Opportunistically consolidated picking

Disclosed are various embodiments for consolidating multiple pickings of an item to fulfill multiple shipments into a single picking of the multiple items. A determination is first made whether a metric representing a plurality of shipments exceeds a threshold, wherein individual ones of the plurality of shipments are mapped to corresponding ones of a plurality of item locations in a fulfillment center. The plurality of shipments are then remapped to an individual one of the plurality of item locations in response to a determination that the metric exceeds the threshold. Finally, a picking of the items is initiated.

BACKGROUND

Shipments of items are often assembled and fulfilled from distribution or fulfillment centers where the items are stored. Items are pulled from the inventory located at the distribution or fulfillment center by employees, packed, and shipped. Items in the inventory in the fulfillment center may be stored in one or more locations within the fulfillment center, either together as a group or separately throughout the fulfillment center.

DETAILED DESCRIPTION

The present disclosure involves various embodiments for consolidating retrieval of items to be shipped from an inventory storage area in a fulfillment center. A fulfillment center may be any one of a number of material handling facilities, such as a warehouse, distribution center, or similar facility. The number of unfulfilled shipments for a particular item that are assigned to the fulfillment center is monitored. As shipments are assigned to the fulfillment center, the shipments or items within the shipments are mapped to locations of items within the fulfillment center. When fulfilling a given shipment, one or more pickers on pick routes stop at item locations mapped to the shipment to retrieve the items to be shipped. In situations where multiple shipments exist that include the same or a common item, inefficiencies may be created as multiple pickers on multiple pick routes attempt to separately retrieve the item for their respective shipments. For example, one or more units of an item may be stored at different locations throughout the fulfillment center. According to various embodiments, when the number of unfulfilled shipments for a particular item exceeds a threshold number, the unfulfilled shipments are remapped to a shared item location or set of item locations and consolidated into a single pick route. In some embodiments, wherein some of the unfulfilled shipments include multiple items, individual item locations for the particular item to be picked are remapped to a shared item location or set of item locations and consolidated into a single pick route. In various embodiments, the shared item location is a single item location, such that multiple shipments for the item can be fulfilled by a picker on a single pick route. As such, picking for shipments for the same item are consolidated, thereby increasing efficiency and providing other benefits.

In the following discussion, a general description of the system and its components is provided, followed by a discussion of the operation of the same.

Beginning withFIG. 1, shown is a pictorial diagram of a fulfillment center100. A fulfillment center100is any material handling facility where orders for items are fulfilled and/or shipments of items corresponding to orders originate. As such, a fulfillment center may, for example, correspond to a warehouse, a distribution center, a processing center, or a similar structure. A fulfillment center100may be divided into multiple sections. For example, a fulfillment center100may include one or more inventory storage areas103, one or more sorting/packing areas106, and one or more loading areas109where shipments are loaded onto delivery vehicles for delivery to customers or other recipients pursuant to orders for such items. The fulfillment center100may also have one or more mechanisms or methods for moving items between sections, including conveyors, forklifts, robotic handling equipment, and other means. In addition, a fulfillment center100may have one or more pickers or other employees who traverse pick routes or other paths generated by a shipment or order fulfillment system or process in order to retrieve items within the fulfillment center100for shipment.

The inventory storage area103includes one or more item locations113where one or more items116may be located for long-term or bulk storage. An item location113may correspond to any number of physical structures. For example, a shelf, set of shelves, a pallet on a floor, a bin and/or a series of bins, or similar structures may be considered to be an item location113.

There is no requirement that identical items116be stored together at the same or neighboring item locations113. In some embodiments, it may be more efficient to organize the inventory storage area103such that identical or similar items116are stored together. For example, all DVD's may be stored in a group or cluster of adjacent item locations113, with all DVD's corresponding to a particular movie located in a single item location113. In other embodiments, it may be more efficient to store an item116in any item location113with sufficient capacity. In such embodiments, multiple instances of the same item116may be stored in separate item locations113on opposite sides of the inventory storage area103. For example, DVD's corresponding to a particular move may be located in multiple item locations113spread through the inventory storage area103for more efficient accessibility in certain situations or scenarios.

The sorting/packing area106is where items116are sorted and packed for shipment. Within a sorting/packing area106, items116may be located at item location113according to various embodiments of the present disclosure. Items116at item locations113within the sorting/packing area106may be located such that pickers may be able to quickly and efficiently retrieve items116for fulfillment or shipments. Generally, as items116within the item locations113of the sorting/packing area106are used to fulfill shipments, items116at item locations113within the inventory storage area103are automatically moved from the inventory storage area103to the sorting/packing area106. The automated movement of items from the inventory storage area103to the sorting/packing area106may be directed by automated systems or processes that track inventory levels at item locations113within the sorting/packing area and dispatch employees or automatons to transfer goods from the item locations113within the inventory storage area103to the item locations113within the sorting/packing area106.

As shipments for particular items116are received, one or more pickers may be dispatched to retrieve one or more items116from item locations113within the sorting/packing area106. A single picker may retrieve multiple items116of a shipment236and one or more pickers may be assigned to pick items116of the shipment236. If items116are not at item locations113within the sorting/packing area106, or an insufficient quantity of items116are located within the sorting/packing area106, then the pickers may be dispatched to the inventory storage area103to retrieve the items116and deliver them to the sorting/packing area106. In some embodiments, pickers may be designated employees at the fulfillment center100who retrieve items116. In other embodiments, pickers may be machines, such as robots or other automatons that retrieve items116from the inventory storage area103.

Pickers generally follow designated pick routes, which are generated to minimize the time and distance necessary for the picker to travel to retrieve the requested items116from the items locations113within the sorting/packing area106or the inventory storage area103. For a given pick route, a picker may retrieve one or more items116corresponding to one or more shipments. The items116retrieved may be a number of different items corresponding to one or more shipments or the items116may be one or more of the same item116corresponding to one or more shipments, depending on the requirements behind planning the pick route.

With reference toFIG. 2, shown is a networked environment200according to various embodiments. The networked environment200includes a computing environment203and a client device206, which are in data communication with each other via a network209. The network209includes, for example, the Internet, intranets, extranets, wide area networks (WANs), local area networks (LANs), wired networks, wireless networks, or other suitable networks, etc., or any combination of two or more such networks. For example, such networks may comprise satellite networks, cable networks, Ethernet networks, and other types of networks.

Various applications and/or other functionality may be executed in the computing environment203according to various embodiments. Also, various data is stored in a data store213that is accessible to the computing environment203. The data store213may be representative of a plurality of data stores213as can be appreciated. The data stored in the data store213, for example, is associated with the operation of the various applications and/or functional entities described below. The components executed on the computing environment203, for example, include consolidated picking application216and the electronic commerce application219, and other applications, services, processes, systems, engines, or functionality not discussed in detail herein.

The consolidated picking application216is executed to consolidate picking of items116from item locations113depending on the current shipment volume of items116. The consolidated picking application216may delay the addition of items116to pick routes in order to generate one or more pick routes dedicated to retrieving a multitude of a particular item116, as will be further described herein.

The electronic commerce application219is executed in order to facilitate the online purchase of items116over the network209. The electronic commerce application219also performs various backend functions associated with the online presence of a merchant in order to facilitate the online purchase of items116. For example, the electronic commerce application219generates network pages such as web pages or other types of network content that are provided to client devices206for the purposes of selecting items for purchase, rental, lease, or other form of consumption.

The data stored in the data store213includes, for example, a consolidation threshold223, one or more orders226, a shipment history229, data related to one or more fulfillment centers100, and potentially other data. For each fulfillment center100, the data store213may also store information related to the item locations113within each fulfillment center and inventory233of items116stored in each fulfillment center100as well as each shipment236assigned to the fulfillment center100for fulfillment.

The consolidation threshold223represents one or more values or conditions which, when met, indicate that the consolidated picking application216should remap a plurality of shipments236or remap individual item locations113for picking of items116in the plurality of shipments236to the same item location113so that a single picker can fulfill the plurality of shipments with one stop at the item location113. For example, the consolidation threshold223may represent a minimum number of shipments236for an item116for which remapping of shipments236to an item location113is economical, practical, or otherwise satisfies a cost/benefit analysis. In some embodiments the consolidation threshold223may be equal to a defined or preset value. In various embodiments, the consolidation threshold223may be empirically derived by the consolidated picking application216based at least in part on the shipment history229using various machine learning approaches, such as neural networks, Bayesian networks, decision trees, and/or other machine learning approaches. In some embodiments, a hybrid of the previous two approaches may be used, whereby the consolidation threshold223is initially set equal to a defined value, which is then updated using various machine learning approaches as previously described.

The orders226are representative of one or more customer orders226placed through the electronic commerce application219for purchase and/or lease of one or more items116. Individual orders226may correspond to a single shipment236of one or more items116or a plurality of shipments236, each of which may contain one or more items116ordered and each of which may be shipped from the inventory233of multiple fulfillment centers100. For example, an order226for a book and a DVD may be fulfilled by one shipment236originating from a fulfillment center100or by two separate shipments236from the same or different fulfillment centers100. The number of shipments236that correspond to an order226and whether the shipments236originate from the same or different fulfillment centers100depends on factors such as the location of particular fulfillment centers100, available inventory at particular fulfillment centers, shipping costs associated with each shipment236, and other factors.

The shipment history229is representative of previously placed and/or fulfilled shipments for items116from the fulfillment center100. In some embodiments, the shipment history229may include details such as the items116included in each shipment236, how long it took to fulfill the shipment236, the cost of the shipment236, the frequency of recurring shipments236, and other such data. In some embodiments, the shipment history229may also include data such as the cancellation rate or consolidation rate of shipments236of a given item116. The shipment history229may be used by various embodiments to empirically determine an appropriate consolidation threshold223for shipments236involving particular items116or to determine whether to lock or remap fulfillment of individual shipments236from individual item locations113to a particular item location113, as further described herein.

The fulfillment centers100are representative of individual fulfillment centers100within a fulfillment or distribution network. Each fulfillment center100may be representative of a warehouse, distribution center, shipping center, or similar structure within a network of fulfillment centers100.

The item locations113represent the physical location of items116within a particular fulfillment center100. As such, the item locations113stored in the data sore213facilitate tracking the locations of items116of inventory233within a particular fulfillment center100.

The inventory233represents the items116stored in the fulfillment center. Inventory233may include the quantity of the items116in a particular fulfillment center100. Inventory233may also include the quality of particular items116(e.g. new, used, refurbished, etc.) that may be found in the particular fulfillment center100.

The shipments236are representative of one or more shipments236of items116from a fulfillment center100to satisfy a respective customer order226out of a potential plurality of customer orders226. Each shipment236may be for one or more items116from the inventory233. Accordingly, each order226may correspond to one or more shipments236assigned to one or more fulfillment centers100. In some embodiments, individual items116of individual shipments236may be initially mapped to an individual item location113for fulfillment. Accordingly, the same item116included in multiple shipments236may initially be mapped to different item locations113, such that an item116used to fulfill a first shipment236may be retrieved from a different item location113in the fulfillment center100than the item116used to fulfill a second shipment236.

The client device206is representative of a plurality of client devices206that may be coupled to the network209. The client device206may comprise, for example, a processor-based system such as a computer system. Such a computer system may be embodied in the form of a desktop computer, a laptop computer, personal digital assistants, cellular telephones, smartphones, set-top boxes, music players, web pads, tablet computer systems, game consoles, electronic book readers, or other devices with like capability. The client device206may include a display. The display may comprise, for example, one or more devices such as liquid crystal display (LCD) displays, gas plasma-based flat panel displays, organic light emitting diode (OLED) displays, electrophoretic ink (E ink) displays, LCD projectors, or other types of display devices, etc. The client device206may be configured to execute various applications such as, for example, a browser, a dedicated application, email applications, social network applications, word processors, spreadsheets, and so forth.

Next, a general description of the operation of the various components of the networked environment200is provided. To begin, customers place orders226for items116through the electronic commerce application219. The electronic commerce application219creates one or more shipments236to correspond to each order226, and assigns each shipment236to one of the fulfillment centers100. The electronic commerce application219then maps each item116in each shipment236to an item location113in the fulfillment center100. Items116are subsequently retrieved or picked from the item location113by a picker to fulfill the shipment236.

The consolidated picking application216monitors the shipments236assigned to each fulfillment center100. If the number of shipments236assigned to a particular fulfillment center100for a particular item116in the inventory233of the fulfillment center100exceeds a value specified by the consolidation threshold223, then the consolidated picking application216remaps fulfillment of the item116included in each shipment236of the item116to a particular item location113. The consolidated picking application216subsequently initiates a picking of the items116from the item location113, such that all of the items116are picked in a single trip by a given picker instead of being picked over the course of multiple trips by one or more pickers.

Among the multiple advantages of the various embodiments described herein is an improved efficiency in fulfilling multiple shipments that include the same item116. In fulfillment centers100where shipments236are fulfilled as they are assigned, a picker may traverse, for each shipment236, a pick route that includes a stop at the mapped item location113to retrieve the item116to be shipped. In scenarios where multiple shipments236include the same item116, one or more pickers may traverse one pick route for each shipment236. In contrast, according to the various embodiments of the present disclosure, a picker may fulfill a plurality of shipments236for the same item116while traversing a single pick route. This decreases the number of pick routes traversed by a picker and the amount of time spent by a picker on a pick route, thereby increasing the efficiency of the pickers within the fulfillment center100as well as resulting in other benefits and advantages.

Referring next toFIG. 3, shown is a flowchart that provides one example of the operation of a portion of the consolidated picking application216according to various embodiments. It is understood that the flowchart ofFIG. 3provides merely an example of the many different types of functional arrangements that may be employed to implement the operation of the portion of the consolidated picking application216as described herein. As an alternative, the flowchart ofFIG. 3may be viewed as depicting an example of elements of a method implemented in the computing environment203(FIG. 2) according to one or more embodiments.

To begin, it is assumed that shipments236(FIG. 2) are assigned to a fulfillment center100(FIG. 2) for fulfillment. As shipments236are assigned to the fulfillment center100, they are initially mapped to an item location113(FIG. 1) within the fulfillment center100corresponding to an item116(FIG. 2) included in the shipment236. Pick routes are then generated for pickers to retrieve the items116from the inventory storage area103(FIG. 1).

Moving to box303, the consolidated picking application216determines whether currently unfulfilled shipments236that have an item116in common exceed a consolidation threshold223(FIG. 2) for a defined period or window of time. For example, the consolidated picking application216may determine that the number of shipments236for a particular item116(FIG. 2) equals or exceeds a number specified by the consolidation threshold223. In some embodiments, the consolidated picking application216may further determine and/or require that the number of shipments236for the particular item116exceeds the consolidation threshold223by a specified amount. In such embodiments, the specified amount provides a buffer to account for potential cancellations of orders226or shipments236during the remapping process described in box309. For example, between the time that remapping begins and ends, as described in box309, one or more orders and/or shipments may be cancelled such that the number of shipments no longer exceeds the consolidation threshold223. Including a buffer reduces such a risk. If the consolidated picking application216determines that the shipments236do not exceed or satisfy the condition(s) specified by the consolidation threshold223, then execution proceeds to box306. However, if the consolidated picking application216does determine that the shipments236satisfy the condition(s) specified by the consolidation threshold223, then execution proceeds to box309.

Moving to box306, the consolidated picking application216updates the time window used for the determination made at box303. For example, in embodiments where the consolidated picking application216makes a determination based on orders226and/or shipments236placed or requested within a recent amount of time, such as four hours or other time periods, the consolidated picking application216may adjust the time window by a period, such as 15 minutes or other adjustments, and delay execution of the next step accordingly. This permits the consolidated picking application216to keep a running tally of shipments236which have been requested but not yet fulfilled, while allowing normal fulfillment processes to proceed in parallel with the execution of the consolidated picking application216. After the time window is updated, execution loops back to box303.

However, assuming that the consolidated picking application216determines that the shipments236having an item116in common exceed the consolidation threshold223in box303, then in box309, the consolidated picking application216remaps individual shipments236involving the item116to a new item location113. Remapping involves changing the item location113from which a picker will retrieve the item116for an individual shipment236to an item location113where a picker may retrieve multiple ones of the item116to satisfy multiple shipments236. However, in those embodiments where items116included in shipments are not initially mapped for picking to a particular item location113, the initial mapping of the item116to an item location116for picking may occur at box309. After an item116included in a shipment236has been mapped or remapped to an item location113, the consolidated picking application216locks the item116included in the shipment236to the mapped or remapped item location113to prevent additional mappings or remappings before picking and/or fulfillment. In some embodiments, locking may involve an indication to or notation by the consolidated picking application216that the item116in ineligible for mapping or remapping to another item location113in a later iteration of the approach depicted inFIG. 3.

In some embodiments, the consolidated picking application216may preferentially select an item location113to remap multiple shipments236, as discussed above, according to one or more criteria. For example, the consolidated picking application216may preferentially select an item location113in the inventory storage area103(FIG. 1) of a fulfillment center100(FIG. 1) that is closest to a sorting/packing area106(FIG. 1) to minimize the length and/or duration of the pick route or retrieval. As another example, the consolidated picking application216may preferentially select an item location113with a sufficient quantity of items116to satisfy all outstanding shipments236for the item116in order to minimize the number of trips and/or pick routes necessary.

In some embodiments, the consolidated picking application216may preferentially select item locations113that are most accessible to a picker. For example, a pallet of items116on the top shelf in a warehouse may require a special forklift or other machinery to reach. Accordingly, the consolidated picking application216may exclude that item location113from consideration or prefer other, more accessible, available item locations113. Alternatively, the consolidated picking application216may select the item location113and cause the necessary equipment to be provided to the location so that the picker can pick the items.

In some embodiments, the consolidated picking application216may also preferentially select an item location113with full pallets and/or lots compared with item locations113with partial pallets and/or lots, or vice versa, in order to minimize the amount of time spent sorting and/or separating items116. To illustrate the example, if there are 500 items116in a pallet of items116and the consolidated picking application216has detected a sufficient demand for shipping 500 or more items116, then the consolidated picking application216may preferentially remap shipments236to an item location113with a full pallet of 500 items116so that the entire pallet of items can be picked. In contrast, if the consolidated picking application216has determined that there is demand for shipping only 250 items116, then the consolidated picking application may preferentially remap shipments236to an item location113with a partial pallet of 300 items116. In these instances, the consolidated picking application216is selecting the appropriate item location113necessary for minimizing retrieval time by avoiding unnecessary labor involved in breaking down a pallet of items116.

Referring next to box313, the consolidated picking application216initiates picking of the items116from the remapped item location113. Initiation of picking may involve communicating to a picker to retrieve the items116from the remapped item location113. For example, the consolidated picking application216may send an electronic message to an employee device with directions to the item location113and specifying the number of items116to be picked. In other embodiments, initiation of picking may involve the consolidated picking application216generating a pick route that includes the remapped item location113and adding the generated pick route to a queue of pick routes. Alternatively, the consolidated picking application216may send a message to a scheduling system requesting a pick route be generated that includes the remapped item location113. In some embodiments, the consolidated picking application216may further update the status of the shipments236to “fulfilled” or “in fulfillment” to prevent attempts to fulfill the shipments236twice, either by the consolidated picking application216or other fulfillment applications.

In some embodiments, additional pick routes may also be generated for remaining items116within the individual shipments236. In such embodiments, these additional pick routes will have the same destination in the sorting/packing area106(FIG. 1) as pick route including the remapped item location113. Execution subsequently proceeds to box316.

Moving to box316, the consolidated picking application216unlocks and remaps overflow shipments236. Overflow shipments236are shipments236for the item which could not be fulfilled from the remapped item location113. For example, in those embodiments where a buffer of shipments236is included to account for order226or shipment236cancellations, the number of orders226and/or shipments236cancelled may be less than the number of orders226and/or shipments accounted for by the buffer. Accordingly, a small number of shipments236may be unable to be fulfilled from the remapped item location113as anticipated. These overflow shipments236are therefore unlocked and remapped to other item locations113within the fulfillment center100for eventual fulfillment. Appropriate pick routes may then be created to facilitate fulfillment of such shipments236.

For example, 500 shipments236for one unit each of an item116may be fulfilled from a pallet of 500 units of the item116. Accordingly, the consolidated picking application216may remap 550 shipments236for one unit each of the item116to the pallet of 500 units of the item116. This would provide for a buffer of 50 shipments236of one unit each. If 30 shipments236of one unit each are cancelled, for example as a result of the cancellation of 30 corresponding orders226, then there would be an overflow of 20 shipments236which would need to be remapped as described above. Execution subsequently ends.

With reference toFIG. 4, shown is a flowchart that provides one example of the operation of box309depicted in the flowchart ofFIG. 3according to various embodiments. It is understood that the flowchart ofFIG. 4provides merely an example of one of the many different types of functional arrangements that may be employed to implement the operation of the portion of the consolidated picking application216(FIG. 2) as described herein. As an alternative, the flowchart ofFIG. 4may be viewed as depicting an example of elements of a method implemented in the computing environment203(FIG. 2) according to one or more embodiments.

Beginning with box403, it is assumed that the consolidated picking application216has received one or more requests for shipments236(FIG. 2) of one or more items116(FIG. 2). It is further assumed that individual shipments236requested have been initially mapped to an item location113from which the individual shipment236will be fulfilled. In response, the consolidated picking application216determines whether the demand, as measured by the quantity of items116to be shipped or some other metric, meets or exceeds a threshold or otherwise satisfies a condition. For example, the consolidated picking application216may determine that the quantity of items116is greater than the quantity of items116located at an item location113within the inventory storage area103(FIG. 1) of a fulfillment center100(FIG. 1). Such an item location113may include, for example, a full and/or unopened pallet of items116. If the consolidated picking application216determines that the quantity of items116exceeds the predefined threshold, then execution proceeds to box406. Otherwise, execution ends.

Moving on to box406, the consolidated picking application216determines whether one or more constraints would be satisfied if fulfillment of an item116included in multiple ones of the shipments236were to be remapped to a particular item location113, such as an item location113within the inventory storage area103. Such constraints may include satisfying a customer delivery time or window for one or more of the shipments236, a labor cost involved in remapping the shipments236compared to a labor savings from remapping the shipments236, as well as the position of the item location113within the fulfillment center100. For example, if a customer delivery window for several of the shipments236could not be met if the shipments were remapped, then the consolidated picking application216might determine that some or none of the shipments236are eligible for remapping. Likewise, if the labor costs involved with remapping shipments236to a particular item location113exceed the labor costs from individually fulfilling the shipments236, then the consolidated picking application216might determine not to remap shipments236to an item location113. As another example, the position of the item location113may impose a constraint, impacting the labor costs and/or impacting fulfillment of other shipments236not being remapped by the consolidated picking application216.

Moving on to box409, the consolidated picking application maps and/or remaps shipments236to an item location113with a sufficient quantity of items116to fulfill all of the mapped and/or remapped shipments236. Remapping involves changing the item location113from which a picker will retrieve the item116for an individual shipment236to an item location113where a picker may retrieve multiple ones of the item116to satisfy multiple shipments236. However, in those embodiments where items116included in shipments are not initially mapped for picking to a particular item location113, the initial mapping of the item116to an item location116for picking may occur. Execution subsequently ends.

With reference toFIG. 5, shown is a schematic block diagram of the computing environment203according to an embodiment of the present disclosure. The computing environment203includes one or more computing devices500. Each computing device500includes at least one processor circuit, for example, having a processor503and a memory506, both of which are coupled to a local interface509. To this end, each computing device500may comprise, for example, at least one server computer or like device. The local interface509may comprise, for example, a data bus with an accompanying address/control bus or other bus structure as can be appreciated.

Stored in the memory506are both data and several components that are executable by the processor503. In particular, stored in the memory506and executable by the processor503are the consolidated picking application216and the electronic commerce application219, and potentially other applications. Also stored in the memory506may be a data store213and other data. In addition, an operating system may be stored in the memory506and executable by the processor503.

Also, the processor503may represent multiple processors503and/or multiple processor cores and the memory506may represent multiple memories506that operate in parallel processing circuits, respectively. In such a case, the local interface509may be an appropriate network that facilitates communication between any two of the multiple processors503, between any processor503and any of the memories506, or between any two of the memories506, etc. The local interface509may comprise additional systems designed to coordinate this communication, including, for example, performing load balancing. The processor503may be of electrical or of some other available construction.

Further, any logic or application described herein, including consolidated picking application216and the electronic commerce application219, may be implemented and structured in a variety of ways. For example, one or more applications described may be implemented as modules or components of a single application. Further, one or more applications described herein may be executed in shared or separate computing devices or a combination thereof. For example, a plurality of the applications described herein may execute in the same computing device500, or in multiple computing devices in the same computing environment203. Additionally, it is understood that terms such as “application,” “service,” “system,” “engine,” “module,” and so on may be interchangeable and are not intended to be limiting.