U.S. patent application number 16/796714 was filed with the patent office on 2020-08-20 for return ordering system and method.
The applicant listed for this patent is America's Collectibles Network, Inc.. Invention is credited to David BYRD, Lei CAO, Dustin W. COLE, G. Shannon MEADE, Mahendra SATRASALA, Bradley K. WALLER, George F. WILLARD, III.
Application Number | 20200265381 16/796714 |
Document ID | 20200265381 / US20200265381 |
Family ID | 1000004852674 |
Filed Date | 2020-08-20 |
Patent Application | download [pdf] |
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United States Patent
Application |
20200265381 |
Kind Code |
A1 |
WILLARD, III; George F. ; et
al. |
August 20, 2020 |
RETURN ORDERING SYSTEM AND METHOD
Abstract
The customer order fulfillment and return system for returning
items from a customer order to specified locations in a warehouse.
The returned items are assigned to specific sub-compartments of a
tote, and the tote is assigned to a specific mobile return cart.
The system then generates a return tour and the returned items are
then returned to specific locations in the warehouse.
Inventors: |
WILLARD, III; George F.;
(Knoxville, TN) ; CAO; Lei; (Oak Ridge, TN)
; COLE; Dustin W.; (Louisville, TN) ; SATRASALA;
Mahendra; (Knoxville, TN) ; BYRD; David;
(Maryville, TN) ; MEADE; G. Shannon; (Knoxville,
TN) ; WALLER; Bradley K.; (Lenoir City, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
America's Collectibles Network, Inc. |
Knoxville |
TN |
US |
|
|
Family ID: |
1000004852674 |
Appl. No.: |
16/796714 |
Filed: |
February 20, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16773821 |
Jan 27, 2020 |
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16796714 |
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16727676 |
Dec 26, 2019 |
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16773821 |
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16514897 |
Jul 17, 2019 |
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16727676 |
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62700619 |
Jul 19, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06Q 10/0837
20130101 |
International
Class: |
G06Q 10/08 20060101
G06Q010/08 |
Claims
1. A customer order fulfillment system for returning items from a
customer order to one or more locations in a warehouse, the system
comprising a return order generating subsystem for assigning
returned items in a tote having one or more sub-compartments to a
return cart, the return order generating sub-system including a map
unit for storing a map having map data associated therewith that
corresponds each of the returned items with the one or more
locations in the warehouse, a return cart building unit for
assigning a plurality of the totes to the return cart, wherein each
of the plurality of totes has identification information associated
therewith and the return cart has identification information
associated therewith, wherein the identification information of the
plurality of totes and the return cart are correlated together, and
a return order generating unit for generating a return tour for the
returned items assigned to the return cart, the return tour having
return instructions associated therewith, wherein the return
instructions of the return tour correlate the returned items in
each of the plurality of totes of the return cart to the locations
in the warehouse, and an interface providing a visual
representation of the tote and the associated one or more
sub-compartments, and providing a visual indicator of the returned
items assigned to the one or more sub-compartments of the tote.
2. The customer order fulfillment system of claim 1, further
comprising an automated fulfillment system for receiving one or
more of the totes and for automatically returning one or more of
the returned items in the one or more sub-compartments of the totes
to a selected location in one or more carousels.
3. The customer order fulfillment system of claim 1, wherein the
interface comprises a window having a visual representation of one
or more of the totes and the sub-compartments and for performing
the return tour for returning the returned items in the
sub-compartments to a plurality of locations in the warehouse, and
a visual representation of one or more of the totes and the
sub-compartments for performing a return tour for returning the
returned items in the sub-compartments to an automated fulfillment
system.
4. The customer order fulfillment system of claim 1, wherein the
customer order includes customer data and returned item data, and
wherein the customer data includes customer order data, customer
address data, and customer name data.
5. The customer order fulfillment system of claim 4, wherein the
item data includes product data, product quantity data, barcode
data, and return time period data.
6. The customer order fulfillment system of claim 1, further
comprising an order collection unit for collecting information
associated with the plurality of customer orders from a plurality
of customers and generating customer order data that includes data
associated with each of the plurality of customer orders and the
plurality of customers, wherein each of the plurality of customer
orders includes one or more items associated therewith, an order
generating unit for receiving the customer order data from the
order collection unit and generating in response thereto
consolidated order fulfillment data, a pick tour generating
subsystem for receiving the consolidated order fulfillment data
from the order generating unit and in response thereto generating
pick instructions associated with a pick tour or a pick tour plan
from the consolidated order fulfillment data, and a bulk pick order
fulfillment unit for receiving the consolidated order fulfillment
data from the order generating unit and grouping together similar
ones of the items associated with the plurality of customer orders
to form a plurality of bulk picks, wherein one or more of the
plurality of bulk picks forms part of one or more bulk pick
tours.
7. The customer order fulfillment system of claim 6, further
comprising an automated fulfillment system for receiving the
consolidated order fulfillment data from the order generating unit
and for automatically selecting one or more of the items in the
customer order from one or more carousels, wherein the automated
fulfillment system is configured for receiving the pick tour plan
or the pick tour and for automatically selecting the items in the
customer order set forth in the pick tour plan or the pick tour
from the one or more carousels, and is configured for receiving one
or more of the plurality of bulk picks for automatically selecting
one or more of the items in the customer order from the one or more
carousels.
8. The customer order fulfillment system of claim 1, wherein the
return order generating sub-system further comprises a graph
generating unit for generating a value sorted tree graph by
employing a value sorted tree mapping technique based at least on
the map data, and wherein the value sorted tree graph includes data
associating one or more of the items from the plurality of customer
orders with a selected location in the warehouse.
9. The customer order fulfillment system of claim 8, wherein the
value sorted tree graph is an associative array data type having
values associated therewith, wherein the value sorted tree graph
sorts the values in a selected order.
10. The customer order fulfillment system of claim 9, wherein the
values correspond to the locations in the warehouse or to a number
of the items at the locations in the warehouse.
11. The customer order fulfillment system of claim 6, further
comprising a graph generating unit for generating a value sorted
tree graph by employing a value sorted tree mapping technique based
at least on the map data and the consolidated order fulfillment
data, and wherein the value sorted tree graph includes data
associating one or more of the items from the plurality of customer
orders with a selected location in the warehouse.
12. The customer order fulfillment system of claim 11, wherein the
locations within the warehouse include one or more bays associated
with each location in the warehouse, and wherein the pick tour plan
comprises plan data correlating the location of the bay with
selected ones of the items at the locations of the bays to be
placed in selected totes in the mobile cart.
13. The customer order fulfillment system of claim 12, wherein the
pick tour plan is generated by the pick tour generator by mapping
the consolidated order fulfillment data generated by the order
generating unit with the warehouse configuration stored in the map
unit via the graph generating unit.
14. The customer order fulfillment system of claim 13, wherein the
pick tour generator converts the pick tour plan into a pick tour,
wherein the pick instructions of the pick tour includes an ordered
list of pick tasks.
15. The customer order fulfillment system of claim 14, wherein each
of the pick tasks includes a plurality of: the location of the bay,
identification information associated with the location of the bay,
shipping information associated with one or more of the customer
orders, a quantity of the items, identification information
associated with each of the items, one or more of the items to be
picked from the bay, and the tote on the mobile cart in which to
place the picked items.
16. The customer order fulfillment system of claim 6, wherein the
bulk pick order fulfillment unit groups the items in the
consolidated order fulfillment data into shipments according to one
or more predetermined logical parameters.
17. The customer order fulfillment system of claim 16, wherein the
bulk pick order fulfillment unit includes processing hardware that
is configured to: map the one or more items in each of the
plurality of customer orders to product identification data,
generate one or more bulk picks having associated therewith one or
more bulk pick recipes from the data associated with the customer
orders, wherein each of the bulk pick recipes includes a selected
quantity of the one or more items from the plurality of customer
orders and a selected quantity of one or more additional items, and
generate a bulk pick ticket associated with each of the bulk
picks.
18. The customer order fulfillment system of claim 17, wherein the
bulk pick ticket includes information about the one or more items
in the bulk pick recipe, and location information associated with
the location of the one or more items in the warehouse.
19. The customer order fulfillment system of claim 17, wherein the
bulk pick order fulfillment unit generates a connected graph of
groupings of the items from the customer orders and the one or more
additional items, wherein the items from the customer orders and
the additional items form nodes of the connected graph.
20. A method for returning items from a customer order to one or
more locations in a warehouse, the method comprising providing an
interface having a visual representation of a tote having one or
more sub-compartments, and providing a visual indicator of the
returned items assigned to the one or more sub-compartments of the
tote, storing a map having map data associated therewith that
corresponds each of the returned items with the one or more
locations in the warehouse, assigning a plurality of the totes to a
mobile return cart, wherein each of the plurality of totes has
identification information associated therewith and the return cart
has identification information associated therewith, and wherein
the identification information of the plurality of totes and the
return cart are correlated together, and generating a return tour
for the returned items assigned to the return cart, the return tour
having return instructions associated therewith, wherein the return
instructions of the return tour correlate the returned items in
each of the plurality of totes of the return cart to the locations
in the warehouse.
21. The method of claim 20, further comprising receiving one or
more of the totes and for automatically returning one or more of
the returned items in the one or more sub-compartments of the totes
to a selected location in one or more carousels of an automated
fulfillment system.
22. The method of claim 20, wherein the interface comprises a
window having a visual representation of one or more of the totes
and the sub-compartments and for performing the return tour for
returning the returned items in the sub-compartments to a plurality
of locations in the warehouse, and a visual representation of one
or more of the totes and the sub-compartments for performing a
return tour for returning the returned items in the
sub-compartments to an automated fulfillment system.
23. The method of claim 20, further comprising collecting
information associated with a plurality of customer orders from a
plurality of customers and generating customer order data that
includes data associated with each of the plurality of customer
orders and the plurality of customers, wherein each of the
plurality of customer order includes one or more items associated
therewith, generating in response to the customer order data
consolidated order fulfillment data, and receiving the consolidated
order fulfillment data and generating pick instructions associated
with a pick tour plan or a pick tour from the consolidated order
fulfillment data by a pick tour generating subsystem, receiving the
consolidated order fulfillment data from the order generating unit
and grouping together similar ones of the items associated with the
plurality of customer orders to form a plurality of bulk picks with
a bulk pick order fulfillment unit, wherein one or more of the
plurality of bulk picks can form part of one or more bulk pick
tours, and receiving the consolidated order fulfillment data from
the order generating unit and for automatically selecting one or
more of the items in the customer order from one or more carousels
of an automated fulfillment system, wherein the automated
fulfillment system is configured for receiving the pick tour plan
or the pick tour and for selecting the items in the customer order
set forth in the pick tour plan or the pick tour from the one or
more carousels, and is configured for receiving one or more of the
plurality of bulk picks for selecting one or more of the items in
the customer order from the one or more carousels.
24. The method of claim 23, wherein the pick tour generating
subsystem comprises a map unit for storing a map having map data
associated therewith that corresponds to a location of each of the
items in a warehouse, a cart building unit for generating
information associated with a mobile cart for use by a pick agent,
wherein the mobile cart has a plurality of totes associated
therewith and wherein each of the plurality of totes includes
identification information, a graph generating unit for generating
a value sorted tree graph by employing a value sorted tree mapping
technique based on the map data and the consolidated order
fulfillment data, and wherein the value sorted tree graph includes
data associating one or more of the items from the plurality of
customer orders with a selected location in the warehouse, and a
pick tour generator for generating the pick tour plan having the
pick instructions based on the value ordered tree graph and the map
data, wherein the pick tour plan correlates items of the customer
orders at multiple selected locations in the warehouse with one or
more of the plurality of totes in the mobile cart, wherein, the
cart building unit determines the number of totes for the mobile
cart and the identification information associated with each of the
plurality of totes based on the pick tour plan.
25. The method of claim 24, further comprising generating the pick
tour plan by mapping the consolidated order fulfillment data
generated by the order generating unit with the warehouse
configuration stored in the map unit via the graph generating
unit.
26. The method of claim 25, further comprising converting with the
pick tour generator the pick tour plan into the pick tour having
the pick instructions, wherein the pick instructions of the pick
tour includes an ordered list of pick tasks.
27. The method of claim 23, wherein the bulk pick order fulfillment
unit includes processing hardware that is configured to: map the
one or more items in each of the plurality of customer orders to
product identification data, generate one or more bulk picks having
associated therewith one or more bulk pick recipes from the data
associated with the customer orders, wherein each of the bulk pick
recipes includes a selected quantity of the one or more items from
the plurality of customer orders and a selected quantity of one or
more additional items, and generate a bulk pick ticket associated
with each of the bulk picks.
28. The method of claim 27, wherein the bulk pick ticket includes
information about the one or more items in the bulk pick recipe,
and location information associated with the location of the one or
more items in the warehouse.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation-in-part patent
application of U.S. patent application Ser. No. 16/773,821, filed
on Jan. 27, 2020, and entitled MULTI-LINE SYSTEM AND METHOD FOR
RETRIEVING AND FULFILLING ITEMS IN A CUSTOMER ORDER, which is a
continuation-in-part patent application of U.S. patent application
Ser. No. 16/727,676, filed on Dec. 26, 2019 and entitled SYSTEM AND
METHOD FOR PERFORMING BULK PICK OF ITEMS OF A CUSTOMER ORDER, which
in turn is a continuation-in-part patent application of U.S. patent
application Ser. No. 16/514,897, entitled SYSTEM AND METHOD FOR
PERFORMING BULK PICK OF ITEMS OF A CUSTOMER ORDER, filed on Jul.
17, 2019, which claims priority to provisional patent application
Ser. No. 62/700,619, filed on Jul. 19, 2018, and entitled SYSTEM
AND METHOD FOR PERFORMING BULK PICK OF ITEMS OF A CUSTOMER ORDER.
The contents of all of the foregoing applications are incorporated
herein by reference.
BACKGROUND OF THE INVENTION
[0002] Vendors, particularly in home shopping industries involving
telephone ordering, mail ordering, or e-commerce, often need to
fulfill and package customer orders to be shipped to customers. The
customer order may include one or more product items, as well as
promotional literature. In some circumstances, product fulfillment
and packaging may be done manually with a worker picking items
corresponding to the customer order from a fulfillment center or
warehouse and then inserting orders into packages. In order to
increase efficiency over conventional manual picking and packaging
techniques, automated picking stations and packing machines have
been introduced. However, such picking processes are designed to
have a person simply pick an item from a selected location and then
transfer the item to a packing station for packaging, without
regard to optimizing the pick route or picking and packaging
process.
[0003] Further, conventional item picking and packaging systems
require large capital investments, and still are not fully adapted
to optimize the item picking and packaging process.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to an order fulfillment
system that receives and processes customer orders, and then
determines whether the specific items in the collected customer
orders warrant the creation and execution of a bulk pick or a pick
tour to be executed by a pick agent. If the system determines that
a series of pick tours are required, the pick tour subsystem
receives information from the order collection unit, determines the
location of the items in the warehouse based on a warehouse map,
instructs the pick agent how to manage or setup a mobile pick cart,
generates a value sorted tree map, and then generates a pick tour
plan. The pick tour plan is then converted into a pick tour to be
performed by the pick tour agent. In the pick tour, the location of
the items in the warehouse are proved to the pick agent and the
pick tour agent is instructed to select the items at specific
locations in a predefined sequence.
[0005] Further, the order fulfillment system can include a return
order generating unit for allowing an agent to process items that
are returned by the customer. The return agent can build a return
cart that has a plurality of return totes associated therewith. The
order fulfillment system can generate a return tour, similar to the
pick tour but in reverse, wherein the items in the return totes of
the return cart can be returned to selected locations within the
warehouse or to an automated fulfillment system. Specifically, the
customer order fulfillment and return system of the present
invention returns items from a customer order to specified
locations in a warehouse. The returned items are assigned to
specific sub-compartments of a tote, and the tote is assigned to a
specific mobile return cart. The system then generates a return
tour and the returned items are then returned to specific locations
in the warehouse.
[0006] The present invention includes a customer order fulfillment
system for returning items from a customer order to one or more
locations in a warehouse, the system includes a return order
generating subsystem for assigning returned items in a tote having
one or more sub-compartments to a return cart and an interface. The
return order generating sub-system includes a map unit for storing
a map having map data associated therewith that corresponds each of
the returned items with the one or more locations in the warehouse;
a return cart building unit for assigning a plurality of the totes
to the return cart, wherein each of the plurality of totes has
identification information associated therewith and the return cart
has identification information associated therewith, wherein the
identification information of the plurality of totes and the return
cart are correlated together; and a return order generating unit
for generating a return tour for the returned items assigned to the
return cart, the return tour having return instructions associated
therewith, wherein the return instructions of the return tour
correlate the returned items in each of the plurality of totes of
the return cart to the locations in the warehouse. The interface
provides a visual representation of the tote and the associated one
or more sub-compartments, and providing a visual indicator of the
returned items assigned to the one or more sub-compartments of the
tote.
[0007] The interface can also include a window having a visual
representation of one or more of the totes and the sub-compartments
and for performing the return tour for returning the returned items
in the sub-compartments to a plurality of locations in the
warehouse, and a visual representation of one or more of the totes
and the sub-compartments for performing a return tour for returning
the returned items in the sub-compartments to an automated
fulfillment system.
[0008] The customer order fulfillment system of the present
invention includes an order collection unit for collecting
information associated with a plurality of customer orders from a
plurality of customers and generating customer order data that
includes data associated with each of the plurality of customer
orders and the plurality of customers, wherein each of the
plurality of customer order includes one or more items associated
therewith; an order generating unit for receiving the customer
order data from the order collection unit and generating in
response thereto consolidated order fulfillment data; and a pick
tour generating subsystem for receiving the consolidated order
fulfillment data from the order generating unit and in response
thereto generating pick instructions associated with a pick tour
plan or a pick tour from the consolidated order fulfillment data.
Further, the order fulfillment system includes a bulk pick order
fulfillment unit for receiving the consolidated order fulfillment
data from the order generating unit and grouping together similar
ones of the items associated with the plurality of customer orders
to form a plurality of bulk picks, wherein one or more of the
plurality of bulk picks can form part of one or more bulk pick
tours, and an automated fulfillment system for receiving the
consolidated order fulfillment data from the order generating unit
and for automatically selecting one or more of the items in the
customer order from one or more carousels associated therewith. The
automated fulfillment system is configured for receiving the pick
tour plan or the pick tour and for automatically selecting the
items in the customer order set forth in the pick tour plan or the
pick tour from the one or more carousels, and/or is configured for
receiving one or more of the plurality of bulk picks forming the
bulk tour or automatically selecting one or more of the items in
the customer order from the one or more carousels.
[0009] The pick tour generating subsystem comprises a map unit for
storing a map having map data associated therewith that corresponds
to a location for each of the items in a warehouse; a cart building
unit for generating information associated with a mobile cart for
use by a pick agent, wherein the mobile cart has a plurality of
totes associated therewith and wherein each of the plurality of
totes includes identification information; a graph generating unit
for generating a value sorted tree graph by employing a value
sorted tree mapping technique based on the map data and the
consolidated order fulfillment data, and wherein the value sorted
tree graph includes data associating one or more of the items from
the plurality of customer orders with a selected location in the
warehouse; and a pick tour generator for generating a pick tour
plan based on the value ordered tree graph and the map data,
wherein the pick tour plan correlates items of the customer orders
at multiple selected locations in the warehouse with one or more of
the plurality of totes in the mobile cart. The cart building unit
determines the number of the totes for the mobile cart and the
identification information associated with each of the plurality of
totes based on the pick tour plan.
[0010] According to another aspect of the invention, one or more of
the plurality of totes includes a plurality of sub-compartments
where each of the plurality of sub-compartments includes
identification information. The totes can be arranged on the mobile
cart according to the requirements of the pick tour plan and
optionally according to the sequence of the locations of the items
in the warehouse.
[0011] According to another aspect of the invention, the value
sorted tree graph is an associative array data type having values
associated therewith, wherein the value sorted tree graph sorts the
values in a selected order. The values correspond to the locations
in the warehouse or to a number of the items at the locations in
the warehouse. Further, the locations within the warehouse include
one or more bays associated with each location in the warehouse,
and the pick tour plan comprises plan data correlating the location
of the bay with selected ones of the items at the locations of the
bays to be placed in specific totes in the mobile cart.
[0012] According to still another aspect of the invention, the pick
tour plan is generated by the pick tour generator by mapping the
consolidated order fulfillment data generated by the order
generating unit with the warehouse configuration stored in the map
unit via the graph generating unit. The pick tour generator
converts the pick tour plan into a pick tour that sets forth an
ordered list of pick tasks. Further, each of the pick tasks
includes a selected one of the following: the location of the bay,
identification information associated with the location of the bay,
shipping information associated with one or more of the customer
orders, a quantity of the items, identification information
associated with each of the items, one or more of the items to be
picked from the bay, and the tote on the mobile cart in which to
place the picked items. The pick tour generator generates the pick
tour based on a similarity in the customer orders and the location
of the items in the warehouse.
[0013] According to yet another aspect of the invention, the system
further includes a bulk pick order fulfillment unit for receiving
the consolidated order fulfillment data from the order generating
unit and grouping together similar ones of the items associated
with the plurality of customer orders to form a plurality of bulk
picks, wherein one or more of the plurality of bulk picks can form
part of one or more bulk pick tours, The bulk pick order
fulfillment unit groups the items in the consolidated order
fulfillment data into shipments according to one or more
predetermined logical parameters. Still further, the bulk pick
order fulfillment unit includes processing hardware that is
configured to map the one or more items in each of the plurality of
customer orders to product identification data, generate one or
more bulk picks having associated therewith one or more bulk pick
recipes from the data associated with the customer orders, wherein
each of the bulk pick recipes includes a selected quantity of the
one or more items from the plurality of customer orders and a
selected quantity of one or more additional items, and generate a
bulk pick ticket associated with each of the bulk picks.
[0014] The bulk pick ticket includes information about the one or
more items in the bulk pick recipe, and location information
associated with the location of the one or more items in the
warehouse. The bulk pick order fulfillment unit generates a
connected graph of groupings of the items from the customer orders
and the one or more additional items, wherein the items from the
customer orders and the additional items form nodes of the
connected graph.
[0015] According to another aspect of the invention, the system can
also include a packing and shipping sub-system for packing and
shipping the items from the customer orders, as well as a
controller for scheduling one or more selected time periods for
performing the bulk pick tour or the pick tour.
[0016] The present invention is also directed to a method for
retrieving items from a customer order from a warehouse so as to
fulfill a customer order, comprising collecting information
associated with a plurality of customer orders from a plurality of
customers and generating customer order data that includes data
associated with each of the plurality of customer orders and the
plurality of customers, wherein each of the plurality of customer
order includes one or more items associated therewith; generating
in response to the customer order data consolidated order
fulfillment data; and receiving the consolidated order fulfillment
data and generating pick tour instructions associated with a pick
tour from the consolidated order fulfillment data by a pick tour
generating subsystem.
[0017] The method also includes receiving the consolidated order
fulfillment data from the order generating unit and grouping
together similar ones of the items associated with the plurality of
customer orders to form a plurality of bulk picks with the bulk
pick order fulfillment unit, wherein one or more of the plurality
of bulk picks can form part of one or more bulk pick tours, and
receiving the consolidated order fulfillment data from the order
generating unit and for automatically selecting one or more of the
items in the customer order from one or more carousels with the
automated fulfillment system. The automated fulfillment system is
configured for receiving the pick tour plan or the pick tour and
for automatically selecting the items in the customer order set
forth in the pick tour plan or the pick tour from the one or more
carousels, and is configured for receiving one or more of the
plurality of bulk picks for automatically selecting one or more of
the items in the customer order from the one or more carousels.
[0018] According to another aspect of the invention, the method
includes generating the pick tour plan by mapping the consolidated
order fulfillment data generated by the order generating unit with
the warehouse configuration stored in the map unit via the graph
generating unit. The method can also include converting with the
pick tour generator the pick tour plan into a pick tour that sets
forth an ordered list of pick tasks.
[0019] According to still another aspect of the invention, the
method also includes a bulk pick order fulfillment unit for
receiving the consolidated order fulfillment data from the order
generating unit and grouping together similar ones of the items
associated with the plurality of customer orders to form a
plurality of bulk picks, wherein one or more of the plurality of
bulk picks can form part of one or more bulk pick tours. The method
can also include grouping the items in the consolidated order
fulfillment data into shipments according to one or more
predetermined logical parameters.
BRIEF DESCRIPTION OF DRAWINGS
[0020] These and other features and advantages of the present
invention will be more fully understood by reference to the
following detailed description in conjunction with the attached
drawings in which like reference numerals refer to like elements
throughout the different views. The drawings illustrate principals
of the invention and, although not to scale, show relative
dimensions.
[0021] FIG. 1 is a schematic block diagram of the order fulfillment
system of the present invention.
[0022] FIG. 2 is a schematic flowchart diagram illustrating the
steps for generating a bulk pick recipe according to the teachings
of the present invention.
[0023] FIG. 3 is a connected tree map diagram for determining the
relationship between various items in various customer orders
according to the teachings of the present invention.
[0024] FIG. 4 is a depiction of the bulk picks and corresponding
bulk pick recipes according to the teachings of the present
invention.
[0025] FIG. 5 is a schematic block diagram of a bulk pick ticket
generated by the order fulfillment system of the present
invention.
[0026] FIG. 6 is a schematic flow chart diagram illustrating the
steps involved with generating a bulk pick ticket and associated
bulk pick tour according to the teachings of the present
invention.
[0027] FIG. 7 is a tree map that operates as a visual
representation of the relative amount of work that can potentially
be fulfilled via a bulk pick order via a set of configurable
operating parameters according to the teachings of the present
invention.
[0028] FIG. 8 is a schematic block diagram illustrating the pick
tour generating unit and associated components according to the
teachings of the present invention.
[0029] FIG. 9A is a schematic representation of a conventional
unsorted tree map generated according to known techniques.
[0030] FIG. 9B is a schematic representation of a value sorted tree
map generated by the graph generating unit according to the
teachings of the present invention.
[0031] FIG. 10 is a schematic representation of the display of a
handheld device employed by the pick agents during a pick tour
according to the teachings of the present invention.
[0032] FIG. 11 is a schematic flow chart diagram illustrating the
steps involved with generating a pick tour plan and associated pick
tour according to the teachings of the present invention.
[0033] FIG. 12 is a schematic representation of a pick tour plan
generated by the pick tour generating unit of the order fulfillment
system of the present invention.
[0034] FIG. 13 is a schematic representation of a pick tour
generated from a pick your plan by the pick tour generating unit
according to the teachings of the present invention.
[0035] FIG. 14 is a schematic flow chart diagram illustrating the
steps involved with picking items from a customer order via a bulk
pick recipe by employing the automated fulfillment system according
to the teachings of the present invention.
[0036] FIG. 15 is a schematic flow chart diagram illustrating the
steps involved with picking items from a customer order via a pick
tour by employing the automated fulfillment system according to the
teachings of the present invention.
[0037] FIG. 16 is a schematic flow chart diagram illustrating the
steps involved with picking items from a customer order via a bulk
pick recipe and/or a pick tour by employing the automated
fulfillment system as well as a pick agent according to the
teachings of the present invention.
[0038] FIG. 17 is a schematic representation of the automated
fulfillment system of the present invention.
[0039] FIG. 18 is a schematic block diagram of the order
fulfillment system of the present invention that includes a return
order generating unit.
[0040] FIG. 19A is a schematic representation of a display of an
electronic device, such as a handheld scanner, for depicting a
return cart for returning items returned by a customer to the
warehouse.
[0041] FIG. 19B is a further schematic representation of a display
of an electronic device, such as a handheld scanner, for showing
the information associated with a return tour and associated
returned items to be returned to the warehouse.
[0042] FIG. 20 is a schematic block diagram illustrating the return
order generating unit and associated components according to the
teachings of the present invention.
[0043] FIG. 21 is a schematic flow chart diagram illustrating the
steps involved with generating a return or put away tour according
to the teachings of the present invention.
[0044] FIG. 22 is a schematic representation of the display of an
electronic device, such as a scanner, illustrating the various
totes and associated sub-compartments that form part of a return
cart according to the teachings of the present invention.
[0045] FIG. 23 is a schematic block diagram depicting an embodiment
of a network environment comprising client devices in communication
with servers through a network arrangement.
[0046] FIGS. 24 and 25 are schematic block diagrams depicting
embodiments of computing devices useful for the methods and systems
described herein.
DETAILED DESCRIPTION
[0047] Exemplary embodiments of the present invention address these
and other problems associated with the picking of items
corresponding to a customer order by employing an order fulfillment
system for picking the items and then packaging and shipping the
items to the customer.
[0048] The present invention is directed to a time based customer
ordering and customer order consolidation system suitable for use
in an automated or partially automated order fulfillment
environment. The customer order can include one or more items that
the customer has selected or purchased, and can if desired include
additional items, such as warranty information, sales or
promotional literature and related brochures, item instructions and
the like.
[0049] As shown in FIG. 1, the order fulfillment system 10 of the
present invention includes an order collation or collection unit 12
for collecting or collating customer orders and associated data as
they are entered into the system. As is known in the art, the
customer orders can be introduced or entered into the system either
through the Internet via a website ordering operation or can be
entered into the system by a customer service representative while
accepting order instructions directly from the customer, such as
over a telephone. The customer order collection unit 12 in
connection with the database 24 can generate customer and order
information or data that is transmitted and received by an order
generating unit 14. The order collection unit 12 consolidates the
incoming customer orders and organizes and consolidates selected
order and customer information from the customer orders, including
for example the customer ID, the shipment address, type of
shipment, number of items in the customer order, and the like. This
information can be stored at one or more locations, including for
example the database 24. The order generating unit 14 is configured
for controlling and managing the order data for fulfillment at a
warehouse and/or automated fulfillment system in a time based
manner. As used herein, the term "warehouse" is intended to include
any facility or building that stores items therein for retrieval by
personnel and/or an automated fulfillment system for subsequent
shipping to, for example, a customer or another building. The
warehouse can include for example a fulfillment facility. The order
data is preferably organized and managed by the order generating
unit 14 so as to optimize the selection (e.g., picking) of the
items in the customer order and then shipping the items to the
customer in an expeditious manner.
[0050] The order generating unit 14 can be monitored by a separate
computing system and/or a warehouse supervisor via the computing
system to determine the order fulfillment actions that need to be
taken. The order generating unit 14 is adapted or configured to
prepare a set of order fulfillment instructions or data for
fulfilling the incoming customer orders in a time based manner. The
fulfillment order instructions can be based on a set of logical
rules and ordering priorities for releasing one or more customer
orders to be fulfilled by the order fulfillment system 10.
[0051] The consolidated order fulfillment instructions or data
generated by the order generating unit 14 can be transmitted to an
automated fulfillment system 16, such as an automated product
picking system, as shown for example in FIG. 17. An example of an
automated product picking system suitable for use with the present
invention includes the systems manufactured and sold by SSI
Schaefer, Germany. As is known in the art, the automated
fulfillment system 16 can include a series of vertical towers,
stacks or carousels that include a number of distinct receptacles
for storing one or more items. The stacks can be stationary or
adapted to rotate about a central longitudinal axis. The stacks can
be coupled to one or more movable retrieval arms or mechanisms that
are adapted to move vertically along the stacks and if desired
between the stacks. The items or products retrieved by the movable
arms can be placed in one or more totes or bins, which in turn can
be moved or conveyed along a conveyance system. The conveyance
system can include tracks with rollers and the like. The automated
fulfillment system 16 can be controlled or operated by a central or
a dedicated computing system.
[0052] Alternatively, the order generating unit 14 can transmit the
order fulfillment instructions to a bulk pick order fulfillment
unit 18. For example, according to one practice, the order
generating unit 14 can be configured to group together a set of
customer orders that share similar features, items or traits, into
a larger bulk pick order, and the bulk pick order data can be
transmitted to the bulk pick order fulfillment unit 18.
Alternatively, the bulk pick order fulfillment unit 18 can generate
the bulk pick order data from the consolidated order fulfillment
data from the order generating unit 14. The bulk pick orders (e.g.,
a bulk pick order wave) are groupings of customer orders that may
be picked or fulfilled in aggregate in a warehouse and/or the
automated fulfillment system 16 as opposed to fulfilling each
customer order separately and independently. As such, warehouse
data can include the configuration of the warehouse, which can
include for example rows of storage racks with associated storage
bins, and data associated with specific items located in specific
bins at specific warehouse locations, can be stored in the database
24 or elsewhere in the system 10 and is accessible by the order
generating unit 14, the bulk pick order fulfillment unit 18, the
pick tour generating unit 20, and the return order generating unit
240 (FIG. 18). The bulk pick orders forming the bulk pick wave are
selected so as to optimize the fulfillment process by selecting
orders that have certain features, items or traits in common. The
bulk pick order fulfillment unit 18 can generate data associated
with a bulk pick that can form part of a bulk pick tour or wave,
and which can be fulfilled by the automated product picking system
16, by one or more mobile operators or pick agents that manually
pick one or more items corresponding to the bulk pick tour, or by
both. As used herein, the term "bulk pick," "bulk pick tour," or
"bulk pick wave," is intended to mean a plurality of similar or
identical items that are grouped or bulked together and which can
be selected based on the warehouse data from a selected warehouse
location. The bulk picks or grouped items when assigned to the
automated fulfillment system and/or to a pick tour agent for
retrieval form the bulk pick tours. A series of the bulk picks or
bulk pick tours can then be assigned to the pick agents and/or to
the automated fulfillment unit separately, concurrently or in
series, to form a bulk pick wave.
[0053] Additionally or alternatively, the order generating unit 14
can interface with a pick tour generating unit 20, which receives
the order fulfillment data from the order generating unit 14. The
pick tour generating unit 20 can generate pick tour instructions
for a single item or a multi-item order. The pick tour instructions
can be forwarded to the automated product picking system and/or to
a pick tour mobile operator or agent for performing a pick tour.
The pick tour generating unit 20 generates pick tour instructions
based on the consolidated customer order information received from
the order generating unit 14. The pick tour instructions leverage
the similarity in customer orders and item locations within the
warehouse so as to minimize the amount of time it takes to pick the
one or more items that comprise the customer order. The pick tour
instructions can generate or be converted into pick plan, which in
turn can be used to form a pick tour that can be assigned to pick
agents or mobile operators. The pick agents can utilize a mobile
cart that has selected compartments associated therewith to
manually pick or select the items that correspond to the customer
orders from the warehouse. The pick agent can employ any suitable
electronic device, such as for example a handheld scanning device,
such as for example the conventional handheld scanners sold by
Intermec, that can guide the pick agent to the selected location of
the item and assist the pick agent in selecting the correct item.
The handheld device also serves to allow the order fulfillment
system 10 to track and verify the location of the pick agent, and
to perform product and location verification in real time. As used
herein, the term "pick tour" is intended to mean a series of
instructions that include one or more pick instructions or tasks
that when aggregated or consolidated together form a tour. The tour
is in essence a series of instructions sent to the pick agent to
pick, select or retrieve one or more items associated with one or
more customer orders from selected locations within the warehouse.
Alternatively, the pick tour can be performed by the automated
fulfillment system 16, which receives the aggregated list of items
(or tour) from the pick tour generating unit 20 and retrieves the
items from selected locations within the automated fulfillment
system.
[0054] Once the customer order has been picked and fully assembled,
the contents of the order can be assembled into totes or
compartments of totes, which are then placed on a conveyor belt and
sent to a packing and shipping subsystem 22. A packaging and
shipping subsystem suitable for use with the present invention
includes the packing station disclosed in U.S. Publ. No.
2014/0360141, to the assignee hereof, the contents of which are
herein incorporated by reference. In transit, the order fulfillment
system 10 can also include structure for automatically printing a
customer invoice and/or packing slips for insertion within the
corresponding compartment within the tote. The illustrated packing
and shipping subsystem 22 receives the totes and packages the
contents of each compartment of the tote for shipping to the
customer.
[0055] As shown, the illustrated order fulfillment system 10 can
also include a general database 24 for storing information
concerning the customers, items in the warehouse, customer orders
as well as selected information corresponding to each of the
illustrated units and subsystems. Specifically, the database 24 can
store customer information, including customer name, address,
financial payment details, order history and the like. The database
24 can also store information regarding the items that are stored
in the warehouse as well as the warehouse information. The item
information can include details of each item, including item type,
description, price, quantity and the like. The database can also be
configured to store information regarding the programs and
associated segments or plays that are broadcast, as well as the
sequence of items that are displayed and discussed during the
program.
[0056] The order generating unit 14 of the present invention is
configured to collect data associated with the customer orders from
the order collection unit 12 and prepare a set of consolidated
order fulfillment data or instructions for fulfilling the incoming
customer orders in a time based manner. The order fulfillment
instructions can be based on a set of logical rules and ordering
priorities for releasing one or more customer orders to be
fulfilled by the order fulfillment system 10. The order generating
unit 14, based on the number of customer orders, and the overlap or
similarity between the items in the orders, can send instructions
to the bulk pick order fulfillment unit 18 to execute a bulk pick
of selected items. The order generating unit 14 or the bulk pick
order fulfillment unit 18 can schedule the bulk pick at a time of
day that is convenient based on the total number of customer orders
being handled, the time of day, the number of pick agents assigned
to the warehouse floor, and the like.
[0057] The order generating unit 14 can generate a color coded or
non-color coded tree map that can be displayed to the supervisors
on a suitable display device as a visual representation of the
relative amount of work that can potentially be fulfilled via a
bulk pick order by the bulk pick order fulfillment unit 18 under a
set of configurable operating parameters. An example of such a tree
map is shown in FIG. 7. As shown, the order fulfillment system 10
can generate content that is displayed on a window or interface on
a display device. The illustrated window 112 can include one or
more panes 114 to display selected content associated with the
customer orders and to enable or allow a user to customize via
selectable parameters the metric associated with a bulk pick, bulk
tour, or bulk wave. The panes 114 can include pane 114A that is
positioned in an upper portion or region of the window 112 and
which displays a set of user selectable parameters 116. The
parameters 116 can include the selected warehouse 116A, the maximum
number of results 116B to be considered by the bulk pick order
fulfillment unit 18, the maximum and minimum number of different
multi-item combinations (e.g., recipes) 116C to generate per bulk
pick, the maximum number of recipes per bulk pick 116E, the line
type 116F which includes whether a single item, multi-item, or both
single item and multi-item orders should be included in the tree
map and the pick location 116G (e.g., static (non-automated) or
automated fulfillment system 16). The order generating unit 14
and/or the bulk pick order fulfillment unit 18 can then generate a
map of the bulk wave for visual display to the user. The
flexibility of these parameters enables the supervisor to adapt the
amount and types of work they have pending in the order collection
unit 12 to the available pick agents and availability of other
system equipment, including the automated fulfillment system 16.
The foregoing features or parameters can be presented to the
supervisor in any suitable format, and can preferably be displayed
in a dashboard format via the pane elements 114. The order
generating unit 14 can release order information to the bulk pick
order fulfillment unit 18 to generate bulk picks and to the pick
tour generating unit 20 to generate mobile pick tours for the pick
agents. The order generating unit 14 via the window 112 can display
the map that can be illustrated as a set of pane elements
114A-114F. Each of the respective panel elements 114A-114F contains
the total number of customer orders that are included in the bulk
pick. Larger numbers are contained in larger rectangles in the tree
map and are ordered such that the larger total order counts are
placed in a top-to-bottom left-to-right configuration that is
ordered by size. In addition to the size of the rectangle
indicating the relative number of orders, the color of the
rectangle may be used as a visual indicator of the estimated size
or effort (e.g., red indicating a large number of orders, and blue
representing a lower number of orders). This coloring technique
offers a visual heat map of the orders that can be generated into
bulk picks allowing a user to rapidly visually inspect the number
of orders and estimate the effort involved to fulfill the
respective bulk picks when released. The window 112 also displays
on a bottom portion thereof parameter values selected by the user,
including the bulk pick count, shipment count, as well as action
buttons 118 that allow the user to select the illustrated
parameters or to release the bulk wave to the system 10. As used
herein, a pane element can be a user interface or portion thereof,
such as a screen, a space, a surface, or the like.
[0058] The bulk pick order fulfillment unit 18 employs processing
hardware for implementing heuristics and rule based schedules that
determine the optimal way to group items in the customer orders
into shipments. The logical parameters include consideration of the
payment status of the customer or of the customer orders,
destination addresses, and services such as sizing and appraisals
that may have been applied to the items of the customer order. The
bulk pick order fulfillment unit 18 also considers the shipping
option selected by the customer and the guaranteed or estimated
shipping dates that were communicated to the customer, as well as
other factors, including grouping of items based on specific
product brand, sales of items, and different sales channels.
[0059] Consolidating customer orders into shipments using the
foregoing time-based process has multiple benefits and advantages.
One advantage is that the process reduces the amount of shipment
packaging materials needed, reduces the number of promotional
inserts needed, and reduces the overall postage cost of shipping
the packages. Additionally, customers may be incentivized to
purchase additional items by reduced shipping and handling rates
for additional items purchased within a selected time period, such
as for example a twenty four hour time period.
[0060] FIG. 2 is a schematic flow chart diagram that illustrates
the process or method that the bulk pick order fulfillment unit 18
employs to generate one or more bulk picks or bulk pick recipes
from the consolidated order fulfillment data received from the
order generating unit 14. The bulk pick order fulfillment unit 18
includes processing hardware, such as a hardware processor or
controller as described below, that is configured to initially map
items in the customer order to product identification (ID) data and
selected quantities of product, step 30. For example, as shown in
FIG. 3, the illustrated bulk pick order fulfillment unit 18
generates a connected graph 26 of groupings of customer orders and
corresponding items, and then devolves the customer orders into
constituent items and corresponding inserts such as informational,
warranty, and marketing materials, and places them on the connected
graph as nodes. As shown, and according to a simple example, the
items that form part of this potential bulk group of customer
orders include three different product items designated as ABC123,
DEF456, and DQK928 that were purchased by customers and forms part
of the customer order data. In addition to the customer items, the
example assumes that the orders also include a new customer card
designated as NEW CUST and a warranty card. The number of purchased
items that overlap and require warranty and new customer cards are
illustrated by the connecting lines with corresponding amounts or
numbers. Specifically, the number of customers that purchased
selected items and require a warranty and/or new customer card are
shown in the intermediate number boxes. As shown, one hundred (100)
customers purchased all three items and require a warranty card and
a new customer card; one hundred fifty (150) customers only
purchased the item DQK928; only forty (40) customers purchased item
DEF456; forty (40) customers purchased all three items and are not
receiving any inserts, and so forth. Other item amounts are also
shown.
[0061] The bulk pick order fulfillment unit 18 can also generate
one or more bulk pick recipes from the data associated with the
connected graph, step 32. As used herein, the term "recipe" or
"bulk pick recipe" is intended to mean a collection of selected
items from the customer orders and the additional items that are
correlated or grouped together. As shown in FIG. 4, a user such as
the supervisor can select various parameters or features 58 of the
bulk pick in the bulk pick order fulfillment unit 18. For example,
a user or the system 10 can define the maximum number of recipes
per bulk pick, the maximum item count per bulk pick, and the
minimum bulk group item count. Once the user has selected these
parameters, the resulting calculated values for the bulk pick are
presented including the total number of ingredients (i.e. items),
the total number of recipes, and the total number of bulk picks
that are generated. As shown, the bulk pick order fulfillment unit
18 generates and constructs bulk picks 42, 44, and 46, where each
bulk pick comprises a selected number of bulk pick recipes or bulk
groups. The bulk pick order fulfillment unit 18 can determine the
bulk pick group or recipe sequence by determining the largest or
smallest matching product or item count and then determining the
largest or smallest number of inserts. The system can thus organize
and aggregate the data in ascending or descending order relative to
the number of items in the bulk pick. Those of ordinary skill in
the art will readily recognize that the item data from the
connected graph 26 can be organized in other ways as well. As
illustrated, bulk pick 42 includes bulk pick recipes 52, 54 and 56;
bulk pick 44 includes recipes 60 and 62; and bulk pick 46 includes
recipes 66 and 68. Each of the above recipes includes one or more
ingredients or items. For example, recipe 52 includes five
ingredients, including items DQK928, ABC123, and DEF456, as well as
the new customer insert NEW CUST and the warranty insert. Recipe 54
includes items DQK928, ABC123, and DEF456 with no additional
inserts, and recipe 56 includes, for ingredients, items ABC123 and
DEF456 and the new customer insert NEW CUST. Once the maximum
number of recipes for each of the bulk picks is reached, the bulk
pick order fulfillment unit 18 creates a further bulk pick. The
bulk pick order fulfillment unit 18 can also generate less than the
maximum number of bulk pick recipes, such as those associated with
the bulk picks 44 and 46. The bulk pick order fulfillment unit 18
generates and organizes the bulk picks so that the most difficult
recipes are collated first into the first bulk pick. For example,
as shown in FIG. 4, the bulk pick 42 includes recipes 52, 54, 56
that are more complicated than the recipes in the other bulk picks
44 and 46.
[0062] When the bulk pick order fulfillment unit 18 generates one
or more bulk pick recipes that include ingredients (or the recipe
itself) outside of one or more of the predetermined parameters, the
unit 18 does not generate a bulk pick employing these recipes. The
bulk picks and corresponding bulk pick recipes can be utilized by
the order fulfillment system 10, such as by the pick tour
generating unit 20 or the automated fulfillment system 16 so that
the ingredients within the recipe are selected either by pick
agents via a mobile tour or by the automated fulfillment system 16.
Further, the bulk pick order fulfillment unit 18 partitions or
separates the bulk picks from each other according to the bulk pick
group count parameter and the maximum item count per bulk pick
parameter.
[0063] The bulk pick order fulfillment unit 18 then generates a
bulk pick sheet or ticket that corresponds to each of the bulk
picks 42, 44, 46, step 34. The bulk pick ticket is sent to either a
mobile pick agent and/or to the automated fulfillment system 16 to
retrieve the items, step 36. If the bulk pick ticket is sent to the
automated system 16, processing hardware and corresponding software
associated with the system 10 or the automated system 16 can
perform the retrieval of the items based on the information
contained within the bulk pick ticket. FIG. 5 is an example of a
bulk pick ticket 80 generated by the bulk pick order fulfillment
unit 18 according to the teachings of the present invention. The
bulk pick ticket 80 can be printed by any suitable printing device
associated with or coupled to the bulk pick order fulfillment unit
18 or the bulk pick ticket can be transmitted to other portions of
the system 10 via processing hardware. The illustrated bulk pick
ticket 80 can include any selected type and arrangement of
information, and includes for example a description and image of
one or more items, such as the illustrated Item 1 and Item n. The
first listed item in the bulk pick ticket 80 is Item 1, and
includes information such as the description and image of the item
82 to be picked from the warehouse, one or more locations of the
item 84 in the warehouse, as well as the quantity of the item 86 to
be picked. Similarly, Item n includes information such as the
description and image of the item 92 to be picked from the
warehouse, a location of the item 94 in the warehouse, as well as
the quantity of the item 96 to be picked. The bulk pick order
fulfillment unit 18 can print one or more of the bulk pick tickets
80 for use by the system and by, for example, a pick agent. A bar
code 88 can also be associated with the bulk pick ticket 80 so that
the pick agent and subsequent handlers of the items can determine
the customer orders associated with the items via barcode scan.
[0064] The items identified by the bulk pick process of the bulk
pick order fulfillment unit 18 and as set forth in the bulk pick
ticket 80 can be picked according to the following process. One of
ordinary skill in the art will readily recognize that the process
can include additional steps or can omit one or more of the
following steps without departing from the spirit and scope of the
present invention.
[0065] As shown in FIGS. 1 and 6, the order fulfillment system 10
of the present invention collates and collects the customer order
information with the order collection unit 12, and conveys this
information to the order generating unit 14. The order generating
unit 14 visually displays the order data through a display device
to a warehouse supervisor, who sets or selects certain bulk wave
parameters. For example, the system 10 can generate the tree map
shown in FIG. 7 for use by the supervisor. The order generating
unit 14 also receives other related information, such as additional
customer information, order status information, and other system
related information, from the database 24. The order generating
unit 14 then transmits consolidated order fulfillment information
to the bulk pick order fulfillment unit 18. The bulk pick order
fulfillment unit 18 generates the bulk picks, step 102, as shown in
FIG. 6, from the bulk pick recipes, which in turn are formed from
the connected graph 26. The bulk pick and related customer order
and item information is sent to a print device to print the bulk
pick ticket 80, step 104. The bulk pick ticket 80 is received by a
pick agent in the warehouse who creates or employs a bulk pick cart
for temporarily storing the items associated with the bulk pick.
The pick agent then starts a bulk pick tour, step 106. The pick
agent moves along a path in the warehouse that is optionally
optimized by the order fulfillment system 10 to retrieve or pick
the items at selected locations. The selected items are then placed
in selected compartments within each tote that is stored on the
cart, or kept separated in containers or bags. The bulk pick ticket
is then associated with one or more of the totes, step 108.
Specifically, the bulk pick ticket can be placed on one of the
totes, typically the tote on top when stacked, or is affixed to the
cart in cases of very large bulk picks. The cart and associated
totes are then moved to a selected area in the warehouse, and the
totes are moved from the cart to a temporary holding station, and
are then transferred by any suitable mechanism, including a
conveyor belt system, to a bulk packing station, step 110. A bulk
pack agent associated with the bulk pack station then scans the
barcode on the bulk pick ticket 80 to determine if the recipes of
the bulk pick are complete. If not, then the agent keeps assembling
customer orders according to the bulk pick recipe until the recipe
is complete. If more than one recipe is included in the bulk pick,
then the next unfinished recipe is loaded for continued processing.
The items are then packed and shipped to the customer according to
known techniques.
[0066] The bulk picking of items in customer orders by the bulk
pick order fulfillment unit 18 offers additional benefits and
advantages. For example, a bulk pick is more efficient than a
shipment pick performed by pick agents in situations where there
are many customers that ordered the same set of items. This is
because the pick agent only needs to visit a location once per
item, and can pick multiple ones of the same item at the same time.
Although the pick agent can employ a mobile cart for picking
multiple single item shipments, or multiple multi-item shipments on
a cart while performing non-bulk picks, a barcode scan is required
on each item and tote compartment to perform an association to
ensure item movement tracking accuracy. The bulk pick process can
handle much larger quantities or items per pick, and does not
require a barcode scan.
[0067] By way of example, consider a situation where one hundred
customers ordered the same item. A pick agent can be directed to
pick one hundred of the same item from a stock location and then
take the entire group to a bulk processing station where the weight
of the item and inserts is acquired once, customer invoices are
printed, and then the agent assembles the individual shipments like
stuffing envelopes. In addition to single item bulk picks, the
system 10 supports multi-item picks and also takes into account any
promotional, product oriented, or customer oriented inserts such
that each of the recipes is unique. An example of a multi-item bulk
pick is an ensemble scenario where one hundred customers ordered a
ring, and fifty of those customers also ordered the matching
bracelet, and another twenty five customers ordered just the
bracelet. This would yield a bulk pick with two items: one hundred
rings, and seventy five bracelets. This example bulk pick is then
assembled into separate customer orders from a total of three
recipes: fifty of just the ring, fifty of the ring and bracelet,
and twenty-five of just the bracelet. In addition, customer
oriented inserts yield more variations of these recipes, but
ultimately there is a single pick of just two items that was able
to fulfill all of these permutations.
[0068] The ability to pick single item shipments and multi-line
shipments in parallel via bulk pick reduces the amount of distance
and time that it takes to pick the customer shipments. An
additional benefit of using the bulk pick process and system is
being able to utilize less sophisticated machinery to perform the
final packaging step of processing the shipment.
[0069] The illustrated pick tour generating unit 20 in FIGS. 1 and
8 is described in further detail herein, with reference for example
to FIGS. 1-7 and with further reference to FIGS. 8-13. The order
generating unit 14 of the order fulfillment system 10 interfaces or
communicates with the pick tour generating unit 20, which receives
the order fulfillment instructions 26 from the order generating
unit 14. The pick tour generating unit 20 generates pick
instructions for a single item or a multi-item order. The pick
instructions can be forwarded to the automated fulfillment system
16 and/or to a pick tour mobile operator or agent for performing a
pick tour.
[0070] As shown in FIGS. 1 and 8, the order generating unit 14
communicates with the pick tour generating unit 20 via output data
signal 28. The order generating unit 14 organizes and collates
customer orders into a set of shipments. The pick tour generating
unit 20 forms part of the illustrated pick tour generating
sub-system 29. A shipment consists of a unique shipment identifier
and a set of location and quantity pairs. Further, a graph, map or
other representation of the warehouse layout or footprint ("map")
can be created and stored, such as for example in the warehouse map
unit 120. The warehouse map can include indicia indicative of
multiple rows of shelving, as well as indicia associated with the
bays or vertical locations located along the rows of shelving.
Other types of marking or location related information can also be
used. The warehouse map unit 120 can be any selected storage
element that is configured for storing warehouse map data. The
warehouse map unit 120 can be a stand-alone storage element or can
be integrated with one or more other system units, such as for
example with the database 24 or the pick tour generating unit 20.
For the sake of simplicity, the warehouse map unit 120 is
illustrated as a separate unit. The warehouse map unit 120 can also
store the locations in the warehouse where various items are
stored, as well as the selected vertical bay at the warehouse
location. The items correspond to one or more items that form part
of the customer order.
[0071] The order fulfillment system 10 of the present invention
employs a cart building unit 128 that stores, transmits and
receives data associated with a mobile cart, and specifically
includes a container or tote data for use by the pick agent as how
to best arrange totes or containers on a mobile cart employed by
the pick agent for a subsequent pick tour. The tote data can
correspond to data associated with specific totes as well as to
sub-compartments within the totes. The totes and associated
sub-compartments are arranged and scheduled consistent with the
pick orders sent to the pick agent. Similar to the warehouse map
unit 120 and the graph generating unit 124, the cart building unit
128 can be a separate element or can form part of the pick tour
generating unit 20. The totes on the mobile cart can be uniquely
identified by identification (ID) information, which can include
any type of suitable data, including for example alphanumeric data.
The ID information can be encoded in a barcode that can be placed
on the front or back of the tote that is scanned while on a cart or
on a suitable transport system (e.g., a conveyor belt) within the
warehouse. The tote can include one or more sub-compartments, such
as for example four sub-compartments or quadrants. In addition to
the barcodes on the exterior of the tote, each sub-compartment of
the tote can also include unique identification information, such
as a barcode. The ID information associated with each
sub-compartment is used and scanned by the pick agent. The
sub-compartments can house one or more selected items associated
with a shipment. The ID information can be exchanged with the cart
building unit 128 and/or with the pick tour generating unit 20.
[0072] The pick tour generating unit 20 can for example perform a
mapping between the customer orders or shipments and warehouse
locations in the form of a map, such as a shipment-bay graph. This
mapping or graphing can be performed by the graph generating unit
124. The graph generating unit 124 can be a separate element or can
form part of the pick tour generating unit 20. The graphing can be
performed in a manner so as to optimize the time and distance that
a pick agent needs to travel when picking or selecting certain
items. The items correspond to one or more portions of one or more
customer orders. The graphing can also be optimized so as to avoid
potential collisions between pick agents and to consider the
location of any selected transport system, such as conveyor belts,
so as to ensure that the pick agent has relatively easy and speedy
access to the transport system. The graph generating unit 124 also
generates the graph employing shipments or customer orders that
include more than one item located at more than one location.
[0073] The illustrated graph generating unit 124 can employ a value
sorted tree map technique when generating the map or graph. An
example of the value sorted tree map 130 is shown for example in
FIGS. 9A and 9B. Specifically, FIG. 9B illustrates that the value
sorted tree map 130 is an associative array data type that enables
high-speed graph modification while concomitantly maintaining value
sort order. The associative array data type, also known as a map,
comprises a collection of keys, including (key, value) pairs, such
that a value can be quickly retrieved by the key, without
necessitating an ordering of the set of values that the keys are
mapped to. When employing the value ordered tree map 130, the
ordering of the values are retained during access, insertions, and
deletions, thus allowing for optimization of graph traversal
because the values do not need to be re-sorted before use or after
modification.
[0074] An example of the value sorted tree map 130 compared to
traditional mapping techniques is shown in FIGS. 9A and 9B. FIG. 9A
shows a map 132 with a list of items having associated
identifications, such as L101, L102, L103, and L104. The items are
mapped to graph nodes A, B, C, and D, which can according to one
practice correspond to warehouse locations. The traditional map
implementation does not guarantee the order in which the values
associated with the items illustrated in the map 132 are retrieved
by the pick agent. Before deciding which graph node is the next in
the sequence to be processed, the map values have to be sorted
again. For example, the values for the A node are L102, L101, and
L103, which needs to be sorted into L101, L102 and L103 before
selecting the next node in the sequence. The sorting functionality
is also required when processing the other map nodes B, C, and D.
The continuous need for re-sorting introduces significant overhead
when processing large graphs in both computation times for the
sort, as well as the physical computing resources required, such as
processing capabilities and memory.
[0075] The value sorted tree map 130 of the present invention
ensures that the values or node links remain in a sorted order
during access, insertion, and deletion which removes the need to
sort all of the value nodes when deciding which node to process
next in the graph. For example, as shown in FIG. 9B, the items are
presorted and listed as L101, L102, L103, and L104, and then mapped
to the graph nodes A, B, C and D. When the value L101 is removed
for example from the value sorted map for node A, then the new
first value becomes L102, without the need to re-sort the values of
the map. The value sorted map technique of the present invention is
highly beneficial for graph processing algorithms that alter the
graph by removing nodes during graph traversal. As such, the
present sorting technique significantly reduces the amount of
processing overhead and memory needed while processing the graph.
By maintaining the high speed key to value lookup characteristics
of a map, and automatically implementing and maintaining sort order
on modification, the value sorted tree map provides a very
efficient technique for optimizing graph processing. Further,
shipments of customer orders that have more than one location pick
are placed in the graph. The orders that have a single item or
location can be handled separately.
[0076] When creating the value sorted tree map 130, the incoming
customer orders or shipments are analyzed by the order generating
unit 14 to determine if the order is to be handled by the automated
shipment system 16, by the pick agent as part of a pick tour plan
or a pick tour, or a combination of both. When the order
fulfillment system 10 with the assistance of the supervisor
determines that the order or part of the order is to be handled by
the pick agent, the pick tour generating unit 20 determines if the
order includes items located at multiple different locations in the
warehouse. The system can easily determine the warehouse bay from
the warehouse location as set forth in the warehouse map 120. If
the bay node exists, then the quantity of the pick from the bay can
be incremented. If the shipment node does not already exist in the
map, the pick tour generating unit 20 creates a new graph or bay
node in the map. The system then adds a link from the shipment node
to the bay node in the graph and the pick tour generating unit 20
tracks the quantity of the shipment in the bay/node structure. The
resultant graph or map is then value sorted by the first bay
location and/or bay count, and then the subsequent bay location.
The map is then sorted by location. The graph is processed in such
a manner that optimizes the assignment of orders into an N number
of the sub-compartments or the compartments of the mobile cart.
Further, the order fulfillment system 10, such as through the pick
tour generating unit 20 and/or the graph generating unit 124,
analyzes the customer order and shipment information and inserts
the shipment data into the graph and creates a new graph node for
the shipment if the bay node does not exist. For each item of the
shipment determine a corresponding warehouse location, and then
determine a warehouse bay from the location. The system then adds a
link in the graph between the bay node and the shipment node. The
shipment graph is then value sorted by the first bay location, bay
count, and then subsequent bay location.
[0077] The pick tour generating unit 20 then constructs a pick tour
plan or a pick tour having pick instructions associated therewith.
The pick tour plan and the pick tour essentially provide a schedule
or list of tasks for the pick agent to follow. The pick tour plan
is constructed or generated by the pick tour generating unit 20 so
as to optimize the path distance through the warehouse as well as
the number of pick tasks that a pick agent can execute when
eventually performing the pick tour. Factors that the pick tour
generating unit 20 considers when optimizing or constructing the
pick tour plan can include but are not limited to avoiding
impediments or obstacles within the warehouse, such as for example
walls and machinery, preferred human walking paths, opportunistic
drop-off points like the central conveyor belt and location stock
density as well as travel distance and quantities of products
picked. Permissions required of the pick agent are also considered
as picking expensive items, oversized items, or fragile items may
require different levels of authorization or skill sets to perform.
For example, a new pick agent may not have permission to execute a
tour that contains important or expensive items.
[0078] Further, the cart building unit 128 employs the pick tour
plan to help construct the pick cart by determining the number of
totes and sub-compartments, and associating therewith the
appropriate identification information. The pick tour plans are
preferably constructed or generated so as to include trips by the
pick agents to generally the same number of bays as well as the
same number of picks or items, while concomitantly minimizing the
overall or total walking distance by the pick agent. The pick plans
are constructed by mapping the shipments or customer orders
collected by the order generating unit 14 with the warehouse
configuration data stored in the warehouse map unit 120 by the
graph generating unit 124. The shipments that include more than one
location pick are placed in the graph. The shipments that are
directed to a single piece or warehouse location can be later added
to the below pick tour. The pick plan includes a list or set of
pick tasks that are segmented or partitioned into selected
warehouse locations, thus creating different pick tasks for each
warehouse zone.
[0079] As shown in FIG. 12, a pick tour plan 156 can be created by
the pick tour generating unit 20 and includes the illustrated pick
instructions 157. According to one practice, the pick tour plan 156
can be optionally employed by the pick agent to retrieve or pick
the items set forth in the pick instructions. Alternatively, the
pick tour plan 156 can be converted into the pick tour 174 for use
by the pick agent. By way of illustrative example, the illustrated
pick tour plan 156 has been generated by the pick tour generating
unit 20 and includes pick instructions 157 directed to four
different customer shipments, which are labeled as `a`, `b`, `c`
and `d`. By way of illustration, an exemplary mobile cart can be
configured by the cart building unit 128 to use only three reusable
slots 153 of the various slots on the cart. The slots 153 can be
designated as slot1, slot2, and slot3, and form part of the pick
instructions 157. When a customer shipment has been fully
assembled, as depicted by suitable completion indicia, such as
darkened triangles 155 in the bottom corner of the pick tour plan
156, the customer shipment is placed in a bag by the pick agent and
labeled with a barcode so that the same slot may then be used to
assemble a different customer shipment. In the example
configuration of FIG. 12, the initial state of the pick tour plan
is the start state 158 where each of the three slots 153 on the
mobile cart is indicated as being empty. The warehouse map stored
in the warehouse map unit 120 can include a number of bay locations
154 in the map. The pick tour plan 156 essentially sets forth a
series of bay locations in the warehouse that the pick agent is
instructed to visit to retrieve selected items located at the bay
locations and that correspond to various customer orders. The bay
locations 154 can include for example a first bay location in the
warehouse that forms part of the pick tour plan 156, which can have
any suitable designation, such as for example L102, as illustrated.
As such, the pick agent is instructed by a mobile device user
interface to pick a selected item for customer shipment `a` into
slot1 and the same item into slot2 for shipment `b`. No pick was
planned for slot3 at bay location L102, thus slot3 remains empty.
The pick agent is then directed by the mobile device user interface
to walk to the next bay location K105. Additional items are picked
from this location for shipments `a` and `b`, and which are placed
in slot1 and slot2, respectively, and customer shipment `c` is
started by placing the item in the formerly empty slot3. The pick
agent is then directed by the mobile device user interface to walk
to the next bay location J102. Items are picked for shipment `a` in
slot1 and shipment `c` in slot3, however, shipment `b` does not
have any picks at location J102. However, the previously picked
items continue to occupy slot2 because not all items for customer
shipment `b` have been picked. The customer shipments "a" and "c"
are completed, as indicated by the completion indicia 155, and
hence these items are bagged by the pick agent and labeled with the
shipment number and then placed in a bin of completed shipments on
the cart or directly on conveyance equipment such as a central
conveyor belt destined for the packaging operation. Because
customer shipments `a` and `c` are now complete, the respective
slots slot1 and slot3 are now eligible to be used to assemble a
different shipment. The pick agent is then directed by the mobile
device user interface to walk to the next bay location M201. The
pick agent is directed to pick items for customer shipment `d`,
which is placed in slot1, as well as for customer shipment `b`,
which is in slot2. The last item for customer shipment `b` is
picked, as indicated by the completion indicia 155. Slot3 remains
empty because shipment `c` has already been completed and taken out
of the slot on the previous bay visit. The pick agent is then
directed by the mobile device user interface to walk to the last
bay location M202, where the agent picks the last item for shipment
`d` from this location and the pick tour plan is complete with all
four shipments `a`, `b`, `c`, and `d` having been picked and
assembled on the mobile cart and now destined for the packing
operation.
[0080] When compartmentalized totes on the mobile cart are used,
the slots 153 represent sub-compartments of the totes and are
typically not re-used because the tote itself is used as the
container of the product instead of a bag. Once all picks for all
sub-compartments of the tote have been completed, the tote is then
transported by automated conveyance or by moving the mobile cart to
a destination for unloading the totes for further processing.
[0081] As shown in FIGS. 8 and 13, the pick tour generating unit 20
can preferably convert the pick tour plan 156 into the pick tour
174 having pick instructions associated therewith that are conveyed
to the mobile device of the pick agent. As such, the pick tour plan
156 can be directly converted to the pick tour 174 prior to be
being sent to the pick agent. The pick tour 174 can be, if desired,
tours that are confined to selected zones or regions of the
warehouse. As such, the location of the pick agent is considered
when assigning a pick tour to a selected pick agent. The pick tour
174 includes pick instructions that are, in essence, an ordered
list of tasks to perform, which includes the location, quantity,
and specific items to pick as well as the mobile cart slot number
to place the picked items into for subsequent shipment. The pick
tour instructions leverage the similarity in customer orders and
item locations within the warehouse so as to minimize the amount of
time it takes to pick the one or more items that comprise the
customer order. The pick tour includes a path that is optimized for
time and distance for the pick agent. The path can have any
selected configuration, and is typically a serpentine path. The
mobile handheld device guides the pick agent to the selected
location of the item in the warehouse and assists the pick agent in
selecting the correct item. The handheld device also serves to
allow the order fulfillment system 10 to track and verify the
location of the pick agent, and to perform product and location
verification in real time. The interface on the handheld device
presents a visual interface that guides the pick agent through a
pick tour walking path in the warehouse while concomitantly
assembling multiple customer shipments on a mobile cart in
parallel. As noted above, the mobile cart has a series of totes,
and each tote can have one or more sub-compartments. The pick tour
generating unit 20 optimizes the use of the totes and associated
sub-compartments to sequence the assembly of multiple multi-line
orders. The pick tour generally is confined to a selected duration
so that multiple sequential pick tours can be performed by a pick
agent. The duration of the pick tours can be between about 30
minutes and about 90 minutes, and preferably are about 45
minutes.
[0082] FIG. 13 shows for the purposes of simplicity and
illustration an exemplary pick tour 174 that was generated from the
pick tour plan 156. The pick tour 174 is similar to the pick tour
plan 156 with additional detailed information where specific item
locations, product IDs, and quantities are specified. Unlike the
pick tour plan which focused on creating multiple optimal plans,
the pick tour 174 focuses on having all of the information
necessary to execute the pick or retrieval of the product by the
pick agent. The sequence 174A is the order in which each of the
pick tasks should be performed. The location 174B is the exact bin
number at the bay location and also the bar-coded value that is
placed on the bin. The shipment information 174C is the unique
shipment ID that represents a customer order or grouping of
customer orders for the same shipping destination address. The
product ID 174D and quantity (QTY) 174E of the product to be picked
from the location 174B is used to verify that the correct product
and number of products is being picked. The slot information 174F
is the destination of the picked item on the mobile pick cart which
may be a re-usable bin or the sub-compartment of a tote. The closed
flag or indicator 174G indicates if all of the items for the
shipment have been picked upon the completion of the pick task. In
the exemplary pick tour 174, shipments 2 and 3 174C correspond to
piece picks where a customer only ordered a single product and only
one quantity of that product, thus they do not need to be assembled
with other products and are not placed in a slot, but instead are
directly placed in a bag with an affixed printed adhesive barcode
to identify the shipment in the bag. Once the pick agent has
completed all of the pick tasks in a pick tour 174, the pick tour
is complete and the pick agent may request a new pick tour. The
pick tour assignment is based on the location of the pick agent in
the warehouse relative to the first picking location for available
pick tours. In some cases, the product stock may be segregated
where special permissions may be required, such as for example when
picking high end, fragile, oversized, or otherwise categorized
products or items. The identity of the pick agent, the location of
the pick agent, the permissions of the agent, and the priority of
the pick tour are factors that the pick tour assignment algorithm
uses in assigning pick tours to pick agents.
[0083] Once the pick tour plan 156 is generated and transmitted to
the mobile device of the pick agent, the pick tour 174 can be
created and started by the pick agent. According to the present
invention, the pick tour 174 includes shipments or orders that
correspond to items at multiple locations in the warehouse. The
pick tour generating unit 20 can add a task to an existing pick
tour that corresponds to an item located in a convenient or
"opportunistic" location along the existing pre-defined pick tour
path of the pick agent. The pick tour generating unit 20 can sort
the additional individual piece pick tasks by location and then
compares the piece pick tasks to the current pick tours or the pick
tours as of yet to be assigned. The additional piece pick task
typically includes one or more items disposed at a single location
that is opportunistically located along the walking path of
existing pick tour. The opportunistic piece pick task added to a
pre-existing pick tour is a pick task that meets selected heuristic
calculations regarding the closeness of the location of the item to
the pick agent, the remaining pick cart capacity, the additional
time added to the existing pick tour, and overall collision or
contention reduction with other piece pick tours. Other factors can
include whether the pick agent has already visited the warehouse
location as part of the current pick tour, and whether the item
location is along or sufficiently near the path of the current pick
tour. The closeness of the piece pick location can be calculated in
terms of time and/or distance to the current pick agent and current
pick tour path, and the pick tour generating unit 20 can define an
overall maximum distance or time to be added to the current pick
tour in order to add one or more selected piece pick tasks to the
tour. Thus, the pick tour generating unit 20 contemplates adding
one or more additional piece pick tasks to the tour provided that
the maximum or overall distance and time added to the pick tour is
at or below the maximum amounts.
[0084] FIG. 10 illustrates an exemplary interface or display 136 of
the mobile handheld device employed by the pick agent. The device
has associated therewith suitable hardware, such as a scanner,
processing hardware, memory and the like (not shown). The device
has a display 136 that can be configured in any selected manner. As
shown, the display 136 has a series of dedicated regions or areas
that display selected types of information. For example, the
display has a top area or region that has sub-regions 142, 144,
146, a central area or region 140, and a bottom area or region that
has sub-regions 148, 150, and 152. The top sub-region 142 can set
forth the warehouse location and bay of the item to be retrieved.
The warehouse location and bay can have identification information
associated therewith, such as a barcode. The handheld device can
scan the barcode of the location, and if the location matches the
location displayed in sub-region 142, a visual or audible alert can
be provided. In the event that the location does not match, an
alternate visual or audible alert can be provided that indicates an
error. For example, the sub-region can change color to visually
indicate that a match exists. Conversely, the handheld device can
produce an audible sound or generate a tactile sensation. The
handheld device can then be used to scan a barcode attached to the
item to verify that the correct item is being picked. The item to
be picked can be displayed in the central region 140 along, if
desired, a barcode number. The pick agent can thus perform a
secondary visual check to ensure that the picked item visually
matches the item displayed in the region 140. This provides
redundancy in the system to ensure that the pick agent is selecting
or picking the correct item and can identify situations where an
item may have the incorrect tag or barcode. The pick agent can
touch the region 140 to display more detailed information about the
picked product, such as product SKU, product description, and other
associated information that could be used to identify the item in
the case that a product image is not available or more information
about the product is needed. Next, the pick agent scans the target
tote compartment where the product is to be placed, as shown in
sub-compartment 146. The pick agent can also visually determine and
confirm the number of items to be picked from the warehouse
compartment, as indicated in sub-region 144. Any one of or all of
the sub-regions 142, 144, 146 can change color to visually indicate
a match between the ordered item and the product retrieved from the
warehouse bay. When completed, the pick agent travels to the next
warehouse location provided in the pick tour.
[0085] The display 136 also includes a bottom region that includes
a sub-region 148 that allows the pick agent to pause or cancel the
pick tour, a display sub-region showing the number of tasks
completed and the number of total tasks (sub-region 150), as well
as a display sub-region that allows exception information to be
entered or can be used as a visual indicator of the network
connection status (sub-region 152).
[0086] Once the last item for a shipment is picked and placed in a
slot or sub-compartment of the tote, the pick agent is instructed
that the sub-compartment is now closed and the shipment has been
fully assembled. This information can be conveyed to the pick agent
through the mobile handheld device. The completed totes may then be
taken off of the mobile cart and placed on a central conveyor belt
or otherwise delivered to the next step in the packing and shipping
process. Alternatively, the contents of the sub-compartment are
then placed in shipping bags by the pick agent, and then the bags
and/or the tote(s) are then placed on a central conveyor belt and
are sent to the packing and shipping subsystem 22.
[0087] FIG. 11 is a flowchart depiction of the pick tour generation
process performed by the order fulfillment system 10 according to
the teachings of the present invention. The system 10 receives
customer order information from the customer and the order
information is collated by the order collection unit 12. The order
collection unit 12 then conveys this information to the order
generation unit 14. The customer order information is combined with
the customer shipment or address information either provided by the
client for first time customers or the information is retrieved
from the database 24, step 160. The graph generating unit 124 maps
the shipment data with the warehouse map data stored in the
warehouse map unit 120 to generate a shipment-bay graph or
connected map, step 162. The map is value sorted to create a value
sorted tree map. The cart building unit 128 then provides the pick
tour generating unit 20 with cart specific information or data,
including identification information of the containers or totes on
the mobile cart, as well as identification information for any
sub-compartments within each container or tote, step 164.
[0088] Once this information is determined, the pick tour generator
20 initially generates a pick tour plan 156, step 166. The pick
tour plan 156 is constructed or generated so as to optimize the
path distance through the warehouse as well as the number of pick
tasks that a pick agent can execute when eventually performing the
pick tour. The pick tour plan 156 includes location information of
the customer items, including warehouse location and corresponding
bay, as well as container and sub-compartment information of the
mobile cart. The pick tour plan is then converted into a pick tour
174 by the pick tour generator 20, step 168. The pick tour 174 can
include any information required by the pick our agent to conduct
the pick tour, including the location information of the items to
be picked, identification information of the items, and the
quantity of the items to be picked. During the pick tour, the pick
tour generator 20 can add a pick task to the current pick tour of
the agent if the agent is located in a selected proximity to the
item, step 170. This opportunistic piece pick enables orders to be
processed by the order fulfillment system 10 as expeditiously as
possible.
[0089] As shown in FIGS. 14-17, the automated fulfillment system or
sub-system 16 of the present invention can be any commercially
available product picking or fulfillment system, such as those
manufactured by SSI Schaefer of Germany. The automated fulfillment
system 16 can include a series of vertically and horizontally
extending stacks or carousels 220, each of which can include a
plurality of spatially separated shelves or racks (not shown). The
totes or tubs 222 from the system 10 can be conveyed to the
carousels 220 via a transport system, such as the illustrated
conveyor system 226. The conveyor system 226 can include a series
of mechanical connections that allow one or more tubs 222 to travel
both horizontally between rows of shelves as well as vertically
among the shelves. The stacks or carousels 220 thus function as
automated racks of tubs that can retrieve a specific storage item
and deliver it to the conveyor system 226. The conveyor system can
be coupled to the shelves so that the tubs containing the items can
be transported within as well as to and from the automated
fulfillment system 16. Mechanical arms (not shown) place items from
the shelves into the tubs 222 and when a customer order is
complete, the tubs 222 are conveyed via the conveyor system 226 to
a pick station 230. At the pick station 230, the items of the
customer order are removed from the tubs 222 and then placed in
pick totes 228. The tubs 222 are then returned to the carousels
220. The system can be controlled by known hardware and software,
and employs a control station to control the movement of the bins
throughout. The control station can form part of the bulk pick
order fulfillment unit 18 and/or the pick tour generating unit 20,
or can be a separate control station that communicates with these
as well as other units.
[0090] Similar to the above in connection with the bulk pick order
fulfillment unit 18, and as shown in FIG. 14, the order fulfillment
system 10 receives shipment and item data, step 180, from the
customer orders. The customer order collection unit 12 generates
customer and order information that is transmitted and received by
the order generating unit 14. The order collection unit 12
consolidates the incoming customer orders and organizes and
consolidates selected order and customer information from the
customer orders. The order generating unit 14 is configured for
controlling and managing the order data for fulfillment in a time
based manner. The order data is preferably organized and managed by
the order generating unit 14 so as to optimize the selection or
picking of the items in the customer order and then shipping the
items to the customer. The order generating unit 14 then transmits
the order fulfillment instructions or data to a bulk pick order
fulfillment unit 18 to generate a bulk pick recipe, step 182.
[0091] The automated fulfillment system 16 can receive bulk pick
instructions from the bulk pick order fulfillment unit 18 and
perform an automated picking of items to fulfill a customer order,
step 184. As described above, the order generating unit 14 can be
configured to group together a set of customer orders that share
similar features into a larger bulk pick order, and then the bulk
pick order data can be transmitted to the bulk pick order
fulfillment unit 18. The bulk pick orders (e.g., a bulk order wave)
are groupings of customer orders that may be picked or fulfilled in
a warehouse in aggregate. The bulk pick orders are selected to
optimize the fulfillment process by selecting orders that have
certain features in common. The bulk pick order fulfillment unit 18
generates bulk pick tour data corresponding to one or more bulk
pick tours that can be fulfilled by the automated fulfillment
system 16.
[0092] The automated fulfillment system 16 can pick the selected
bulk pick items and then place them in one or more totes or
container elements. The totes are then conveyed by the conveyor
system to the packing and shipping subsystem, step 186.
[0093] For items within the customer order that are not located in
the automated fulfillment system 16, the system 10 via the bulk
pick order fulfillment unit 18 can generate a bulk pick recipe and
a bulk pick sheet for dissemination to a pick agent, as described
above.
[0094] With reference to FIG. 15, the order fulfillment system 10
can generate and send instructions to the automated fulfillment
system 16 to perform non-bulk picks. For example, the pick tour
generating sub-system 29 receives information from the order
generating unit 14 regarding the customer order information, step
190. The pick tour generating unit 20 then performs a mapping
between the customer orders or shipments and warehouse locations in
the form of a map, such as a shipment-bay graph, via the graph
generating unit 124 and the warehouse map unit 120. The pick tour
generating unit 20 then generates pick instructions and constructs
a pick tour plan and/or schedule for the pick agent, the automated
fulfillment system 16, or both. The pick tour plan 156 is
constructed or generated so as to optimize the path distance
through the automated system as well as the number of pick tasks
that a pick agent can execute when eventually performing the pick
tour. The pick tour generating unit 20 then converts the pick plans
into pick tours 174, step 192, that are conveyed to the mobile
devices of the pick agent, to the automated fulfillment system 16,
or to both. The pick tour 174 is an ordered list of tasks to
perform, which includes the location, quantity, and specific items
to be picked.
[0095] The automated fulfillment system 16 then picks the selected
items listed in the pick tour 174 and the places the items in one
or more tubs, totes or containers, step 194. The tubs or totes are
then conveyed by the conveyor system to the packing and shipping
subsystem, step 196.
[0096] For items within the customer order that are not located in
the automated fulfillment system 16, the system 10 via the pick
tour generating unit 20 can generate a pick tour plan 156 or a pick
tour 174 for dissemination to a pick agent, as described above.
[0097] Further, the order fulfillment system 10 allows for one or
more items picked through either the bulk wave process or the pick
tour process to be added to items picked by the automated
fulfillment system 16 prior to transfer to the packing and shipping
subsystem 22. This enables the system 10 to be able to add one or
more items not located in the automated fulfillment system to be
added to an order that is primarily filled by the automated
fulfillment system. For example, as shown in FIG. 16, the customer
order collection unit 12 generates customer and order information
that is transmitted and received by the order generating unit 14.
The order generating unit 14 controls and manages the order data
for fulfillment in a time based manner, step 200. The order
generating unit 14 then transmits the order fulfillment
instructions or data optionally or alternatively to either or both
the bulk pick order fulfillment unit 18 to generate a bulk pick
recipe, step 202, or to the pick tour generating unit 20, step 204,
for generating a pick tour. The steps 202 and 204 are shown in
phantom to represent that either or both are optional steps. The
order fulfillment system 10 then transfers either or both the bulk
pick recipe or the pick tour plan 156 to the automated fulfillment
system 16 to automatically pick or retrieve the selected customer
items, step 206. Once the automated system selects one or more of
the customer items, the system determines whether an item in the
bulk tour or the pick tour is located in the warehouse and not in
the automated fulfillment system. Specifically, the order
fulfillment system 10 determines if a static pick is needed, step
208. If a static pick is not needed, and hence all of the customer
items are found within the automated fulfillment system 16 and are
retrieved, then the system transfers or conveys the items to the
packing and shipping subsystem 22, step 210. However, if one or
more items are located outside of the automated fulfillment system
and hence one or more static picks are needed, then the system 10
generates either a bulk tour recipe or a pick tour that is conveyed
to the handheld device of the pick agent. The pick agent retrieves
the selected one or more customer items from the bays in the
shelving in the warehouse, step 212. The items are eventually
combined with the items picked by the automated fulfillment system.
When there are no additional items required to be picked, the items
are conveyed or transferred to the packing and shipping subsystem
22.
[0098] The present invention can also include a system and method
for handling customer returns and/or replenishing items in the
warehouse. For the sake of simplicity, we reference herein the
processing of items returned by a customer, and the placement of
the returned items in the warehouse, as also encompassing the
replenishment of items in the warehouse. One of ordinary skill in
the art will readily recognize that the building of the totes and
mobile carts, and the put away or return tours (similar to the pick
tours) are equally applicable to replenishing or adding items to
the warehouse floor. As shown in FIG. 18, the order fulfillment
system 10 of the present invention can also include a return order
generating unit 240. The return order generating unit 240 can
create or generate, in essence, a reverse pick tour, that is, a
tour that guides the pick or return agent through the warehouse to
return selected items to selected locations rather than retrieve
items. The return tour can be generated to optimize the return time
and return trip of the return agent, similar to the generation of
the pick tour. The processing of customer returns can be handled in
the same facility as the fulfillment of customer orders or in an
adjacent or separate facility.
[0099] The returned items from the customers that form part of the
customer order can be processed according to known techniques.
According to one practice, the order fulfillment system 10
retrieves information associated with the returned orders that
enables the returned items to be properly processed and credited to
the associated customer account. The customer related information
as well as order related information can be stored for example in
the database 24. The information retrieved from the returned items
can include customer information retrieved directly from the
returned packaging or invoice, including customer identification
information, including customer identification data, name data, and
address data. If this information is lacking, or additionally, the
information can be retrieved from the customer order number, the
shipment number or associated identification information (e.g.,
postal or shipping service identification information), the product
or item identification information, and the like.
[0100] The order fulfillment system 10 or the return agents
assigned to inspect or review the returned items initially assess
the returnability of the items. For example, the system 10 or the
return agents inspect the items for damage or wear and tear on the
items in order to determine if the items can be accepted for
return. The system or the return agent also reviews the order
information, including item identification data, quantity, and the
like, to determine if any customization to the product occurred,
such as sizing. The order fulfillment system 10 or the return agent
also verifies if the returned items are being returned within the
return time period and whether a warranty covers the returned
items. Alternatively, if the items are still in the original
packing with an associated barcode, the barcode can be scanned by
any suitable scanning device, such as by the handheld device
employed by the pick agents, as well as by other agents.
[0101] The items to be returned to the warehouse, which includes
the warehouse bays as well as the automated fulfillment system 16,
are eventually assigned to a sub-compartment of a tote on a return
cart. Prior to constructing the return cart, the items to be
returned can be placed within selected compartments of a return
tote and when filled, placed on a conveyer system to be transferred
to a return tote area or region. Once a return cart is created, the
return order generating sub-system 241 determines the specific
destination in the warehouse of the returned items. Specifically,
the illustrated system 10 determines the location of the returned
items based on the location of similar or identical items presently
located in the warehouse, or where the items are most efficiently
picked when sold again. To determine a proper item location or
return tour path of the return agent, the system 10 and the return
order generating unit 240 consider a number of different
parameters, including for example the current inventory levels,
future predicted returns, and existing customer orders to determine
if the item needs to be directed to the stacks or carousels 220 of
the automated fulfillment system 16 or to static warehouse
locations.
[0102] For example, as shown in FIG. 20, the return order
generating unit 240 forms part of the illustrated return order
generating sub-system 241. This sub-system is similar to the
sub-system 29. The return order generating sub-system 241 includes
for example the return order generating unit 240. The return order
generating sub-system 241 can also include a warehouse map unit 300
for storing a graph, map or other representation of the warehouse
layout or footprint ("map"). The warehouse map can include indicia
indicative of multiple rows of shelving, as well as indicia
associated with the bays or vertical locations located along the
rows of shelving. Other types of marking or location related
information can also be used. The warehouse map unit 300 can be any
selected storage element that is configured for storing warehouse
map data. The warehouse map unit 300 can be a stand-alone storage
element or can be integrated with one or more other system units,
such as for example with the database 24 or the return order
generating unit 240. For the sake of simplicity, the warehouse map
unit 300 is illustrated as a separate unit. The warehouse map unit
300 can also store the locations in the warehouse where various
items are stored, as well as the selected vertical bay at the
warehouse location. The items correspond to one or more items that
form part of the customer order.
[0103] The return order generating sub-system 241 of the present
invention can also include a return cart building unit 302 that
stores, transmits and receives data associated with a mobile return
cart, and specifically includes one or more containers or totes and
associated tote data for use by the return agent when building the
return cart. The tote data can correspond to data associated with
specific totes as well as to sub-compartments within the totes. The
totes and associated sub-compartments are arranged and scheduled
consistent with the items to be returned to the warehouse by the
return agent. Similar to the warehouse map unit 300, the cart
building unit 302 can be a separate element or can form part of the
return order generating unit 240. The totes on the return cart can
be uniquely identified by identification (ID) information, which
can include any type of suitable data, including for example
alphanumeric data. The ID information can be encoded in a barcode
that can be placed on the front or back of the tote that is scanned
while on a cart or on a suitable transport system (e.g., a conveyor
belt) within the warehouse. The tote can include one or more
sub-compartments, such as for example anywhere from between 1 to 24
sub-compartments. In addition to the barcodes on the exterior of
the tote, each sub-compartment of the tote can also include if
desired unique identification information, such as for example a
barcode. The ID information associated with each sub-compartment
and/or each tote is used and scanned by the return agent. The
sub-compartments can house one or more selected items associated
with an item to be returned. The ID information of the tote and
cart can be exchanged with the return cart building unit 302 and/or
with the return order generating unit 240.
[0104] According to one practice, the return order generating unit
240 can for example optionally perform a mapping between the items
to be returned and contained within the totes and warehouse
locations in the form of a map, such as a shipment-bay graph. This
mapping or graphing can be performed by the graph generating unit
304, which is similar to the graph generating unit 124. The graph
generating unit 304 can be a separate element or can form part of
the return order generating unit 240. The graphing can be performed
in a manner so as to optimize the time and distance that a return
agent needs to travel when returning or replenishing certain items.
The items correspond to one or more portions of one or more
customer orders that have been returned by a customer. The graphing
can also be optimized so as to avoid potential collisions between
pick and return agents and to consider the location of any selected
transport system, such as conveyor belts, so as to ensure that the
pick agent has relatively easy and speedy access to the transport
system. The graph generating unit 304 also generates the graph
employing shipments or customer orders that include more than one
item located at more than one location. The illustrated graph
generating unit 304 can optionally employ a value sorted tree map
technique when generating the map or graph, similar to the value
sorted tree maps 130 shown for example in FIGS. 9A and 9B. For each
returned item, the return order generating sub-system 241
determines a corresponding warehouse location, and then determine a
warehouse bay from the location. The value sorted tree map or graph
is then value sorted by the first bay location, bay count, and then
subsequent bay location.
[0105] Once the return cart has been built, the return order
generating unit 240 then constructs a return tour having return
instructions or tasks associated therewith. The return tour
essentially provides a schedule or list of tasks for the return
agent to follow. The return tour is constructed or generated by the
return order generating unit 240 so as to optimize the path
distance through the warehouse as well as the number of return
tasks that the return agent can execute when eventually performing
the return tour. Factors that the return order generating unit 240
considers when optimizing or constructing the pick tour plan can
include but are not limited to avoiding impediments or obstacles
within the warehouse, such as for example walls and machinery,
preferred human walking paths, opportunistic drop-off points like
the central conveyor belt and location stock density as well as
travel distance and quantities and locations of items that need to
be returned. Permissions required of the return agent are also
considered as returning expensive items, oversized items, or
fragile items that may require different levels of authorization or
skill to perform. For example, a new agent may not have permission
to execute a return tour that contains important or expensive
items.
[0106] Further, the return cart building unit 302 enables the
return agent to build a return cart by associating one or more
totes with a specific mobile cart. Once the return cart is built,
the return order generating unit 240 can generate a return tour
based on the specific items within the totes assigned to the return
cart. The return tours are preferably constructed or generated so
as to minimize the overall or total walking distance by the return
agent. The return tours can include a list or set of return tasks
that can be optionally segmented or partitioned into selected
warehouse locations, thus creating different return tasks for each
or different warehouse zones.
[0107] The order fulfillment system 10 and the return order
generating sub-system 241 provide the ability to reconfigure totes
on a return cart, such as by the return cart building unit 302, by
choosing different tote configurations while concomitantly allowing
the return agent to move or place items in various totes to ensure
that the items are securely located within the tote. Because the
items can vary in type, size and quantity, the return agent needs
to be able to reconfigure the contents of the totes. The return
agent is also provided via the handheld device with information and
images throughout the return process to ensure the accurate
slotting and put-away of the returned items.
[0108] Further, the order fulfillment system 10 and the return
order generating unit 240, prior to returning the items to the
warehouse, can also check to determine if the item to be returned
forms part of a new or existing customer order that has yet to be
picked. If so, the item can be routed to an existing order tote and
eventually sent to the packing and shipping subsystem 22 for
shipment to the customer.
[0109] The returned items can then be placed within one or more
compartments or sub-compartments of a tote or carrier element that
form part of a return cart. The return cart building unit 302
determines the number of totes and sub-compartments associated with
each tote of the return cart. The compartments of the tote can have
associated therewith identification (ID) information, such as
alphanumeric data, barcode data, or positional coordinates within
the tote, identifying the specific compartment within the tote as
well as the specific tote. The ID information associated with each
compartment or sub-compartment is scanned by the return agent. The
ID information can be exchanged with or provided to, for example,
the return order generating unit 240. The returned items are added
to the tote until the return order generating sub-system 241
determines that there exist enough items in the tote to be returned
to the warehouse. The return cart can be built according to this
technique.
[0110] Alternatively, according to another practice, the return
agent can fill selected totes and associated sub-compartments with
items to be returned to the warehouse. The tote is then moved to a
selected area in the warehouse by any suitable transport or
conveying mechanism, including a conveyor belt system, such as for
example a portion of the conveyor system 226. The totes can be
temporarily stored in a holding area awaiting a return agent to
construct a return cart. The totes can be conveyed to the automated
fulfillment system 16 and/or to the return agents. The totes can be
constructed using logic that enables a return agent during a put
away or return tour to optimize the distance and time during the
tour. The returned items can be sorted among multiple totes during
item processing so as to arrange the totes in a manner to optimize
the returns to the warehouse.
[0111] The return order generating sub-system 241, and specifically
the return cart building unit 302, can employ a hand held device
that has an interface or display 136 adapted for building the
return or put away cart. The handheld device can include an
appropriate processor, display, keypad, memory, and scanner, as
well as other suitable and well known electronic components. The
handheld device communicates with the return order generating unit
240. The handheld device can include software and hardware for
placing the device in a Return Cart Builder mode 302, in addition
to the foregoing Pick Tour Cart Building mode (FIG. 10), for
building a mobile put-away or return cart. The display 136 of the
handheld device can display a re-creation of the mobile return
cart. An example of a suitable display on the interface/display 136
is shown in FIG. 19A. The illustrated region 242 of the display 136
can display a representation of a return cart 244 that can be
constructed by the return agent and representations of totes 246
thereon in a specific manner or sequence. The return agent
initially takes a first tote from the holding area and then scans
the identification information on the tote and then scans the
return cart to associate the tote with the cart 244. If necessary,
the return agent can scan the identification information on one or
more individual compartments of the tote as well. The display 136
on the handheld device then visually indicates the area or areas of
the cart 244 that can accept totes 246. The return agent can
highlight or select a tote area (e.g., tote areas A-H) of the cart
244 in the display region 242, which corresponds to particular tote
locations. For example, if tote area A is selected, then the pick
agent scans the identification information of the first tote and
places the first tote in tote area A of the cart. The tote is now
associated with that specific tote area of a specific return cart.
The return agent then selects a second tote area on the display of
the handheld device, such as for example tote area B, and then
scans the identification area of a second tote. The second tote is
placed on the cart at the selected area, and the second tote is now
associated with tote area B. This process is repeated until a
specific number of totes are loaded in the mobile return cart
244.
[0112] The illustrated display 136 can also include any selected
number of bottom sub-regions 246. For example, the display can
include sub-regions 248A, 248B, and 248C. The sub-region 248A can
provide and display information associated with the user status.
The sub-region 248B can provide and display information associated
with the confirmation status of the cart 244 and/or totes. The
agent can activate this feature by selecting the confirmation
status to confirm the loading of a tote or to cancel a tote. The
sub-region 248B can also be employed to clear the contents of the
cart. The sub-region 248C can be used to indicate the status of the
server (e.g., return order generating unit 240), such as whether
the handheld device is properly communicating with the server or
the system 10.
[0113] Once the mobile return cart 244 has been constructed, the
return agent can access or communicate with the order fulfillment
system 10 and specifically the return order generating unit 240 via
the handheld device. The handheld device can be disposed in a Put
Away or Return mode. The Put Away mode requests that the return
order generating unit 240 create or construct a put away or return
tour that enables the return agent to put away the items in the
totes. The put away or return tour is similar to the pick tour, as
described above. As used herein, the term "put away tour" or
"return tour" is intended to mean a series of instruction that
include one or more return instructions or tasks that when
aggregated or consolidated together form a tour. The tour is in
essence a series of instructions sent to the return agent to put
back or return one or more items associated with one or more
customer orders to selected locations within the warehouse.
Alternatively, the return tour can involve returning items to the
automated fulfillment system 16, which receives the aggregated list
of items via a tote or from the return tour generated by the return
order generating unit 240 and returns the items to selected
locations within the automated fulfillment system 16.
[0114] According to this embodiment, the formation or loading of
the return totes is performed first and hence is initially
decoupled from the return cart. This enables the returns to be
processed in a separate location of the warehouse or in a separate
facility. Further, the return cart building unit can include logic
for preventing the loading or assignment of a tote to more than one
return cart or assigning the tote to a return cart that already has
a return tour in progress.
[0115] The handheld device also includes a Tote Lookup mode that
allows the return agent to identify the items or contents in a
specific tote, as well as the destination of the tote. This mode is
also helpful if a tote or mobile return cart 244 with a number of
totes is dropped or turned over. The Tote Lookup mode can assist
the return agent in identifying the contents of the tote and cart
so as to enable the agent to rebuild the tote or cart.
[0116] During the put away or return tour, the display 136 of the
device presents a visual interface that guides the pick agent along
the put away or return tour. The return tour guides the return
agent to selected locations in the warehouse so that the agent can
return items from the totes in the cart to the warehouse locations.
The totes in the mobile cart can have any selected number of
sub-compartments depending upon the arrangement of the specific
tote. For example, the totes can be divided into or support
compartment dimensions of 1.times.1, 2.times.1, 2.times.2,
3.times.2, 3.times.4, and 6.times.4. The various arrangements thus
allow for up to 192 total compartments per cart for a put away
tour. Each compartment preferably contains a selected quantity of a
single item.
[0117] During the return tour, the handheld device assists the
return agent in identifying the tote and tote location of the item
to be returned at each location in the put away or return tour. For
example, as shown in FIG. 19B, the display 136 has a series of
dedicated regions or areas that display selected types of
information associated with the return tour as well as the totes on
the return cart 244. For example, the display has a top area or
region that has top sub-regions 252, 254, 256, a central area or
region 250, and a bottom area or region that has bottom sub-regions
258, 260, 262, and 264. The top sub-region 252 can set forth the
warehouse location and bay of the item to be returned or put away.
The warehouse location and bay can have identification information
associated therewith, such as a barcode. The handheld device can
scan the barcode of the location, and if the location matches the
location displayed in the sub-region 252, a visual or audible alert
can be provided. For example, the sub-region can change color to
visually indicate that a match exists. Conversely, the handheld
device can produce an audible sound or generate a tactile
sensation. The number of items to be returned can be displayed in
the sub-region 254, and a visual representation of the item to be
returned can be displayed in the sub-region 256. The return agent
can thus perform a secondary visual check to ensure that the picked
item visually matches the item displayed in the sub-region 256.
This provides redundancy in the system to ensure that the return
agent is selecting or returning the correct item.
[0118] The central region of the display 250 can display a visual
representation of the physical layout of a specific tote. For
example, if the tote in tote area A on the mobile cart has a
3.times.4 layout configuration, then there are four rows and three
columns of compartments in the tote layout. If the item displayed
in sub-region 256 is to be returned at the selected location, and
the item is located at location 2, 3 (e.g., second column, third
row) of the tote, then this location can be highlighted on the
display 136 so as to provide a visual guide or indication to the
return agent. The return agent retrieves the number of items set
forth in sub-region 254 from the tote, and scans the barcode on one
of the items. This enables the order fulfillment system 10 to
verify that the return agent is returning the correct item to the
proper warehouse location.
[0119] The bottom sub-region 258 can include a user status icon or
visual indication that allows the return agent to pause or cancel
the put away or return tour, a task number sub-region 260 that
displays the number of tasks in the put away tour as well as the
specific task number being performed. For example, if there are 21
tasks in the put away tour and the return agent is in the process
of handling task 3, then the display sub-region can show 3/21 in
the sub-region 260. The bottom sub-regions can also include an
exception button sub-region 262 that allows exception information
to be entered, and a visual indicator of the network connection
status in sub-region 264.
[0120] In operation and as shown in FIGS. 18-22, the system user or
return agent places the handheld device in Return Cart Building
mode, where the handheld device communicates with the return order
generating unit 240, step 270. The Return Cart Building mode can be
a function that forms part of the return order generating unit 240
or can be a separate unit, such as the return cart building unit
302 of the return order generating sub-system 241. The Cart
Building mode functionality can be added to the interface or
display 136 of the handheld device, or can be a selectable function
added to the return order generating unit 240. For example, the
return order generating unit 240 can include a processor, memory,
and if desired a display for visually displaying the Cart Building
mode functionality. The user can then select this
functionality.
[0121] The return agent can then scan or enter the ID information
associated with the cart, step 272. The user can select either a
mobile cart for returning or replenishing items in the warehouse,
or a static return cart for use with the automated fulfillment
system 16. Specifically, the user can select the type of cart that
can be constructed. The display 136 preferably includes in addition
the display region 242 the bottom sub-regions 248, which includes
regions 248A, 248B, and 248C. The regions includes icons or other
selectable visual representations of actions that can be selected
by the user. The actions include the ability to select the mobile
cart for the warehouse and look up the content of the totes. The
user then obtains the ID information associated with the selected
totes, and then loads the totes in the cart. The display region 242
can visually highlight selected tote regions or areas A-H of the
cart. The visual highlight can include any selected visually
distinguishing feature, including the prompt SCAN on one of the
areas A-H to visually remind the return agent to scan the tote
prior to loading the tote on the cart in the designated tote area
(e.g., tote areas A-H). Once the tote is scanned and loaded on the
cart, the system 10 moves the SCAN prompt to another unfilled tote
area or regions A-H of the cart. This process continues until the
return cart is properly loaded with totes and is ready for the put
away tour, step 274. The interface or display 136 of the handheld
device then displays the various options available to the return
agent once the cart is loaded. These options include the ability to
place the handheld device in the Put Away Tour mode, step 276. The
put away tour mode instructs the order fulfillment system 10, and
specifically the return order generating unit 240, to generate the
put away or return tour, step 278. The put away tour is
communicated to the handheld device, and the return agent starts
the put away tour.
[0122] Alternatively, the put-away totes from the cart may be
directly introduced into the automated fulfillment system 16. The
contents of the compartmentalized totes are electronically
transmitted to the automated fulfillment system 16 once the tote
has been filled with the items to be returned. Once the
compartmentalized tote containing the returned items has been
introduced into the automated system, the pick stations may be run
in an alternate return mode where instead of picking items from
storage tubs and placing them in order totes as is performed in the
picking mode during a bulk or pick tour, the items are instead
picked from the return tote and placed back into the storage tubs
of the same products. This effectively distributes the contents of
the return tote back into the storage tubs of the automated
fulfillment system 16. Once the return tote has been emptied, it
may be routed back to the return processing area of the warehouse
and used once again.
[0123] As noted above, the items returned by the customers are
received from the package carriers, such as the United States Post
Office, United Parcel Service (UPS) and the like, in selected bins.
Each customer package is opened by a return processing agent, and
each of the items being returned is thoroughly examined. The items
that are still in their original packaging and unopened or items
that are still in pristine condition can be returned to stock. When
returning an item back to stock, there are multiple factors that
the system 10 and specifically the return order generating unit 240
use when deciding where the item should be placed in stock in the
warehouse. These factors include, but are not limited to, existing
product storage locations in the warehouse, the velocity (i.e.,
sales volume or customer demand for the item) of the product, if
the product may have additional incoming items from an existing
purchase order to a vendor that it can be joined with in the near
future, and the like. Although the automated fulfillment system 16
can process the items faster than the agent, it is often an
expensive and limited resource, thus "static" shelving systems are
often used. High velocity items and items that are likely to sell
quickly can be placed in the automated fulfillment system 16. Low
velocity items and items that are not likely to sell quickly can be
placed in a shelving or bays of the warehouse.
[0124] The return agent is directed where to place the customer
items based on the foregoing rules or factors. Additional sorting
of which return agent is processing an item to be returned may be
performed before opening the item if an RMA (Return Merchandise
Authorization) process is in place, where the return order
generating unit 240 is aware of what is in a package before the
package is opened. This allows for sorting the packages into
separate processing stations to try to leverage location based
consolidation of items for put-away. Without an RMA process, it is
difficult to determine what is in a package before an agent opens
the package. For this reason, the item placement into totes is
based on the order in which the return agent processes the customer
return packages. For this reason, the put-away tours are
constructed for an optimal walking path and sequence for the
put-away tasks for a set of returned items that are stored in totes
placed on a mobile cart for return to static areas in the warehouse
that contain the same products. For the automated fulfillment
system 16, a "return" mode guides the placement of
compartmentalized items back into storage totes containing the same
items so that they can undergo the picking process again in the
future.
[0125] FIG. 22 shows an example of the return processing
application 280 of the return order generating unit 240 that guides
the return agents to place returned items into specific
sub-compartments of a tote. As shown, the application has a window
or interface 282 that can be displayed on a display of an
electronic or computing device that shows virtual representations
of totes and associated tote sub-compartments suitable for use for
returning items to the warehouse as well as functioning as the
totes or tubs for the automated fulfillment system 16. For example,
the tote 284 displayed in the window or interface 282 is a
representation of a tote for a mobile cart for a return agent to
place the returned items into bays or static locations in the
warehouse. Further, the totes 286, 288 displayed in the right side
of the window 282 are totes that are destined for selected
locations in the automated fulfillment system 16. For example, the
tote 286 can be destined for the upper portions or regions of the
automated fulfillment system 16 and the tote 288 can be destined
for lower portions or regions of the automated fulfillment system
16. The totes 284, 286, 288 can be configured to have any selected
number of sub-compartments, as illustrated, so as to accommodate
items of different sizes. For example, the tote 284 has a series of
sub-compartments 284A; the tote 286 has a series of
sub-compartments 286A; and the tote 288 has a series of
sub-compartments 288A. The agent processing the returned items can
assign an item to one or more of the sub-compartments of each tote
284, 286, 288, and identification information can be associated
with each tote and optionally each of the sub-compartments of the
tote, and the ID information of the tote and sub-compartments can
be entered into the system and hence associated or correlated with
a specific item to be returned. The images of the items can be
visually shown on the display in each of the sub-compartments of
the totes so as to provide a visual representation of the item for
the agent. This assists the agent when placing the item in the
assigned sub-compartment of the tote. Once the specific tote has
been filled, it can be directly introduced into the automated
fulfillment system 16 or conveyed by a transport system to a return
tote holding area. The totes can then be assigned to a return cart
244 via the cart builder mode for static put-away by the return
agent. The barcode of a new tote can then be scanned and put in
place of the previous tote and the agent continues processing
customer returns.
Exemplary Hardware
[0126] Following below and referenced above are more detailed
descriptions of various concepts and associated hardware of the
units of the order fulfillment system 10 of the present invention.
It should be appreciated that various concepts introduced above and
discussed in greater detail below may be implemented in any number
of ways, as the disclosed concepts are not limited to any
particular manner of implementation. Examples of specific
implementations and applications are provided below primarily for
illustrative purposes and for providing or describing the operating
environment of the order fulfillment system of the present
invention.
[0127] Consistent with the foregoing inventive embodiments, it is
helpful to describe aspects of the operating environment as well as
associated system components (e.g., hardware elements) in
connection with the methods and systems described herein. For
example, the order fulfillment system 10 of the present invention
and associated sub-systems and units, including for example the
order collection unit 12, the order generating unit 14, the
automated fulfillment system 16, the bulk pick order fulfillment
unit 18, the packing and shipping sub-system 22, the pick tour
generating unit 20, the cart building unit 128, the graph
generating unit 124, the return order generating unit 240, the
database 24, and any other hardware devices including hand-held
scanners, servers, computers, monitors and printers, can be coupled
together in a network environment. Further, any system unit or
combination of units can be consolidated on a single hardware
device. For example, as shown in FIG. 23, a typical network
environment can include hardware devices such as one or more
clients 512a-512n (also generally referred to as local machine(s)
512, client(s) 512, client node(s) 512, client machine(s) 512,
client computer(s) 512, client device(s) 512, endpoint(s) 512, or
endpoint node(s) 512) in communication with one or more servers
516a-516n (also generally referred to as server(s) 516, node 516,
or remote machine(s) 516) and databases via one or more networks
514. In some embodiments, a client 512 has the capacity to function
as both a client node seeking access to resources provided by a
server and as a server providing access to hosted resources for
other clients 512a-512n. The clients can be any suitable electronic
or computing device, including for example, a computer, a server, a
smartphone, a smart electronic pad, a portable computer, and the
like, such as the computing device 600. The various units 12, 14,
18, 20 and database 24 of the order fulfillment system 10 of the
present invention can be implemented as a client device 512 and/or
a server 516. The sub-systems 16 and 22 of the system 10 can
communicate with the remainder of the system 10 via the network
514. Although FIG. 23 shows a network 514 between the clients 512
and the servers 516, the clients 512 and the servers 516 may be on
the same network 514. In some embodiments, there are multiple
networks 514 between the clients 512 and the servers 516. In one of
these embodiments, a network 514' (not shown) may be a private
network and a network 514 may be a public network. In another of
these embodiments, a network 514 may be a private network and a
network 514' a public network. In still another of these
embodiments, networks 514 and 514' may both be private
networks.
[0128] The network 514 may be connected via wired or wireless
links. Wired links may include Digital Subscriber Line (DSL),
coaxial cable lines, or optical fiber lines. The wireless links may
include BLUETOOTH, Wi-Fi, NFC, RFID Worldwide Interoperability for
Microwave Access (WiMAX), an infrared channel or satellite band.
The wireless links may also include any cellular network standards
used to communicate among mobile devices, including standards that
qualify as 1G, 2G, 3G, 4G, or 5G. The network standards may qualify
as one or more generations of mobile telecommunication standards by
fulfilling a specification or standards such as the specifications
maintained by the International Telecommunication Union. The 3G
standards, for example, may correspond to the International Mobile
Telecommunications-2000 (IMT-2000) specification, and the 4G
standards may correspond to the International Mobile
Telecommunications Advanced (IMT-Advanced) specification. Examples
of cellular network standards include AMPS, GSM, GPRS, UMTS, LTE,
LTE Advanced, Mobile WiMAX, and WiMAX-Advanced. Cellular network
standards may use various channel access methods e.g. FDMA, TDMA,
CDMA, or SDMA. In some embodiments, different types of data may be
transmitted via different links and standards. In other
embodiments, the same types of data may be transmitted via
different links and standards.
[0129] The network 514 may be any type and/or form of network. The
geographical scope of the network 514 may vary widely and the
network 514 can be a body area network (BAN), a personal area
network (PAN), a local-area network (LAN), e.g. Intranet, a
metropolitan area network (MAN), a wide area network (WAN), or the
Internet. The topology of the network 514 may be of any form and
may include, e.g., any of the following: point-to-point, bus, star,
ring, mesh, or tree. The network 514 may be an overlay network,
which is virtual and sits on top of one or more layers of other
networks 514'. The network 514 may be of any such network topology
as known to those ordinarily skilled in the art capable of
supporting the operations described herein. The network 514 may
utilize different techniques and layers or stacks of protocols,
including, e.g., the Ethernet protocol, the internet protocol suite
(TCP/IP), the ATM (Asynchronous Transfer Mode) technique, the SONET
(Synchronous Optical Networking) protocol, or the SDH (Synchronous
Digital Hierarchy) protocol. The TCP/IP internet protocol suite may
include application layer, transport layer, internet layer
(including, e.g., IPv6), or the link layer. The network 514 may be
a type of a broadcast network, a telecommunications network, a data
communication network, or a computer network.
[0130] In some embodiments, the network system may include
multiple, logically-grouped servers 516. In one of these
embodiments, the logical group of servers may be referred to as a
server farm 518 or a machine farm 518. In another of these
embodiments, the servers 516 may be geographically dispersed. In
other embodiments, a machine farm 518 may be administered as a
single entity. In still other embodiments, the machine farm 518
includes a plurality of machine farms 518. The servers 516 within
each machine farm 518 can be heterogeneous, and one or more of the
servers 516 or machines 516 can operate according to one type of
operating system platform (e.g., WINDOWS NT, manufactured by
Microsoft Corp. of Redmond, Wash.), while one or more of the other
servers 516 can operate according to another type of operating
system platform (e.g., Unix, Linux, or Mac OS X).
[0131] In one embodiment, servers 516 in the machine farm 518 may
be stored in high-density rack systems, along with associated
storage systems, and located in an enterprise data center. In this
embodiment, consolidating the servers 516 in this way may improve
system manageability, data security, the physical security of the
system, and system performance by locating servers 516 and high
performance storage systems on localized high performance networks.
Centralizing the servers 516 and storage systems and coupling them
with advanced system management tools allows more efficient use of
server resources.
[0132] The servers 516 of each machine farm 518 do not need to be
physically proximate to another server 516 in the same machine farm
518. Thus, the group of servers 516 logically grouped as a machine
farm 518 may be interconnected using a wide-area network (WAN)
connection or a metropolitan-area network (MAN) connection. For
example, a machine farm 518 may include servers 516 physically
located in different continents or different regions of a
continent, country, state, city, campus, or room. Data transmission
speeds between servers 516 in the machine farm 518 can be increased
if the servers 516 are connected using a local-area network (LAN)
connection or some form of direct connection. Additionally, a
heterogeneous machine farm 518 may include one or more servers 516
operating according to a type of operating system, while one or
more other servers 516 execute one or more types of hypervisors
rather than operating systems. In these embodiments, hypervisors
may be used to emulate virtual hardware, partition physical
hardware, virtualized physical hardware, and execute virtual
machines that provide access to computing environments, allowing
multiple operating systems to run concurrently on a host computer.
Native hypervisors may run directly on the host computer.
Hypervisors may include VMware ESX/ESXi, manufactured by VMWare,
Inc., of Palo Alto, Calif.; the Xen hypervisor, an open source
product whose development is overseen by Citrix Systems, Inc.; the
HYPER-V hypervisors provided by Microsoft or others. Hosted
hypervisors may run within an operating system on a second software
level. Examples of hosted hypervisors may include VMware
Workstation and VIRTUALBOX.
[0133] Management of the machine farm 518 may be de-centralized.
For example, one or more servers 516 may comprise components,
subsystems and modules to support one or more management services
for the machine farm 518. In one of these embodiments, one or more
servers 516 provide functionality for management of dynamic data,
including techniques for handling failover, data replication, and
increasing the robustness of the machine farm 518. Each server 516
may communicate with a persistent store and, in some embodiments,
with a dynamic store.
[0134] Server 516 may be a file server, application server, web
server, proxy server, appliance, network appliance, gateway,
gateway server, virtualization server, deployment server, SSL VPN
server, or firewall, or any other suitable computing device, such
as computing device 600. In one embodiment, the server 516 may be
referred to as a remote machine or a node. In another embodiment, a
plurality of nodes may be in the path between any two communicating
servers. The units 12, 14, 18, 20 and 240 of the order fulfillment
system 10, FIG. 1, as well as the warehouse map unit 120, cart
building unit 128 and the graph generating unit 124 of the present
invention can be stored or implemented on one or more of the
servers 516 or clients 512, and the hardware associated with the
server or client, such as the processor or CPU and memory.
[0135] The client 512 and server 516 may be deployed as and/or
executed on any type and form of computing device, such as for
example a computer, network device or appliance capable of
communicating on any type and form of network and performing the
operations described herein. FIGS. 24 and 25 depict block diagrams
of a computing device 600 useful for practicing an embodiment of
the client 512 and/or a server 516, and thus by extension any unit
or combination of units 12, 14, 18 and 20 of the order fulfillment
system 10 of the present invention. As shown in FIGS. 24 and 25,
each computing device 600 includes a central processing unit 530,
and a main memory unit 532. As shown in FIG. 24, a computing device
600 may include a storage device 538, an installation device 540, a
network interface 542, an I/O controller 544, display devices
546a-546n, a keyboard 548 and a pointing device 550, e.g. a mouse.
The storage device 538 may include, without limitation, an
operating system, and/or software. As shown in FIG. 25, each
computing device 600 may also include additional optional elements,
e.g. a memory port 552, a bridge 554, one or more input/output
devices 560a-560n (generally referred to using reference numeral
560), and a cache memory 562 in communication with the central
processing unit 530.
[0136] The central processing unit 530 is any logic circuitry that
responds to and processes instructions fetched from the main memory
unit 564. In many embodiments, the central processing unit 530 is
provided by a microprocessor unit, e.g.: those manufactured by
Intel Corporation of Mountain View, Calif.; those manufactured by
Motorola Corporation of Schaumburg, Ill.; the ARM processor and
TEGRA system on a chip (SoC) manufactured by Nvidia of Santa Clara,
Calif.; the POWER7 processor, those manufactured by International
Business Machines of White Plains, N.Y.; or those manufactured by
Advanced Micro Devices of Sunnyvale, Calif. The computing device
600 may be based on any of these processors, or any other processor
capable of operating as described herein. The central processing
unit 530 may utilize instruction level parallelism, thread level
parallelism, different levels of cache, and multi-core processors.
A multi-core processor may include two or more processing units on
a single computing component. Examples of multi-core processors
include the AMD PHENOM IIX2, INTEL CORE i5 and INTEL CORE i7.
[0137] Main memory unit or main memory storage unit 564 may include
one or more memory chips capable of storing data and allowing any
storage location to be directly accessed by the processor 530. The
main memory unit 564 may be volatile and faster than memory of the
storage unit 538. Main memory units 564 may be Dynamic random
access memory (DRAM) or any variants, including static random
access memory (SRAM), Burst SRAM or SynchBurst SRAM (BSRAM), Fast
Page Mode DRAM (FPM DRAM), Enhanced DRAM (EDRAM), Extended Data
Output RAM (EDO RAM), Extended Data Output DRAM (EDO DRAM), Burst
Extended Data Output DRAM (BEDO DRAM), Single Data Rate Synchronous
DRAM (SDR SDRAM), Double Data Rate SDRAM (DDR SDRAM), Direct Rambus
DRAM (DRDRAM), or Extreme Data Rate DRAM (XDR DRAM). In some
embodiments, the main memory 564 or the storage 538 may be
non-volatile, e.g., non-volatile read access memory (NVRAM), flash
memory non-volatile static RAM (nvSRAM), Ferroelectric RAM (FeRAM),
Magnetoresistive RAM (MRAM), Phase-change memory (PRAM),
conductive-bridging RAM (CBRAM),
Silicon-Oxide-Nitride-Oxide-Silicon (SONOS), Resistive RAM (RRAM),
Racetrack, Nano-RAM (NRAM), or Millipede memory. The main memory
564 may be based on any of the above described memory chips, or any
other available memory chips capable of operating as described
herein. In the embodiment shown in FIG. 24, the processor 530
communicates with main memory 532 via a system bus 570 (described
in more detail below). FIG. 25 depicts an embodiment of a computing
device 600 in which the processor communicates directly with main
memory 564 via a memory port 552. For example, in FIG. 25 the main
memory 564 may be DRDRAM. The computer executable instructions of
the present invention may be provided using any computer-readable
media that is accessible by the computing or electronic device 600.
Computer-readable media may include, for example, the computer
memory or storage unit 564, 538 described above. The computer
storage media may also include, but is not limited to, RAM, ROM,
EPROM, EEPROM, flash memory or other memory technology, CD-ROM,
digital versatile disks (DVD) or other optical storage, magnetic
cassettes, magnetic tape, magnetic disk storage or other magnetic
storage devices, or any other non-transmission medium that can be
used to store information for access by a computing device. In
contrast, communication media may embody computer readable
instructions, data structures, program modules, or other data in a
modulated data signal, such as a carrier wave, or other transport
mechanism. As defined herein, computer readable storage media does
not include communication media. Therefore, a computer storage or
memory medium should not be interpreted to be a propagating signal
per se or stated another transitory in nature. The propagated
signals may be present in a computer storage media, but propagated
signals per se are not examples of computer storage media, which is
intended to be non-transitory. Although the computer memory or
storage unit 564, 538 is shown within the computing device 600 it
will be appreciated that the storage may be distributed or located
remotely and accessed via a network or other communication
link.
[0138] FIG. 25 depicts an embodiment in which the main processor
530 communicates directly with cache memory 562 via a secondary
bus, sometimes referred to as a backside bus. In other embodiments,
the main processor 530 communicates with cache memory 562 using the
system bus 570. Cache memory 562 typically has a faster response
time than main memory 564 and is typically provided by SRAM, B
SRAM, or EDRAM. In the embodiment shown in FIG. 25, the processor
530 communicates with various I/O devices 560 via a local system
bus 570. Various buses may be used to connect the central
processing unit 530 to any of the I/O devices 560, including a PCI
bus, a PCI-X bus, or a PCI-Express bus, or a NuBus. For embodiments
in which the I/O device is a video display 546, the processor 530
may use an Advanced Graphics Port (AGP) to communicate with the
display 546 or the I/O controller 544 for the display 546. FIG. 25
depicts an embodiment of a computer 600 in which the main processor
530 communicates directly with I/O device 560b or other processors
530 via HYPERTRANSPORT, RAPIDIO, or INFINIBAND communications
technology. FIG. 25 also depicts an embodiment in which local
busses and direct communication are mixed: the processor 530
communicates with I/O device 560a using a local interconnect bus
while communicating with I/O device 560b directly.
[0139] A wide variety of I/O devices 560a-560n may be present in
the computing device 600. Input devices may include keyboards,
mice, trackpads, trackballs, touchpads, touch mice, multi-touch
touchpads and touch mice, microphones, multi-array microphones,
drawing tablets, cameras, single-lens reflex camera (SLR), digital
SLR (DSLR), CMOS sensors, accelerometers, infrared optical sensors,
pressure sensors, magnetometer sensors, angular rate sensors, depth
sensors, proximity sensors, ambient light sensors, gyroscopic
sensors, or other sensors. Output devices may include video
displays, graphical displays, speakers, headphones, and printers
such as inkjet printers, laser printers, and 3D printers.
[0140] Devices 560a-560n may include a combination of multiple
input or output devices, including, e.g., Microsoft KINECT,
Nintendo Wiimote for the WII, Nintendo WII U GAMEPAD, or Apple
IPHONE. Some devices 560a-560n allow gesture recognition inputs
through combining some of the inputs and outputs. Some devices
560a-560n provides for facial recognition which may be utilized as
an input for different purposes including authentication and other
commands. Some devices 560a-560n provides for voice recognition and
inputs, including, e.g., Microsoft KINECT, SIRI for IPHONE by
Apple, Amazon Alexa, Google Now or Google Voice Search.
[0141] Additional devices 560a-560n have both input and output
capabilities, including, e.g., haptic feedback devices, touchscreen
displays, or multi-touch displays. Touchscreen, multi-touch
displays, touchpads, touch mice, or other touch sensing devices may
use different technologies to sense touch, including, e.g.,
capacitive, surface capacitive, projected capacitive touch (PCT),
in-cell capacitive, resistive, infrared, waveguide, dispersive
signal touch (DST), in-cell optical, surface acoustic wave (SAW),
bending wave touch (BWT), or force-based sensing technologies. Some
multi-touch devices may allow two or more contact points with the
surface, allowing advanced functionality including, e.g., pinch,
spread, rotate, scroll, or other gestures. Some touchscreen
devices, including, e.g., Microsoft PIXEL SENSE or Multi-Touch
Collaboration Wall, may have larger surfaces, such as on a
table-top or on a wall, and may also interact with other electronic
devices. Some I/O devices 560a-560n, display devices 546a-546n or
group of devices may be augment reality devices. The I/O devices
may be controlled by an I/O controller 44 as shown in FIG. 24. The
I/O controller may control one or more I/O devices, such as, e.g.,
a keyboard 548 and a pointing device 550, e.g., a mouse or optical
pen. Furthermore, an I/O device may also provide storage and/or an
installation medium 540 for the computing device 600. In still
other embodiments, the computing device 600 may provide USB
connections (not shown) to receive handheld USB storage devices. In
further embodiments, an I/O device 560 may be a bridge between the
system bus 570 and an external communication bus, e.g. a USB bus, a
SCSI bus, a FireWire bus, an Ethernet bus, a Gigabit Ethernet bus,
a Fibre Channel bus, or a Thunderbolt bus.
[0142] In some embodiments, display devices 546a-546n may be
connected to I/O controller 544. Display devices may include, e.g.,
liquid crystal displays (LCD), thin film transistor LCD (TFT-LCD),
blue phase LCD, electronic papers (e-ink) displays, flexile
displays, light emitting diode displays (LED), digital light
processing (DLP) displays, liquid crystal on silicon (LCOS)
displays, organic light-emitting diode (OLED) displays,
active-matrix organic light-emitting diode (AMOLED) displays,
liquid crystal laser displays, time-multiplexed optical shutter
(TMOS) displays, or 3D displays. Examples of 3D displays may use,
e.g. stereoscopy, polarization filters, active shutters, or
autostereoscopy. Display devices 546a-546n may also be a
head-mounted display (HMD). In some embodiments, display devices
546a-546n or the corresponding I/O controllers 544 may be
controlled through or have hardware support for OPENGL or DIRECTX
API or other graphics libraries.
[0143] In some embodiments, the computing device 600 may include or
connect to multiple display devices 546a-546n, which each may be of
the same or different type and/or form. As such, any of the I/O
devices 560a-560n and/or the I/O controller 544 may include any
type and/or form of suitable hardware, software, or combination of
hardware and software to support, enable or provide for the
connection and use of multiple display devices 546a-546n by the
computing device 600. For example, the computing device 600 may
include any type and/or form of video adapter, video card, driver,
and/or library to interface, communicate, connect or otherwise use
the display devices 546a-546n. In one embodiment, a video adapter
may include multiple connectors to interface to multiple display
devices 546a-546n. In other embodiments, the computing device 600
may include multiple video adapters, with each video adapter
connected to one or more of the display devices 546a-546n. In some
embodiments, any portion of the operating system of the computing
device 600 may be configured for using multiple displays 546a-546n.
In other embodiments, one or more of the display devices 546a-546n
may be provided by one or more other computing devices 600a or 600b
connected to the computing device 600, via the network 514. In some
embodiments software may be designed and constructed to use another
computer's display device as a second display device 546a for the
computing device 600. For example, in one embodiment, an Apple iPad
may connect to a computing device 600 and use the display of the
device 600 as an additional display screen that may be used as an
extended desktop. One ordinarily skilled in the art will recognize
and appreciate the various ways and embodiments that a computing
device 600 may be configured to have multiple display devices
546a-546n.
[0144] Referring again to FIG. 24, the computing device 600 may
comprise a storage device 538 (e.g. one or more hard disk drives or
redundant arrays of independent disks) for storing an operating
system or other related software, and for storing application
software programs such as any program related to the software 580
for the order fulfillment system 10 of the present invention.
Examples of storage devices 538 include, e.g., hard disk drive
(HDD); optical drive including CD drive, DVD drive, or BLU-RAY
drive; solid-state drive (SSD); USB flash drive; or any other
device suitable for storing data. Some storage devices may include
multiple volatile and non-volatile memories, including, e.g., solid
state hybrid drives that combine hard disks with solid state cache.
The storage device 538 may be non-volatile, mutable, or read-only.
The storage device 538 may be internal and connect to the computing
device 600 via a bus 570. Further, the storage device 538 may be
external and connect to the computing device 600 via an I/O device
560 that provides an external bus. Some storage devices 538 may
connect to the computing device 600 via the network interface 542
over a network 514, including, e.g., the Remote Disk for MACBOOK
AIR by Apple. Some client devices 512 may not require a
non-volatile storage device 538 and may be thin clients or zero
clients 512. The storage device 538 may also be used as an
installation device 540, and may be suitable for installing
software and programs. Additionally, the operating system and the
software can be run from a bootable medium, for example, a bootable
CD, e.g. KNOPPIX, a bootable CD for GNU/Linux that is available as
a GNU/Linux distribution from knoppix.net.
[0145] The computing device 600 may also install software or
application from an application distribution platform. Examples of
application distribution platforms include the App Store for iOS
provided by Apple, Inc., the Mac App Store provided by Apple, Inc.,
GOOGLE PLAY for Android OS provided by Google Inc., Chrome Webstore
for CHROME OS provided by Google Inc., and Amazon Appstore for
Android OS and KINDLE FIRE provided by Amazon.com, Inc. An
application distribution platform may facilitate installation of
software on a client device 512. An application distribution
platform may include a repository of applications on a server 516
or a cloud 520, which the clients 512a-512n may access over a
network 514. An application distribution platform may include
application developed and provided by various developers. A user of
a client device 512 may select, purchase and/or download an
application via the application distribution platform.
[0146] Furthermore, the computing device 600 may include a network
interface 542 to interface to the network 514 through a variety of
connections including, but not limited to, standard telephone lines
LAN or WAN links (e.g., 802.11, T1, T3, Gigabit Ethernet,
Infiniband), broadband connections (e.g., ISDN, Frame Relay, ATM,
Gigabit Ethernet, Ethernet-over-SONET, ADSL, VDSL, BPON, GPON,
fiber optical including FiOS), wireless connections, or some
combination of any or all of the above. Connections can be
established using a variety of communication protocols (e.g.,
TCP/IP, Ethernet, ARCNET, SONET, SDH, Fiber Distributed Data
Interface (FDDI), IEEE 802.11a/b/g/n/ac CDMA, GSM, WiMax and direct
asynchronous connections). In one embodiment, the computing device
600 communicates with other computing devices 600' via any type
and/or form of gateway or tunneling protocol e.g. Secure Socket
Layer (SSL) or Transport Layer Security (TLS), or the Citrix
Gateway Protocol manufactured by Citrix Systems, Inc. of Ft.
Lauderdale, Fla. The network interface 542 may comprise a built-in
network adapter, network interface card, PCMCIA network card,
EXPRESSCARD network card, card bus network adapter, wireless
network adapter, USB network adapter, modem or any other device
suitable for interfacing the computing device 600 to any type of
network capable of communication and performing the operations
described herein.
[0147] The computing device 600 of the sort depicted in FIG. 24 may
operate under the control of an operating system, which controls
scheduling of tasks and access to system resources. The computing
device 600 can be running any operating system such as any of the
versions of the MICROSOFT WINDOWS operating systems, the different
releases of the Unix and Linux operating systems, any version of
the MAC OS for Macintosh computers, any embedded operating system,
any real-time operating system, any open source operating system,
any proprietary operating system, any operating systems for mobile
computing devices, or any other operating system capable of running
on the computing device and performing the operations described
herein. Typical operating systems include, but are not limited to:
WINDOWS 2000, WINDOWS Server 2012, WINDOWS CE, WINDOWS Phone,
WINDOWS XP, WINDOWS VISTA, and WINDOWS 7, WINDOWS RT, and WINDOWS 8
all of which are manufactured by Microsoft Corporation of Redmond,
Wash.; MAC OS and iOS, manufactured by Apple, Inc. of Cupertino,
Calif.; and Linux, a freely-available operating system, e.g. Linux
Mint distribution ("distro") or Ubuntu, distributed by Canonical
Ltd. of London, United Kingom; or Unix or other Unix-like
derivative operating systems; and Android, designed by Google, of
Mountain View, Calif., among others. Some operating systems,
including, e.g., the CHROME OS by Google, may be used on zero
clients or thin clients, including, e.g., CHROMEBOOK S.
[0148] The computer system 600 can be any workstation, telephone,
desktop computer, laptop or notebook computer, netbook, ULTRABOOK,
tablet, server, handheld computer, mobile telephone, smartphone or
other portable telecommunications device, media playing device, a
gaming system, mobile computing device, or any other type and/or
form of computing, telecommunications or media device that is
capable of communication. The computer system 600 has sufficient
processor power and memory capacity to perform the operations
described herein. In some embodiments, the computing device 600 may
have different processors, operating systems, and input devices
consistent with the device. The Samsung GALAXY smartphones, e.g.,
operate under the control of Android operating system developed by
Google, Inc. GALAXY smartphones receive input via a touch
interface.
[0149] In some embodiments, the computing device 600 is a digital
audio player such as the Apple IPOD, IPOD Touch, and IPOD NANO
lines of devices, manufactured by Apple Computer of Cupertino,
Calif. Some digital audio players may have other functionality,
including, e.g., a gaming system or any functionality made
available by an application from a digital application distribution
platform. For example, the IPOD Touch may access the Apple App
Store. In some embodiments, the computing device 600 is a portable
media player or digital audio player supporting file formats
including, but not limited to, MP3, WAV, M4A/AAC, WMA Protected
AAC, AIFF, Audible audiobook, Apple Lossless audio file formats and
.mov, .m4v, and .mp4 MPEG-4 (H.264/MPEG-4 AVC) video file
formats.
[0150] In some embodiments, the computing device 600 is a tablet
e.g. the IPAD line of devices by Apple; GALAXY TAB family of
devices by Samsung; or KINDLE FIRE, by Amazon.com, Inc. of Seattle,
Wash. In other embodiments, the computing device 600 is an eBook
reader, e.g. the KINDLE family of devices by Amazon.com, or NOOK
family of devices by Barnes & Noble, Inc. of New York City,
N.Y.
[0151] In some embodiments, the computing device 600 includes a
combination of devices, e.g. a smartphone combined with a digital
audio player or portable media player. For example, one of these
embodiments is a smartphone, e.g. the IPHONE family of smartphones
manufactured by Apple, Inc.; a Samsung GALAXY family of smartphones
manufactured by Samsung, Inc; or a Motorola DROID family of
smartphones. In yet another embodiment, the computing device 600 is
a laptop or desktop computer equipped with a web browser and a
microphone and speaker system, e.g. a telephony headset. In these
embodiments, the computing devices 600 are web-enabled and can
receive and initiate phone calls. In some embodiments, a laptop or
a desktop computer is also equipped with a webcam or other video
capture device that enables video chat and video call. In some
embodiments, the computing device 600 is a wearable mobile
computing device including but not limited to Google Glass and
Samsung Gear.
[0152] In some embodiments, the status of one or more machines 512,
516 in the network 514 is monitored, generally as part of network
management. In one of these embodiments, the status of a machine
may include an identification of load information (e.g., the number
of processes on the machine, CPU and memory utilization), of port
information (e.g., the number of available communication ports and
the port addresses), or of session status (e.g., the duration and
type of processes, and whether a process is active or idle). In
another of these embodiments, this information may be identified by
a plurality of metrics, and the plurality of metrics can be applied
at least in part towards decisions in load distribution, network
traffic management, and network failure recovery as well as any
aspects of operations of the present solution described herein.
Aspects of the operating environments and components described
above will become apparent in the context of the order fulfillment
system disclosed herein.
[0153] The foregoing description may provide illustration and
description of various embodiments of the invention, but is not
intended to be exhaustive or to limit the invention to the precise
form disclosed. Modifications and variations of the order
fulfillment system of the present invention may be possible in
light of the above teachings or may be acquired from practice of
the invention. For example, while a series of acts has been
described above, the order of the acts may be modified in other
implementations consistent with the principles of the invention.
Further, non-dependent acts may be performed in parallel.
[0154] In addition, one or more implementations consistent with
principles of the invention may be implemented using one or more
devices and/or configurations other than those illustrated in the
Figures and described in the Specification without departing from
the spirit of the invention. One or more devices and/or components
may be added and/or removed from the implementations of the figures
depending on specific deployments and/or applications. Also, one or
more disclosed implementations may not be limited to a specific
combination of hardware. Furthermore, certain portions of the
invention may be implemented as logic that may perform one or more
functions. This logic may include hardware, such as hardwired
logic, an application-specific integrated circuit, a field
programmable gate array, a microprocessor, software, or a
combination of hardware and software.
[0155] No element, act, or instruction used in the description of
the invention should be construed critical or essential to the
invention unless explicitly described as such. Also, as used
herein, the article "a" is intended to include one or more items.
Where only one item is intended, the term "a single" or similar
language is used. Further, the phrase "based on," as used herein is
intended to mean "based, at least in part, on" unless explicitly
stated otherwise. In addition, the term "user", as used herein, is
intended to be broadly interpreted to include, for example, an
electronic device (e.g., a workstation) or a user of an electronic
device, unless otherwise stated.
[0156] Further, the invention can be employed using any combination
of features or elements as described above, and are not limited to
the current recited steps or features.
[0157] It is intended that the invention not be limited to the
particular embodiments disclosed above, but that the invention will
include any and all particular embodiments and equivalents falling
within the scope of the following appended claims.
* * * * *