Warehousing Monitor and Control System

The present invention relates to a method and apparatus for monitoring and controlling the flow of articles in a warehouse or other installation.

There exists a great variety of systems in which orders are filled by, for example, a central warehouse where items to be shipped to a given destination are manually, semiautomatically, or automatically picked, sorted, and routed to a shipping dock for shipment to, for example, retail stores. Typically, labels identifying the shipping destination are applied to articles as they are picked which labels are subsequently employed at a sorting location for the diverting of articles to a particular shipping area of the installation. U.S. Pat. No. 4,181,947 illustrates a sorting system which can be employed with such a system.

Where, however, a warehouse system is of relatively large size and it is capable of simultaneously handling a great number of orders, maintaining accurate information as to the status of individual orders being filled as well as the operational status of the entire system, while maintaining a maximum throughput efficiency, is virtually impossible with the systems of the prior art.

It is an object of the present invention to provide a method and apparatus for maintaining an accurate account of each transaction occurring within a warehousing system such that at any given time during an operating day, the status of each transaction and order being filled can be monitored and controlled. In order to achieve this objective, each transaction, which in the preferred embodiment of the invention pertains to a given article to be transferred from storage to a dispatching area, is assigned a unique identification number. This number is subsequently applied to an article as it is picked in the form of a machine readable coded label. The number is also entered into a control system memory, and as the article travels through the system, the label is read such that at any given time, the status of each transaction and the operation of the entire system is accurately known and can be controlled.

In the preferred embodiment of the invention, the system incorporates a computer controlled sorting and control system in which each article to be removed from storage and shipped to a destination, is assigned a unique code which identifies a single transaction within the system. Orders to be filled by batch picking and transfer of articles from storage to a given dispatch location at the warehouse, are grouped together in the computer memory to form batches of orders with the customer identification and discharge location being associated with each transaction number. By reading only the transaction number from a encoded label on an article at one or more locations within the system, the computer can continuously update the order status information and provide the operators of the system with current status information as well as provide control information to the sorting system employed. By providing operator interface circuits, reports can be generated either in soft or hard copies to monitor the operational status of each trasaction, order or batch of orders to facilitate the accurate and fast movement of articles within the system. Such information can be employed to quickly identify and correct failures and breakdowns within the system or to rapidly reassign divert locations for the sorting system in the event of a breakdown of a sortation line.

These and other objects, features and advantages of the system will become apparent upon reading the following description thereof together with reference to the drawings in which:

FIG. 1 is a pictorial representation of a warehousing system embodying the present invention including an electrical circuit diagram in block form of the control system;

FIG. 2 is typical label associated with each article and identifying a unique transaction within the system;

FIGS. 3A and 3B are block diagrams showing the module layout of the software employed for the operator interface portion of the control system;

FIG. 4 is a block diagram of the module layout of the software for the file manager portion of the control system;

FIG. 5 is a block diagram of the module layout of the software for the auxiliary functions of the control system;

FIG. 6 is a block diagram of the module layout of the software for the alarm message portion of the control syste including the legend employed for FIGS. 3 through 8;

FIG. 7 is a block diagram of the module layout of the software for the interface between the sorting control system and the main control system; and

FIG. 8 is a block diagram of the module layout of the software for the code reading portion of the control system of the present invention.

FIG. 1 represents a physical installation as well as the control system located within the installation. At the upper portion of the figure above dashed line 10 there is shown a central control area corresponding typically to an office area of a customer's facility, while the portion below line 10 represents the actual warehouse installation including the sortation conveyer equipment, and in which the actual articles to be transferred from storage to a dispatching dock or the like are stored in a conventional warehousing storage system. Such a system may include, for example, tiers of vertically and horizontally arranged storage bins with access aisles extending between adjacent tiers permitting either manual, semiautomatic, or automatic picking of articles from the storage bins to be achieved through the use of stacker cranes or other picking systems. Articles removed from storage are placed on conveying systems which ultimately connect with a sorting conveyer. Not shown in FIG. 1 are the storage bins, access aisles, or the conveyers leading to the induction station and sorting conveyer system. In some installations, the warehouse will be physically separate from the central control area while in other installations the two locations may share a common building at separate areas. Having briefly described the environment in which the present invention pertains, a description of the overall system is now presented.

In FIG. 1, the customer computer 12 typically will be a relatively large computer used by the customer for all of its business operations. Such a computer may be, for example, a commercially available IBM System 3 type computer which is interfaced with a label printer 14 by means of a data link 13 for the printing of labels 20, such as shown in FIG. 2. The label printer can be any one of a number of dot matrix-type printers which are commercially available such as the Printronix Model 600. Also, interfaced with the customer computer 12, is a batch data transfer diskette memory 16 coupled to the computer by a data link 15 for the generation of diskettes containing information corresponding to one batch of orders. The unit 16 may be, for example, a commercially available IBM floppy diskette model 3540. The customer computer 12 is employed in connection with label printer 14 and disketter unit 16 through conventional programming techniques to arrange orders to any one of the several retail outlets of the customer in a logical picking sequence such that the articles can be batch picked. Thus, for example, if the customer is a large grocery chain, with several grocery stores located in the geographical area served by the warehouse, one batch of orders to be filled may include 50 different grocery items with the batch including orders for 15 different retail outlets. The orders are arranged such that each item which is common to the group of articles to be picked will be simultaneously picked by the warehousing picking system. Thus, the computer 12 will be programmed, for example, to print labels in order with all of the labels for example, pertaining to a case of a certain type of produce such as beans to be simultaneously picked for all of the orders. This organization provides for efficient batch picking of articles.

Assigned to each transaction, which corresponds to a single case of a given item, is a unique six digit number which is employed within the control system shown in FIG. 1, to uniquely identify that article such that its progress within the system can be monitored and controlled. This number is applied in machine readable form to the label 20 as seen in FIG. 2 in the form of a bar code 22 which occupies a large portion of the label. The label 20 also includes man readable information 24 at the bottom of the label indicating for example the product identification, pricing information, and shipment location for the customer to which the article being picked is to be transferred. Further, the label will include man readable indicia 25 indicting the storage location of the article within the warehousing system which is contained within the memory of computer 12. Also on label 20 is indicia 26, corresponding to the store number to which the article is to be shipped, indicia 27 showing the unique six digit number (which in the example shown in FIG. 2 is the number 254789); and finally, indicia 28 pertaining to the discharge chute of the sortation conveyor system to which the article is to be sent for shipment.

Each article to be picked corresponding to a single transaction thus receives a label 20 and each label printed by printer 14 in a given day has a unique number 22 as compared to all other labels printed. Information corresponding to the label information as well as additional information is simultaneously recorded on a floppy disc by unit 16 which includes the label information for a plurality of labels forming several orders forming, in turn, a single batch for processing within the control system. Each diskette therefore includes stored data corresponding to each label of a given batch including the six digit label number, the sort lane number, the store number, the product code, which is assigned by the customer to any particular type of product, and information pertaining to where the product is stored in the warehouse. Further, each diskette includes a header record which provides an identification of the particular batch, as well as a description of the batch which can be any 50 character description desired by the customer. Thus, each group of labels provided by printer 14 will have associated with them a single diskette corresponding to a batch of items to be picked. Each batch will typically include several orders, each of which include several transactions with each transaction having a single label associated with it. The system of the present invention is capable of processing simultaneously up to 10 batches with each batch having a capability of 35 orders per batch and total of 9,000 transactions for each batch. Typically, however, only one or two batches will be picked simultaneously with the remaining batch information contained in memory in either a pending status or possibly a completed status, depending upon the operational status of the picking and sorting of the batches. The generation of the labels, as well as the diskette in a batch picking sequence, with the exception of the utilization of a unique number assigned to and associated with each label and transaction is conventional and achieved by computer 12. The labels are manually carried to the warehouse as indicated by dashed line 21 as are the diskettes 23 generated and associated with each batch as indicated by dashed line 17.

Each diskette from the customer computer 12 generated by the diskette unit 16 is read by a batch data transfer diskette memory unit 30 associated with and coupled to a distribution audit system (DAS) computer 32 by means of a data link 31. The diskette unit 30 may comprise for example a commercially available IBM diskette unit model number 4964, while computer 32 may for example be an IBM model 4955D computer. The function of unit 30 is to read the information from the diskette hand carried from unit 16 into a multi-batch storage disc memory unit 34 coupled to computer unit 32 through data link 33. Unit 34 is capable of storing not only the control program for computer 32, but also the data stored on each of the diskettes associated with each batch of articles to be picked. Unit 34 may, for example, comprise a commercially available IBM 4962 disc storage unit. Hard copies of alarm, status, and control information are provided by a systems operations log printer 36 coupled to computer 32 by means of a data link 35. Printer 36 may, for example, comprise a Digital Equipment Corporation matrix printer type LA 120. A second report printer 38 is also coupled to computer 32 through data link 37 and is employed for providing a variety of status reports as discussed below and may be for example an IBM model 4974 matrix printer. Also coupled to computer 32 by means of a data link 39 is an operator terminal 40. Terminal 40 includes a CRT display 42 and a digital keyboard 43 and may be a commercially available IBM model 4979 display station. Several such operator terminals and printers may be positioned at different locations within the system as conveniently desired. Other interface inputs to the computer 32 include one or more bar code scanners 44 selectively coupled to the computer 32 by means of a switch 45 which either couples the scanners 44 which are Accusort model number M scanners to an input of computer 32 or label wand scanners 46 to the computer 32. The wand scanners 46 can be Accusort model number 4600 scanner for detecting the bar code 22 on labels 20 of FIG. 2. Scanners 44 optically read labels on articles prior to transfer or induction onto the sortation conveyor 50 as shown by lines 53 in FIG. 1. Also coupled to computer 32 by means of a data line 49 is a second wand scanner 48 which is employed for scanning stockout labels as described below and which can also be an Accusort model 4600 wand scanner. An additional wand scanner (not shown) is employed for hand scanning excess repack labels as also described below.

The DAS computer 32 interfaces with a programmable sort control (PSC) computer 60 by means of a data interface coupling 62. Associated with the PSC computer 60 is a backup keyboard 64 coupled thereto by means of a serial data link 65, and a conveyer control circuit 66 coupled thereto by means of a data link 67. A plurality of article detecting photo cells 68 are spaced along the sorting conveyer 50 downstream of each article diverter 51 for detecting whether an article has been properly diverted to its assigned discharge or shipping chute 52 associated with the sorting conveyer 50. Further, a line full photo cell detector 69 is also coupled to the PSC computer 60 and is associated with each of the discharge chutes 52 such that a control signal is applied to computer 60 in the event any of the discharge chutes are filled with articles and thereby requiring a different discharge chute to be assigned to a particular order being sorted and staged for shipment.

At the input end of the sorting conveyer 50, there is provided an induction station 54 for receiving articles from several feeder conveyers (not shown) extending throughout the warehousing system and converging the articles onto the sorting conveyer 50. The PSC computer and its associated interface and control circuits to provide the induction and sorting of articles is described in detail in the above identified U.S. Pat. No. 4,181,947, the disclosure of which is incorporated herein by reference.

Sorting conveyer 50 terminates in a T 55 leading to either an error chute 56 or a recirculation loop 58 such that articles not sorted can either be recirculated through the sortation control system as selectively controlled as described below or fed to a storage area associated with the error chute for manual attention to a nonreadable label.

The control of the hardware elements shown in FIG. 1 corresponding to the control system of the present invention is achieved by the programming of computer 32 which program is stored in memory 34 and which is organized according to the module layout chart shown in FIGS. 3 through 8. With reference to these figures, FIGS. 3A and 3B disclose the layout of the programming for the interface between computer 32 and printer 38 and computer 32 and the operator terminal 40. The programming represented by FIG. 4 pertains to the internal handling of data between computer 32 and memory 34 as does the programming diagrammed in FIG. 5. FIG. 6, relates to the alarm messages provided by printer 36 and accordingly the programming for providing such alarms. The programming represented by FIG. 7 pertains to the programming which interfaces computer 32 with computer 60. Finally, the programming represented by FIG. 8 pertains to the intercoupling of computer 32 with the scanning wands 46, 48, and the bar code scanners 44. The module layout of the program as represented by FIGS. 3 through 8 is directly correlated with the pseudo code and structural English printout of the software organization disclosed in appendix A which is attached hereto, made part of the specification and incorporated herein by reference. In FIGS. 3 through 8, each block represents a module which performs a specific operation within the system. Each block is identified by the letters P, S, T, or D (described in the legend accompanying FIG. 6) followed by a number identifying a particular portion of the program employed. In addition, each block includes a label name constituting an acronym which is correlated with the programming information disclosed in appendix A. As can be seen, for example in FIGS. 3A and 3B, many of the modules call up additional modules indicated by an encircled two letter connector. Thus, for example, the panic subroutine shown in FIG. 3B which serves to stop the program in the event of a major failure, is identified by the two letters PA which is called up by many of the modules in the event the module is unable to perform its particular programming function. The programming comprising the source code for the PSC computer is also incorporated herein by reference as appendix B which is attached hereto and made a part of this specification.

Having described the hardware and the broad correlation between the program organization and individual elements of the hardware, a description of the operation of the system to achieve its desired monitoring and control of each transaction, as well as the various status reports available employing the unique transaction number identification of each article to be picked, is now presented.

Before any of the articles to be picked can be recognized and sorted by the DAS control system, the batch and transaction information must first be transferred to the DAS system. This is achieved by the operator control terminal 40 entering a READ command which transfers the information from a diskette 23 placed in unit 30 into the computer memory 34. The program for this is shown in FIG. 3B indicated as READ BATCH. Once the data base has been constructed by the operator for each of the diskettes being processed during a day's operation, the actual picking, sorting, and monitoring functions available are commenced by a START command which changes the batch status from pending to active and enables the DAS computer to sort the product.

The picker applies labels to the correct products and places the unique six digit bar code containing label on each article as they are picked and transferred onto conveyers within the system which feed to the induction station 54. Each article is scanned by scanner 44 for its unique number and this information is supplied to the DAS computer which correlates it with sort location information for that number, and communicates with the PSC computer the sort destination assigned to the particular transaction. Depending upon the selected mode of operation, the article can be stopped and hand wanded by wand 46, recirculated through recirculation loop 58 or shunted into the error chute 56 upon failure of scanner 44 to read the article's number. The status of the article is changed from "not-picked" to "in-sortation" and the PSC performs the physical sorting of the article and informs the DAS computer of the actual status of the package on the sorting conveyer. When the label is transferred to its assigned destination chute 52, (FIG. 1) the status of the article is changed from "in-sortation" to "staged for shipment". If the article is unable to sort to its assigned sorting lane, the PSC informs the DAS of the actual disposition of the package.

Once all of the articles of a batch have been picked and sorted, including articles for several different orders typically, the operator who monitors the progress of the batch picking as described below, enters an END command in the operator terminal 40 which changes the batch status to "complete". At this time, the operator can enter a WRITE command in terminal 40 which generates a new diskette which is returned to the customer computer and which has information as to the completed status of each transaction in the batch which can be employed by the customer for inventory, billing, and other functions such the printing of shipping manifests and other documents. Once the batch has been processed by the DAS control system, it can be deleted from the DAS data base, memory 34 by entering a DELETE command.

There are a variety of system batch and sortation control commands which are employed by the system of the present invention. The system control commands include a listing of system commands for status reports which is identified by the command HELP entered in keyboard 43 to generate a listing of available reports on CRT 42.

By entering the command ERROR a system error report as shown in appendix A is generated by printer 38 which permits the operator to visualize the number of missorts and transfer failures and take corrective action. Another system control command is RESET which is employed by the operator for resetting error counts which may correspond to missorts where an item is discharged to the wrong discharge chute 52 inadvertently, or transfer failures where the PSC computer fails to divert an article to any of the desired discharge chutes. The final system control command is the time setting function which is employed to provide a real time display or printout to all of the various reports and is entered by entering the command $ T employed by the operator to set the system time.

In addition to the system control commands, there are several batch control commands which are entered by keyboard 43 some of which have been previously discussed. The first of these, is the READ command which effects the reading of the customer's diskette 23 by the DAS computer diskette unit 30 reading the information into the memory 34. The START command starts the batch processing monitor and control while an END command as previously discussed, ends the batch processing. The WRITE command causes the diskette to be reprogrammed with the updated status of the orders and transactions therein reported back to the main customer computer through a reprogrammed diskette while a DELETE command then is employed to delete the completed batch information from memory 34. The ASSIGN command is employed for example in the event a given product is out of stock and with the batch processing system, this could affect several transactions associated with several different orders. To provide a quick update of the status of the particular product and therefore the transactions in which it is involved, the operator can assign to the transaction numbers affected, a stockout status so that this condition can be instantaneously displayed at any of the report printers or operator terminals once the condition has been reported.

Finally, there are several sortation control commands entered into keyboard 43 to control the sorting of articles. One mode of operation is identified and controlled by the command HOLD. With the HOLD command, the induction station 54 is stopped when a no-read occurs on scanner 44 and the operator must manually scan the label using wand 46 (FIG. 1) to read the label. He does that by actuating switch 45 such that the wand 46 output information is supplied to the DAS computer 32. The induction station 54 then restarts, and the article is sorted.

With the RECIRC command, articles with labels not read by scanner 44 are automatically directed to recirculation lane 58. Upon initial startup of the system, the command OPEN is employed to open the communications interface 62 between the DAS computer 32, the PSC computer 60. The command REROUTE is employed to assign an alternate sortation line for articles with a common destination contained within all batches being processed. This is employed for example, in the event a sort line 52 has a mechanical failure and it is temporarily shut down. The command RESTORE will automatically reassign rerouted articles not yet processed to the original sort line once it has been repaired.

In addition to the interface between the operator terminal 40 and the system employing the above identified commands, the system will automatically provide two different types of printouts available to management and control personnel for the monitoring and operational control of the system. The first type of printout is provided by the system's operational log printer 36, and provides indications of the status of the system as well as missorts and the like. The following is a typical printout during a short period of time representing a variety of operational conditions of the system.

04/01/80 14:30:34 System Started

04/01/80 14:30:46 PSC Communications Line Open

04/01/80 14:30:59 Start of Batch T02

04/01/80 14:31:04 Hold on Scanner Error

04/01/80 14:31:43 Scanner Error At Induction #1 Scanner

04/01/80 14:31:54 Transaction 984561 at Induction #1 Scanner Not On File

04/01/80 14:32:17 Transaction 411589 at Induction #1 Scanner Out of Batch

04/01/80 14:32:44 Sortation Line 1 Full

04/01/80 14:32:49 Transaction 598402 Missorted To Sort Line 3

04/01/80 14:33:24 Unsuccessful Transfer At Sort Line 1 for Transaction 632368

04/01/80 14:33:27 Scanner Error at Induction #2 Scanner

04/01/80 14:34:29 Transaction 581419 Has Been Lost From Tracking

04/01/80 14:34:46 Recirculate On Scanner Error

04/01/80 14:35:37 End of Batch T02

04/01/80 14:36:08 Transaction 581419 on Sort Line 2 Not On File

04/01/80 14:36:27 PSC Communications Failure

00/00/00 00:00:10 Power Fail/Restart

As can be seen from the above report, the status of the system and its communications with the PSC is indicated as well as events such as scanning errors at the induction station, sortation lines being full, as detected by the line full photo detector 69 (FIG. 1), missorts and the like. This record is automatically printed without a specific operator command such that monitoring personnel can take corrective action as required. Naturally, many of the messages printed simply indicate the status of a particular batch, for example, at 14:30:59, batch T02 was beginning to be processed and at 14:35:37, batch T02 was completed.

The second type of printed information, is specifically requested results from the entry of the system control command HELP, which provides a variety of selectable status reports. These reports are called up using keyboard 44 selectively as indicated by the following table:

Schedule--Work Schedule Batches

Batch--Batch/Order Status

Order--Order/Transaction Status

Transact--Transaction Status

Missort--Missort Exceptions

Route--Sort Line Translations

The reports generated by the entry of the commands at keyboard 43 are provided by the report printer 38 (FIG. 1) and an example of each such report is shown in the attached appendix A which also includes a data dictionary which identifies the manner in which the modules shown in FIGS. 3 through 8 are called up in the program. Basically each report provides a complete current status of batches being processed by the system, orders included in each batch, and particular transactions included in each order. Further, these reports provide an indication as to the percentage of completion, the number of items which are out of stock, and an indication of items not picked, missorted, or in processing. This information is used by the supervisory personnel to monitor on a regular basis the operation of the picking and sorting system, as well as to provide particular commands through terminal 40 for effecting the efficient operation of the system.

In the event that a stockout condition exists where items to be picked are not available, this information can, as previously indicated, be entered through an operator terminal, but also wand 48 can be employed to scan the labels which have not been applied to articles to be picked and the system automatically assigns a stockout status to the transactions and permits the batch to be completed noting the stockout status in the batch status report. An additional wand scanner (not shown) is provided for excess labels to cover the situation where incomplete case loads of materials are ordered and the efficiency of the picker in filling the cartons is unknown. To cover this situation, several additional labels are provided in the event that a greater number of cartons are required due to the packing efficiency. In the event these extra labels are not needed, they are scanned by the additional wand scanner to maintain accurate status information as to all labels and therefore all transactions within the system.

With the system of the present invention, therefore, high speed article processing can be achieved and in the environment of the preferred embodiment a picking and sorting operation for warehouses is provided with a control system for efficiently monitoring the current operational status of a plurality of batch picks each including several orders, in turn, including several transactions. By assigning each transaction a unique identifying number which is physically associated with the article to be picked in the form of a machine readable label, and which is entered into the control system memory in the form of stored data, the current status of each transaction, order, and batch can be continuously monitored and controlled. The resultant system results in a more efficiently operated system with a higher throughput than previously achievable through conventional picking systems.

It will become apparent to those skilled in the art that various modifications to the preferred embodiment of the invention described and disclosed herein can be made without departing from the spirit or scope of the invention as defined by the appended claims. ##SPC1## ##SPC2## ##SPC3## ##SPC4## ##SPC5## ##SPC6## ##SPC7## ##SPC8## ##SPC9## ##SPC10## ##SPC11## ##SPC12## ##SPC13## ##SPC14## ##SPC15## ##SPC16## ##SPC17## ##SPC18## ##SPC19## ##SPC20## ##SPC21## ##SPC22## ##SPC23## ##SPC24## ##SPC25## ##SPC26## ##SPC27## ##SPC28## ##SPC29## ##SPC30## ##SPC31## ##SPC32## ##SPC33## ##SPC34## ##SPC35## ##SPC36## ##SPC37## ##SPC38## ##SPC39## ##SPC40## ##SPC41## ##SPC42## ##SPC43##