether contained in the computer server/CPU 1011, or
elsewhere, the instructions may be stored on a variety of
machine-readable data storage media, such as DASD storage (e.g, a
conventional "hard drive" or a RAID array), magnetic tape,
electronic read-only memory (e.g., ROM, EPROM, or EEPROM), an
optical storage device (e.g., CD-ROM, WORM, DVD, digital optical
tape, etc.), paper "punch" cards, or other suitable signal-bearing
media including transmission media such as digital and analog and
communication links and wireless. In an illustrative embodiment of
the invention, the machine-readable instructions may comprise
software object code, complied from a language such as "C,"
etc.
[0156] Further, it should be noted that the electronic tag may be
considered to be associated not only with the container which
contains items, but also with the item or items stored by (e.g.,
housed in) the container. For example, where the container includes
a single item, the electronic tag (e.g., electronic module) which
is affixed to (e.g., integrally formed with) the container may
likewise be considered to be associated with the item stored in
(e.g., housed by) the container.
[0157] Thus, information (e.g., an expiry date) associated with the
item or items may be stored by the memory device included in the
electronic module affixed to the container which houses the item or
items.
[0158] Further, FIG. 12 illustrates the details of an electronic
module which may be associated with a container or multiple items,
or a single item (e.g., where a single item is included in the
container) in the inventive system 100. As illustrated in FIG. 12,
the electronic tag 1210 associated with the item may be affixed to
a container or containers. As noted above, the container may
include, for example, a tote, package, packet, wrapper, envelope,
pouch, crate, pallet, bin, cylinder, box, carton, bag, can, etc.
and may contain (e.g., store, house, etc.) a single item.
[0159] Further, the small electronic tag 1210 (e.g., electronic
module) may be integrally formed with (e.g., embedded in a wall of)
the container or may be affixed (e.g., adhered to) the container,
for example, by locating the module, in a small translucent pocket
on the container. The tag may include a signaling device (e.g., a
plurality of signaling devices) such as a colored (e.g., red or
green) light emitting device 1220 (e.g., a light emitting diode
(LED) or an audible signaling device. The electronic tag 1210 may
also include a liquid crystal display 1230 (LCD) for numeric or
alphanumeric display, and a switch (e.g., plurality of switches or
buttons) 340 for controlling an operation of the electronic tag
1210.
[0160] FIG. 12 provides a more detailed description of the
electronic tag 1210. As shown in FIG. 12, the electronic tag 1210
additionally may include an inexpensive processor 1225 (e.g., a low
powered four bit microprocessor), a memory device 1235 (e.g., a
random access memory (RAM)) or other nonvolatile memory device for
storing a unique identification number. The identification number
may be permanent, so that it can be changed only with a special
program and transmitter.
[0161] The electronic tag 1210 may also contain a transceiver 1250
(e.g., a transmitter/receiver such as a two-way communication chip)
for allowing the electronic tag 1210 to communicate with a base
station (e.g., controller). The two-way communications chip may be,
for example, a lowcost CMOS analog digital chip. The chip may be
connected to one or more orthogonal ferrite antennas 1260 that are
able to transmit and receive signals using low frequencies (e.g.,
radio frequencies such as about 128 kHz) to a loop antenna which
may be wirelessly connected to a base station (e.g.,
controller).
[0162] For example, antenna 1260 may be small or large relative to
the size of the container. Specifically, the antenna 1260 may be
large and may be formed on at least one side of the container.
[0163] Further, the electronic module 1210 may be integrally formed
with the container. That is, the entire body of the container may
be available for including features of the electronic module 1210.
For example, if the container is a plastic package having 6 sides
(e.g., a tetrahedron-shaped package) the antenna may be integrally
formed (e.g., embedded in) on one or more of the six sides of the
package.
[0164] For example, the container may include a body which contains
the item, and an electronic module integrally formed with (e.g.,
embedded in) the body. In this case, the body may include an
antenna coupled to the electronic module for facilitating wireless
communication with the electronic module. For example, the body may
include a plurality of sides, the antenna being integrally formed
with at least one of the plurality of sides. Specifically, the
antenna may be integrally formed with all of the plurality of
sides.
[0165] Further, the loop antenna (e.g., antennas) may be located in
the warehouse in order to facilitate a two-way communication
between the electronic tag(s) 1210 and the base station (e.g.,
controller). Specifically, the electronic tag 1210 may wirelessly
communicate with the base station via a bi-directional wireless
link. The wireless link may include, for example, a low frequency
conductive loop requiring minimal power and allowing communication
within a small area.
[0166] Further, the LCD 1230 may be programmed to display both
numeric as well as alphanumeric information transmitted to the
electronic tag (e.g., electronic module) via the base station. The
circuitry may be solar powered or powered, for example, by a
battery 1270 or other power source. Battery life using conventional
alkaline batteries is likely to exceed five years, and with AAA
batteries the life may be longer.
[0167] In the present invention, the container which contains an
item (e.g., items) may be transferred to an area where the item can
be sorted and stored (e.g., on shelves) in the warehouse. The
location of the items (e.g., items in containers) can be random or
predetermined. For example, the electronic tag 1210 may be used to
help direct the placement of items at predetermined locations
(e.g., on shelves) in the warehouse. For example, an item's proper
location in the warehouse may be displayed on the LCD 1230 so that
it may be easily viewed, for example, by handlers (e.g.,
picker/packers) at a distribution center. For instance, the items
may be sorted and shelved in the warehouse, for example, by an
expiry date.
[0168] For example, the items can be placed on shelves from left to
right, front to back, upper to lower or lower to upper or in any
other order, according to such factors as the expiry date of the
item.
[0169] In addition, using the loop antenna, the base station (e.g.,
controller) may poll all of the electronic tags 1210 in the
inventive system in search of a particular electronic tag 1210 and
communicate only with that particular tag. For instance, the base
station may poll each of the electronic tags 1210 located near
(e.g., within) a loop antenna at a particular location (e.g., on a
particular shelf) in the warehouse. Thus, the base station is
capable of placing specific information on the display 1230,
activating/deactivating the signaling device (e.g., flashing the
light emitting diodes 1220), selectively activating each electronic
tag 1210 associated with an item (e.g., an electronic tag 1210
affixed to a container which contains item).
[0170] For example, the item (e.g., containers of items) may be
loaded onto shelves at the warehouse (e.g., distribution center).
The loop antenna may, for example, be wired around the back and/or
top of the shelf holding the items (e.g., containers). The loop
antenna is wirelessly connected to the base station (e.g.,
controller) which can transmit and receive to all electronic tags
1210 located in the loop (e.g., located on a particular shelf).
[0171] Each electronic tag 1210 may have a unique identification
number. The base station 120 may poll all of the electronic tags
1210 in the loop (e.g., in the transport vehicle) for a specific
identification number, and then communicate only to that specific
electronic tag. For example, the base station may place specific
information on the display of the electronic tag, activate or
deactivate the signaling device (e.g., LED) while selectively
polling each electronic tag.
[0172] FIG. 13 illustrate another aspect of the present invention
which is similar to the aspects described above and, thus, the
above descriptions of the various aspects of the present invention
are incorporated by reference herein.
[0173] Specifically, as illustrated in FIG. 13, the present
invention includes an item 1305 to be warehoused. The item 1305
includes an electronic module 1310 (e.g., RFID module described
above) associated with the item for wirelessly communicating with a
controller which controls a warehousing of the item 1305.
[0174] The present invention further includes a system 1300 for
warehousing the item 1305. The system 1300 includes the electronic
module 1310 associated with the item 1305, and a controller 1320
which wirelessly communicates with the electronic module 1310, for
controlling a warehousing of the item 1305.
[0175] For example, the controller 1320 may control a warehousing
of the item 1305 by controlling at least one of a location of the
item and a movement of the item.
[0176] Further, the electronic module may be one of affixed to
(e.g., by adhesive, staple, fastener, clip, screw, rivet, etc.) the
item and integrally formed with the item. Thus, for example, where
the item is a plastic device, the electronic module 1310 may be
integrally formed with (e.g., embedded in) the plastic item.
Further, the electronic module 1310 may be formed in (e.g.,
integrally formed in) an adhesive label which can be adhered to the
item 1305.
[0177] With its unique and novel features, the present invention
optimizes each employee's time and leads to highly efficient put
away of products and highly efficient picking of products. The
invention, therefore, offers affordable, state-of-the-art
technology for managing and improving retail and warehouse
operations. The inventive system and method may also be
conveniently offered as an independent or integrated solution to
supply chain needs.
[0178] While the invention has been described in terms of several
preferred embodiments, those skilled in the art will recognize that
the invention can be practiced with modification within the spirit
and scope of the appended claims. For example, while a scenario has
been discussed with various colored lights, obviously different
colored lights could be used, as well as different formats for the
lights (e.g., pulsing, flashing, etc.).
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