Abstract:
An automated storage facility includes a storage and retrieval system and a floor inventory management system. The storage and retrieval system uniquely palletizes bossies and stores palletized bossies and palletized stacks of cases together in the same storage and retrieval system. The system provides order picking of stacked cases for movement out of the storage retrieval system into an accumulator, and retrieving bossie carts from the storage and retrieval system while concurrently receiving and storing new pallets of stacked cases and new pallets with loaded bossies. It provides acceptance of loaded bossie cart-bearing pallets and discharging of loaded bossie cart pallets at one level while storing the pallets with the bossie carts throughout the storage system. Pallets with stacks of cases are delivered to order pick lanes for picking stacks from the pallets, while case stacks on conveyors are accumulated on pallets and accepted for storage on another level. The pallets with stacks of cases concurrently move throughout the storage system. A pallet is also provided, which handles stacked cases and bossie carts, as is a unique method and apparatus for loading and unloading the bossie carts on and off the pallets. The invention is a novel system for storing and retrieving products assembled and organized in different carriers. The inventory management system includes a server, client personal computers, client RF (radio-frequency) terminals, and various other peripherals, all running inventory management software.

Description:
This application claims the benefit of U.S. Provisional Application Ser. No. 60/013,271, filed Mar. 12, 1996, U.S. Provisional Application Ser. No. 60/022,410, filed Jul. 30, 1996, and U.S. Provisional Application Ser. No. 60/022,413, filed Jul. 30, 1996. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to facilities and systems for handling products. 
     Storage retrieval systems are used primarily as short term buffer systems for storing products made in continuous or periodic production according to product life and demands and production line efficiencies. Shipping occurs on a regular periodic basis according to consolidated product orders. For example, milk may be continuously pasteurized, made into separate products and packaged in three shifts of operations. Liquid products associated with the dairy industry may be formulated, constituted and packaged on a regular periodic basis. Many different products in different package configurations may be generated and shipped, including gallons and half gallons in plastic containers with screw tops and handles, and half gallons, quarts, pints and half pints in specially formed, treated and coated paperboard containers. Usually the paperboard containers are filled, sealed, date stamped and placed in cases which are then stacked six high and moved along powered and free roller conveyors to temporary storage and shipment. The large plastic gallon containers, and sometimes the half gallon plastic containers, are placed on shelves on wheeled carts, which are known as bossie carts, and the bossie carts are moved into temporary storage on their way to shipping stations. The temporary storage and movement problems are compounded by the product mix. For example, whole milk, Vitamin D milk, 2% milk, skim milk, half and half, and cream, plus a variety of juices and drinks. 
     The problem is further compounded by the need to assure first in, first out movements and to provide a batch hold capability in the storage. 
     The problem is further intensified by the regular periodic shipping requirements and specific order response requirements. 
     While a production plant may operate continuously on a three-shift basis, shipping may operate on only a one- or two-shift basis. When shipping, it may be necessary to fill ten or more trailer loads per hour. A complexity is added to the problem by mandating a system which is capable of handling, temporarily storing and retrieving high volumes of stacked cases and high volumes of packed bossie carts. 
     Managing product inventory in production plants is difficult as mass quantities of product are continuously placed in and picked from storage areas. Arranging the products for efficient first in, first out picking is a necessity. Immediate verification of actual quantities of product in stock and the location of that product is a requirement on both the production and distribution ends. Needs exist for inventory systems that account for each product present in the facility at all times, that track the location of each product placed and picked during plant operation, and that provide for facilitated storage, identification and retrieval of desired product. 
     SUMMARY OF THE INVENTION 
     The present invention is an automated storage facility that includes a storage and retrieval system and a floor inventory management system. 
     The present invention provides a unique storage and retrieval system, which uniquely palletizes bossies and stores palletized bossies and palletized stacks of cases together in the same storage and retrieval system. The system uniquely provides order picking of stacked cases for movement out of the storage retrieval system into an accumulator, and retrieving bossie carts from the storage and retrieval system while concurrently receiving and storing new pallets of stacked cases and new pallets with loaded bossies. 
     The present invention provides the acceptance of loaded bossie cart-bearing pallets and the discharging of loaded bossie cart pallets at one level while storing the pallets with the bossie carts throughout the storage system. Pallets with stacks of cases are delivered to order pick lanes for picking stacks from the pallets, while case stacks on conveyors are accumulated on pallets and accepted for storage on another level. The pallets with stacks of cases concurrently move throughout the storage system. 
     The invention provides a unique pallet which handles both stacked cases and bossie carts, and a unique method and apparatus for loading and unloading the bossie carts on and off the pallets. The invention also provides a novel system for storing and retrieving products assembled and organized in different carriers. 
     The inventory management system of the present facility includes a Hewlett-Packard Unix-based server, client personal computers, client RF (radio-frequency) terminals, and various other peripherals, all running inventory management software. This software performs the following tasks: 
     Permits production data entry at the fillers, using local industrial terminals to tell the system the product code and expiration date being run on each filler. 
     Uses a PLC (programmable logic controller) connected to photocells to determine the actual case count of each product coming off of each filler. 
     Uses real-time handheld RF data terminals to learn from the pullers the actual locations where the stacks have been stored. These terminals are also used when storing received product in the pallet racks. 
     Manages a file-based Ethernet TCP/IP interface to a host computer (supplied by Owner), receiving orders and transmitting shipments and inventory balances. 
     Permits order entry, scheduling, and maintenance. 
     Uses real-time handheld RF data terminals to direct order pickers and to update inventory as orders are picked. This includes inventory on the floor, in the pallet racks, and in the bossie makeup area. Bossies are wheeled racks in which product is placed. 
     Performs all additional transactions necessary to manage inventory in the highrise. 
     These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the claims and drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an automated storage system. 
     FIG. 2 is an enlarged view of an automated storage system. 
     FIG. 3 is a plan view of the warehousing portion of the automated stacker system. 
     FIG. 4 is an end elevation schematically showing the storage retrieval system of the present invention, showing four storage levels, and order picking lanes on the second level. 
     FIG. 5 is a plan view schematically showing the second level with storage lanes and order picking lanes, empty pallet return lanes, infeed conveyors and stack pushers for filling pallets, picked stack conveyors, accumulators and lowerators. 
     FIG. 6 shows a first level with storage lanes and bossie cart pallet loaders and unloaders, bossie cart conveyors and pushers, and stack lowerators and pushers for loading trucks. 
     FIG. 7 schematically shows a partial third level with empty pallet returns to lowerators for lowering the pallets to bossie cart pallet loading stations. 
     FIG. 8 is a schematic plan view of the new pallets. 
     FIG. 9 is an end elevational cross-section along line 1 of the pallet showing cart caster positioning in the pallet, and cart wheel lowering and raising pins for lifting and lowering the caster wheels of the bossie carts. Similar pins are used at bossie cart loading and unloading stations. 
     FIG. 10 is a cross-section along section line 2 showing structural details in end view. 
     FIGS. 11 and 12 are cross-sectional side views of the new pallet taken along sections lines 3 and 4, respectively. 
     FIG. 13 is a schematic of a floor inventory system of the present automated storage facility. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, a high rise storage facility 1 has three aisles 3 served by stacker/retriever (S/R) cranes which move along fixed top and bottom rails in the aisles. An elevator moves vertically along a mast, and the mast moves horizontally along the rails. Cars or rack entry vehicles mounted on the elevators move into and out of the racks, depositing loaded pallets in the racks and withdrawing loaded pallets, all as controlled by a computer. 
     Each pallet contains a number of stacks of product cases, for example eight stacks of six cases per stack. As shown in FIG. 1, the stacks are pushed from the pallets by an unloader 7, and groups 9 of sixteen stacks move along tracks 11 to a high flow product area 13. Stacks are pushed from the conveyor 11 to rows 14 in the high flow product storage area 13. 
     Individual stacks of cases are manually pulled or picked 15 from the lowermost storage racks or order pick lanes in the rack storage areas. 
     The individual stacks 17 move along tracks 19 to single truckload-forming conveyors 20 in a truckload accumulation area 21. Individual stacks are gated from the high flow product storage area 13 and flow along conveyors 23 to the truck conveyors 20 in the truckload makeup area 21. 
     FIG. 2 is an enlarged detail of the rack storage area showing a stacker/retriever crane 25 which is movable along one of the aisles 3. Individual stacks of cases are moved onto the individual stack conveyors 19, which extend into and along the lowermost lanes, which are order pick lanes in the storage racks. 
     As shown in FIG. 3, product flow moves in the direction of arrow 30. Loaded and empty pallets move on the first or ground level in the lanes under the influence of gravity in the directions shown by the small arrows. 
     The stacker/retrievers 25 move within aisles 3. Product flows into the storage rack system on conveyors 31 in cases stacked six high and in groups of sixteen stacks. Pallet loaders 33 push pairs of cases 35 onto pallets 37. When the pallets are full, the pallets are released, and the full pallets move by gravity along pallet infeed lanes 39. Stacks of product which has the highest flow-through are delivered from the production plant on conveyor 41, and those high flow product-loaded pallets are stored in the racks along aisle 43 by the stacker/retriever 25 in that aisle. As the conveyors 14 in the high flow product storage area 13 need stacks of cases, a computer directs the stacker/retriever 25 operating in aisle 43 to pick up two pallets and deliver the pallets to the parallel outfeed lanes 45. The loaded pallets flow by gravity to the bottom of the outfeed lanes, and then to a position in front of the pallet unloaders 7. The pallet unloaders 7 push stacks from the pallets two at a time, grouping all sixteen stacks of cases from two pallets to move along the floor conveyor 11 to the high flow product storage area 13 shown in FIG. 1. The empty pallets are delivered to empty pallet lanes 47, where the empty pallets are stacked and readied for delivery to the receiving platform 49 of the pallet washer 51. The washed pallets 37 are then redelivered to the pallet loaders 33 for receiving stacks of cases. 
     FIG. 3 shows the first level or ground level in which all of the stackers 25 serve the racks along the aisles. The stackers continually load the racks during production period, and keep the order pick lanes 61 at the floor level full of pallets loaded with stacked product cases. Order picking of individual stacks of cases 15 occurs along each order picking outfeed conveyor 19, which send individual stacks of cases to the truckload assembly area 21. Pallets from which all stacks have been picked are removed from the order pick lanes and placed on the closest pallet return lane 63 where the pallets are stacked and then released to flow by gravity down the empty pallet return lane 63. The stacked empty pallets are picked up by the cars 65 on the stacker/retrievers 25 for return to the empty pallet receivers 49 of the pallet washers 51. 
     All of the infeed conveyors 31 are loaded with sixteen stacks of six loaded cases each. Each of the infeed conveyors 31 supplies the stacked cases in groups of sixteen stacks to the individual pallet loaders 33. Pallets in the paired full pallet lanes 39 are loaded with identical products of the same SKU numbers. 
     Throughout the storage racks the products with the identical SKU numbers are stored in side-by-side racks so that the rack entry vehicles 65 on the stacker/retriever cranes 25 may currently deliver and pick up paired pallets in paired lanes which are loaded with identical products. 
     The automated unloaders 7 always unload identical products in groups of sixteen stacks which move along conveyor 11 to the high flow product storage area 13 shown in FIG. 1. The order pick lanes 61 are paired with identical products in two adjacent order pick lanes. 
     The operation of the facility includes the following processes: 
     1. Accumulate a batch of material. 
     Batches of the material are accumulated and released onto the conveyor which leads to the palletizer. The step includes accumulating a batch of material and determining if the batch constitutes two full pallets of product. If the batch does constitute two full pallets of product, the batch is released to the conveyor. If the batch does not constitute two full pallets of product, the operation includes waiting for manual batch release (end of run) and releasing the partial batch to the conveyor. 
     2. Palletize a batch of material. 
     The palletizer creates a pair of pallets from a batch and releases them to a storage/retrieval machine (S/R machine). The step includes receiving a batch from the conveyor, palletizing one pallet, releasing the pallet to the S/R machine, and pointing the palletizer to the other infeed conveyor. If the batch includes a second pallet, the operation further includes palletizing the second pallet, releasing the second pallet to the S/R machine, and pointing the palletizer to the other infeed conveyor. 
     3. Store a pair of pallets. 
     An S/R machine picks up a pair of pallets and deposits them in storage, or directly to an outfeed lane if possible. The step includes picking up a pair of like pallets simultaneously at adjacent infeed addresses and operating according to the following logic: 
     Are the pallets suitable for delivery directly to outfeed lanes? 
     If yes 
     Can the pallets be delivered directly to the depalletizer? 
     If yes 
     Deposit the pallets simultaneously at the adjacent pair of depalletizer outfeed lanes. 
     Stop. 
     Endif 
     Can the pallets be delivered directly to a pair of adjacent outfeed lanes which are assigned to the product? 
     If yes 
     Deposit the pallets simultaneously at the adjacent pair of outfeed lanes. 
     Stop. 
     Endif 
     Can the pallets be delivered directly to a single outfeed lane which is assigned to the product and has room for both pallets? 
     If yes 
     Deposit the pallets consecutively at the outfeed lane. 
     Stop. 
     Endif 
     Can the pallets be delivered directly to a pair of adjacent outfeed lanes to satisfy a particular order which specifies that product? 
     If yes 
     Deposit the pallets simultaneously at the adjacent pair of outfeed lanes. 
     Stop. 
     Endif 
     Endif 
     Is the material of a type which should be stored in adjacent pairs of storage lanes? 
     If yes 
     Can the pallets be delivered to an adjacent pair of storage lanes which already contain at least one pallet of that material? 
     If yes 
     Deposit the pallets simultaneously at the adjacent pair of storage lanes. 
     Stop. 
     Endif 
     Can the pallets be delivered to an adjacent pair of storage lanes which are empty? 
     If yes 
     Deposit the pallets simultaneously at the adjacent pair of empty storage lanes. 
     Stop. 
     Endif 
     Endif 
     Can the pallets be delivered to a storage lane which has room for both pallets and already contains at least one pallet of that material? 
     If yes 
     Deposit the pallets consecutively at the storage lane. 
     Stop. 
     Endif 
     Can the pallets be delivered to an empty storage lane? 
     If yes 
     Deposit the pallets consecutively at the storage lane. 
     Stop. 
     Endif 
     Can any room be found at all? 
     If yes 
     Deposit the pallets consecutively or randomly at one or two storage lanes. 
     If no 
     Sound an alarm. 
     4. Retrieve a pair of pallets to the depalletizer. 
     An S/R machine retrieves a pair of like pallets to replenish a pair of adjacent depalletizer outfeed lanes. The step includes determining the next kind of material required at the depalletizer and operating according to the following logic: 
     Can a pair of the oldest suitable kinds of pallets be found from two adjacent storage lanes? 
     If yes 
     Pick up the pallets simultaneously at the pair of adjacent storage lanes. 
     Deposit the pallets simultaneously at the pair of adjacent depalletizer outfeed lanes. 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
     Pick up the pallets consecutively at the storage lane. 
     Deposit the pallets simultaneously at the pair of adjacent depalletizer outfeed lanes, 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in two separate storage lanes? 
     If yes 
     Pick up the first pallet at the first storage lane. 
     Pick up the second pallet at the second storage lane. 
     Deposit the pallets simultaneously at the pair of adjacent depalletizer outfeed lanes. 
     If no 
     Can one of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
     Pick up the pallet at the storage lane. 
     Deposit the pallet at one of the depalletizer outfeed lanes. 
     If no 
     Sound an alarm. 
     5. Retrieve a pair of pallets to adjacent like assigned outfeed lanes. 
     An S/R machine retrieves a pair of like pallets to replenish a pair of adjacent order-pick outfeed lanes which are assigned to the same type of material. The step includes determining the kind of material assigned to the adjacent outfeed lanes and operating according to the following logic: 
     Can a pair of the oldest suitable kinds of pallets be found from two adjacent storage lanes? 
     If yes 
     Pick up the pallets simultaneously at the pair of adjacent storage lanes. 
     Deposit the pallets simultaneously at the pair of adjacent outfeed lanes. 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
     Pick up the pallets consecutively at the storage lane. 
     Deposit the pallets simultaneously at the pair of adjacent outfeed lanes. 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in two separate storage lanes? 
     If yes 
     Pick up the first pallet at the first storage lane. 
     Pick up the second pallet at the second storage lane. 
     Deposit the pallets simultaneously at the pair of adjacent outfeed lanes. 
     If no 
     Can one of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
     Pick up the pallet at the storage lane. 
     Deposit the pallet at the emptier of the pair of adjacent outfeed lanes. 
     If no 
     Sound an alarm. 
     6. Retrieve a pair of pallets to a single assigned outfeed lane. 
     An S/R machine retrieves a pair of like pallets to replenish a single outfeed lane which is assigned to the material. The step includes determining the kind of material assigned to the outfeed lane and operating according to the following logic: Is there at room for at least two pallets in the lane? 
     If yes 
     Can a pair of the oldest suitable kinds of pallets be found from two Adjacent storage lanes? 
     If yes 
     Pick up the pallets simultaneously at the pair of adjacent storage lanes. 
     Deposit the pallets consecutively at the outfeed lane. 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
     Pick up the pallets consecutively at the storage lane. 
     Deposit the pallets consecutively at the outfeed lane. 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in two separate storage lanes? 
     If yes 
     Pick up the first pallet at the first storage lane. 
     Pick up the second pallet at the second storage lane. 
     Deposit the pallets consecutively at the outfeed lane. 
     If no 
     Can one of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
      Pick up the pallet at the storage lane. 
      Deposit the pallet at the outfeed lane. 
     If no 
      Sound an alarm. 
     If no 
     Can one of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
     Pick up the pallet at the storage lane. 
     Deposit the pallet at the outfeed lane. 
     If no 
     Sound an alarm. 
     7. Retrieve a pair of pallets to a pair of adjacent outfeed lanes assigned to an order. 
     An S/R machine retrieves a pair of pallets (like or unlike) to replenish a pair of adjacent outfood lanes which are assigned to an order. The step includes determining the emptiest pair of outfood lanes assigned to the order and operating according to the following logic: 
     Determine the next kind of material required to satisfy an order. 
     Are at least two more pallets of the material required? 
     If yes 
     Can a pair of the oldest suitable kinds of pallets be found from two adjacent storage lanes? 
     If yes 
     Pick up the pallets simultaneously at the pair of adjacent storage lanes. 
     Deposit the pallets simultaneously at the pair of adjacent outfeed lanes. 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in a single storage lane? 
     If yes 
     Pick up the pallets consecutively at the storage lane. 
     Deposit the pallets simultaneously at the pair of adjacent outfeed lanes. 
     If no 
     Can a pair of the oldest suitable kinds of pallets be found in two separate storage lanes? 
     If yes 
     Pick up the first pallet at the first storage lane. 
     Pick up the second pallet at the second storage lane. 
     Deposit the pallets simultaneously at the pair of adjacent outfeed lanes. 
     If no 
     Sound an alarm. 
     If no 
     Can a pallet of the next required material be found in a storage lane? 
     If yes 
     Pick up the pallet at the storage lane. 
     Is another pallet required for the order? 
     If yes 
     Can a pallet of the next required material be found in a storage lane? 
     If yes 
     Pick up the pallet at the storage lane. 
     Deposit the pallets simultaneously at the pair of adjacent outfeed lanes. 
     If no 
     Deposit the first pallet at the emptier of the pair of adjacent outfeed lanes. 
     Sound an alarm. 
     If no 
     Deposit the first pallet at the emptier of the pair of adjacent outfeed lanes. 
     If no 
     Sound an alarm. 
     8. Recycle empty pallet stacks. 
     An S/R machine picks up a pair of empty pallet stacks from a single return lane or from a pair of return lanes, and delivers them to either a pallet washer or a palletizer. The step proceeds as follows: 
     Is it permitted for two stacks be picked up from a single return lane? 
     If yes 
     Find the fullest return lane. 
     Can one be found with at least two pallets in it? 
     If yes 
     Pick up two pallets consecutively at the return lane. 
     Deposit both pallets simultaneously at the pallet washer or palletizer. 
     Find the fullest return lane. 
     Can one be found? 
     If yes 
     Pick up a pallet at the return lane. 
     Find the next fullest return lane. 
     Can one be found? 
     If yes 
     Pick up a pallet at the return lane. 
     Deposit both pallets simultaneously at the pallet washer or palletizer. 
     If no 
     Deposit the first pallet at the emptiest pallet washer or palletizer. 
     If no 
     Exit. 
     Referring to FIG. 4, an automated storage and retrieval system is generally indicated by the numeral 101. The system has four levels of storage rails 3 with two longitudinal aisles 105. Vertical masts 107 of stacker retriever machines ride on rails 109 and 111. A carriage 113 is driven up and down the masts 107. Rack entry vehicle 115 mounted on the carriage is capable of moving left or right into and out of the storage racks to store and retrieve loaded pallets. 
     The outer lanes 117 on the second level are inclined to slide the pallets downward and outward into the outermost order picking positions 119, in which individual stacks of cases are slid from the pallets onto order picking conveyors 121 by an order picker standing on grating 122. Order picking lanes 117 are kept substantially fully by transfer of pallets loaded with stacked cases from the storage racks or directly from the pallet loaders. 
     The rack vehicles 115 are supported on lateral rollers which move in C-shaped rails in the rack. Platforms on the vehicles lift and lower the pallets. The loaded pallets on the top level show that each rack vehicle is capable of carrying, storing and retrieving five loaded pallets inboard in the racks and three outward. The small numbers represent loaded pallets; the circled numbers identify levels. 
     At the right of FIG. 4 is a lowerator 123 for lowering stacks 125 of empty pallets into positions 127 for loading the pallets with filled bossie carts. The cart-loaded pallets are then moved to the bossie cart pallet input lanes for carriage by the masts 107, elevator carriage 113 and rack entry vehicle 115 to any desired storage position in the rack. The storage positions are dictated by a computer control. 
     FIG. 5 shows a second level 130 of the storage retrieval system 101, showing thirty numbered lanes. Product in stacks of six cases enters the system on powered roller conveyors 131. Gates 133 admit the stacks in groups of three. Pushers 135 push the stacks in groups of three onto pallets 137 until each pallet is filled with twelve stacks of cases. Full pallets are released to move by gravity along the full pallet lanes 139 to pick up positions 141 at the ends of the parallel lanes 139. The loaded pallets 143 are picked up by the rack entry vehicles 115 which move in parallel on the carriage 113, and are carried to any storage location in the entire storage rack on any level, or directly to the order pick lanes 117 on the outside of level 2. When pallets in the extreme outer positions in the gravity outward flow order pick lanes 117 are exhausted, the pallets are moved and stacked on any one of the pallet return lanes indicated by the inward pointing arrows 147. The pallets are stacked in the outermost positions on the pallet return lanes, and stacks of pallets are released for gravity flow inward to innermost positions, where they are picked up by the rack entry vehicles 115 on the carriage 113 and returned to the empty pallet input lane 149. The stacks of empty pallets flow by gravity inward to a position 151, where the lowermost pallets in the stack are pushed by pushers 153 into the pallet loading positions 155. 
     Stacks of cases are pulled from pallets in the ends 119 of the order picking lanes 117 onto the order picking conveyors 121, 157, which carry the stacks forward into the accumulators 159. The stacks are controlled by gates 161 and directed by gates 163 onto the appropriate conveyors 165 and 167, where the stacks are stopped in front of the lowerators 168 and pushed onto the lowerators with the pushers 169 at the appropriate time for loading a truck. 
     FIG. 6 shows the first level 170. Empty pallets 137 are lowered into the bossie cart-pallet loading positions 127 by lowerators 123. Bossies 171 are pushed in pairs 173 onto the empty pallets 137, and the bossie cart-laden pallets are released to move under gravity to positions 175 on pallet conveyor 177. The pallet conveyor then carries the bossie-laden pallet to the bossie cart pallet infeed lane positions 178 and 179. The pallets are then selectively urged onto the gravitational infeed lanes 180 and 181 on the appropriate side, preferably by alternating the movement of the bossie-laden pallets from one side to the other. The pallets then move by gravity to positions 183, where they are picked up by rack entry vehicles 115 on carriages 113. Two bossie cart-laden pallets are carried to any storage location in the entire rack system. 
     At the appropriate time the bossie cart-laden pallets are retrieved and are carried to the parallel outflow lanes 185, which gravitationally feed inward. The bossie carts are elevated and released from the pallets. Individual bossie carts 171 are pulled onto the indexing bossie conveyor 187, which carries the bossie carts to positions in front of the pushers 189. The bossie carts are pushed along paths 188 to load the trucks. 
     Lowerators 168 position the stacks of cases which have been lowered from the second level in front of pushers 190. The stacks of cases are pushed along lines 192 into the trucks. The empty pallets 137 are stacked by a pallet stacker on the empty pallet lanes 191. When a stack of empty pallets is complete, it is released for flow outward to a position to be picked up by the rack entry vehicle. The carriage makes two stops to fill each vehicle 115 with a stack of empty racks. 
     Stacks of empty pallets are carried to the empty pallet movement lanes 193, shown in FIG. 7, on the third level for gravitational movement to the tops of the lowerators 123. The bottommost pallet is lowered into the pallet loading position 127 shown in FIG. 4. 
     FIGS. 8-12 are plan and cross-sectional views of the new pallet. 
     The new pallet is generally indicated by the numeral 200. Pallet 200 has a thick aluminum surface plate 201, elongated aluminum side tubes 203 which have a large rectangular cross-section, and cross tubes 205 which have a square cross-section. A central cross tube 207 has a rectangular cross-section similar to the cross-section of the side tubes 203. Wheel holes 209 have indented lips 211 for receiving the caster wheels 213 of bossie carts. Square cross-section support tubes 215 extend between the cross tubes along the openings 209. Short, square support tubes 217 extend along the wheel openings between the support tubes 215 and the side tubes 203. Rectangular support tubes 219 extend between the short, square support tubes 217 and the cross tubes 205. All of the tube intersections are welded. Two runners 221 extend under the side tubes 203. The tubes are heavy 1/4&#34; thick aluminum square and rectangular tubes. The runners are 1/8&#34; thick aluminum sheet, and the top is 0.090&#34; thick aluminum sheet. 
     As shown in FIG. 9, a ram 223 lifts the wheel 213 so that the bossie cart may be rolled off the top surface 201. The pallet is raised and lowered so that the top surface 201 is even with ground or conveyor level when rolling the bossies on and off the pallet. 
     The present automated facility preferably includes a computer-driven floor inventory management system. The inventory system preferably includes the following hardware: 
     
         ______________________________________Qty       Description______________________________________Server hardware:1         Hewlett-Packard model D200 computer, containing:     75 MHZ PA-RISC processor     256 KB cache     64 MB ECC memory     Dual 2.0 GB hard disk drives (mirrored)     CD-ROM drive     2.0 GB 4mm backup tape drive     16 RS-232 serial ports     Ethernet connection     Console terminalServer software:1         32-user HP-UX operating system license1         MirrrorDisk-UX disk mirroring software1         C compilerProgress Corporation Database/4GL software:32        Workgroup Server license5         Client PC networking license1         ProVision Application Development System (for     Windows)1         4GL Application Development System (for HP-UX)1         Report Builder license1         Report Server licenseClient PCs:3         Client PCS, each containing:     Pentium processor     8 MB RAM     500 MB disk drive     Ethernet connection     17&#34; monitor     Windows 95Radio data network:3         Norand model RB4030E base radio transceiver with     Ethernet link6         Norand model RT1740 radio data terminal6         Integrated barcode scanner for RT17403         High-gain antenna12        Nickel-metal-hydride battery (2-hour charge time)6         Battery charger1         Nonpowered fork-truck terminal mounting bracket6         Belt and carrying case1         Native server softwareOther inventory system peripherals:1         US Robotics high-speed telephone modem3         Hewlett-Packard LaserJet 4+ printer1         Uninterruptible power supply w/shutdown software9         Nematron industrial terminals (for fillers)1         8-port Ethernet ThinNet repeater15        Tapes for backup     All line drivers, cables, and connectors requiredCase detection stations at stackers:54        Photocells with termination boxes1         AB SLC remote I/O adapter     PLC rack, power supply, I/O modules, enclosures,     wireway, and other miscellaneous hardwareConveyor gate controller:1         Allen-Bradley SLC 5/03 processor1         Allen-Bradley Panelview 550 operator interface     terminal     PLC rack, power supply, I/O modules, enclosure,     relays, wireway, and other miscellaneous     hardware______________________________________ 
    
     Installation of conduit, power and communication cables, and 110VAC service for computers and peripherals is accomplished. 
     The two disk drives mirror each other. If one fails, the other automatically takes over. 
     A dedicated telephone line is available to the computer. This line is used to perform remote diagnostics and provide software support. This telephone line runs directly between the computer and the telephone company, bypassing any switchboards. 
     OPERATING SYSTEM AND DATABASE OVERVIEW 
     The computer system is delivered as a turnkey system. No knowledge of the operating system or programming language is required to operate the system. 
     The preferred operating system is HP-UX, and is purchased from Hewlett-Packard. Also included is TCP/IP and NFS networking software. 
     The database and application development system is Progress, and is purchased from Progress Software Corporation. 
     Preferably the programs are written in the fourth-generation programming language that is supplied with Progress. A portion of the S/R machine and conveyor communication system is written in C. A C compiler is included with the system. 
     The software architecture is a mixture of host-based and client-server computing. At the center is the Hewlett-Packard Unix server. The client PCs are connected to the server via an Ethernet network, and operate as remote clients. The radio data terminals are also connected to the server via the Ethernet network, using the Ethernet-based base radios, but operate as local clients. The industrial terminals at the fillers also operate as local clients. 
     SOFTWARE APPEARANCE AND OPERATION 
     The appearance of the screens is consistent throughout the application. Data entry and display preferably use the Microsoft Windows 95 graphical user interface on PCs, consistent with commonly-used Windows operational standards. Consistent use is made of the video characteristics available on the PCs and terminals such as color, underlining, blinking, and intensity control. Prompt lines and error messages always appear in the same places and manner on the screen. 
     All application software, including system administration software, is menu-driven. No knowledge of Unix command level operation is necessary. 
     Consistent use of function keys and defaults keep operator keystrokes to a minimum. 
     STARTING THE SYSTEM 
     A preferred embodiment of the present inventory management system is shown in FIG. 13. The system 301 can be configured to start automatically when the computer 303 is turned on. If the system shuts down abnormally, such as during a power failure, any partially-completed transactions are backed out automatically when the system restarts. 
     Once the system is started, users on PCs 305 can log in by double-clicking on the &#34;Inventory Management System&#34; icon. Users on radio terminals 307 or terminals 309 at the fillers 311 can log in by typing a system name at the Unix command-line prompt. 
     Logging in starts up the application at that PC or terminal, displaying a window where users type in their particular name and password before they have access to the main menu. 
     SECURITY 
     Security is enforced by password control while logging into the application. 
     An internal &#34;user table&#34; specifies the names of all users who can access the system. This table includes the names, passwords, and privileges of each user who is authorized to use the system. This table can be modified by the warehouse manager. Each application program can be turned &#34;on&#34; or &#34;off&#34; for individual users. 
     Passwords are encrypted within the database. Even if the encrypted passwords are discovered and displayed, they are of no value. 
     HOST COMMUNICATIONS 
     A thin-wire Ethernet network link 313 is included with the system. This link can connect the computer to a host computer (supplied by Owner). TCP/IP and NFS networking software is included with the system. The system can perform the following operations via the network: 
     1. Receive orders from the host computer. 
     2. Transmit shipments and inventory balances to the host computer. 
     3. Allow remote users to log into the system and operate the software as if they were using local terminals. 
     The file format for sending and receiving data will be agreed upon by the customer of the project. 
     If the network fails, data can be received and transmitted using 3.5&#34; floppy disks. 
     SOFTWARE OVERVIEW 
     For the following software definition additional detail and customization will be developed, ensuring that the final product is complete and well-suited to operation. 
     SKU DEFINITION 
     Products are defined in the &#34;SKU&#34; (stock-keeping unit) table. This table contains the following minimum data per product: 
     SKU Code 
     UPC code 
     Description 
     Units/Case 
     Cases/Stack 
     Cases/Pallet 
     Units/Bossie 
     Shelf Life, in days 
     LIFO (Last-In, First-Out) Toleration, in days 
     List Of Permitted Fillers 
     Picking Zone 
     SKU definitions can be created, modified, or deleted. SKUs cannot be deleted if there is any material of that type currently in inventory or on order. 
     INVENTORY DEFINITION 
     Inventory locations and contents are tracked in the floor picking area 321, the pallet rack area 323, and the bossie makeup area 325. 
     In the pallet rack 323, inventory is tracked by pallet 327. Each pallet has a location. Each pallet can contain multiple SKUs. Each SKU on a pallet has a SKU code, a quantity, and an expiration date. 
     In the floor picking area 321, inventory is tracked by location on the floor. The floor is divided up into storage zones 329, which can be of any size. Each storage zone can contain multiple SKUS. Each SKU in a zone has a zone code, a SKU code, a quantity, and an expiration date. Absolute location within a zone is not tracked, for convenience. 
     In the bossie makeup area 325, inventory is tracked by bossie 331. Each bossie has a SKU code and an expiration date. Absolute location within the bossie makeup area is not tracked, for convenience. 
     Inventory can be manually adjusted in any area, or can be manually moved from one area to another. Normally, such adjustments and movements are logged by radio unit 307 or automatically as products are received and picked. 
     RECEIVING PRODUCT FROM THE FILLERS 
     Each filler 311 is equipped with a sealed industrial terminal 309 which is connected to the Hewlett-Packard server 303. When a filler begins operation, or during a changeover, the filler operator enters the type of SKU and the expiration date code into the terminal. He can only choose from the approved SKUs 333 for that filler. For example, half-pints cannot be entered at a gallon filler. The computer suggests 335 an appropriate date code based on the type of SKU (current date plus the SKU&#39;s shelf life). 
     Filled products 337 are placed in cases 339, and the cases are stacked 341 six high by a stacker 343. 
     At the output of each stacker is a post 345 which contains six photocells 347. These photocells are connected 349 to a PLC (programmable logic controller) 351, which is in turn connected to the Hewlett-Packard server 303. Whenever a stack passes by the post 345, the PLC 351 detects the number of cases being produced, and sends a message 351 to the server which indicates the filler number and the number of cases. The server then creates a stack in inventory 353, based on the SKU being produced on that filler and the case quantity received from the PLC. 
     PULLING STACKS INTO STORAGE 
     The stacks move along roller conveyors 355 mounted in the floor. Configurations of the conveyors are called the floor loop 357. 
     After production, the stacks travel the floor loop 357 until pulled off 359 into storage by the pullers. 
     The storage zones 329 are identified by barcoded (and human-readable) labels 361 suspended from an overhead bar 363. The pullers decide in which storage zone 329 they wish to place each stack 341. When a stack is in position for storage, the puller pulls it off the conveyor and into the storage zone. He then identifies the product (by UPC code), case quantity, and storage zone using his terminal 307. The case quantity defaults to a full stack. The computer remembers the last several products, minimizing the need to scan each UPC code. The storage zone 329 is entered by scanning the barcode 361 on the overhead bar 363. 
     A group 365 of storage zones 329 is defined as a pick zone 367. Each SKU has a single defined pick zone. The computer verifies that the storage zone chosen is contained in the pick zone for that SKU. Additionally, the computer prohibits multiple expiration dates of the same SKU from sharing the same storage zone. 
     PALLET STORAGE 
     Some material 371 is received on pallets 373. When a pallet arrives, a receiving program 375 permits the pallet&#39;s material to be entered into inventory. A pallet may contain multiple SKUs, each having a quantity and expiration date. Each pallet position 377 in the rack 323 is identified with a barcoded (and human-readable) label 379. When a pallet is identified and stored, the receiver then scans the location label 379 to complete the transaction. 
     BOSSIE STORAGE 
     Some material is diverted 381 from the fillers 311 to a bossie makeup area 325. When a bossie 331 is made, a receiving program permits the bossie&#39;s material to be entered into inventory. Each bossie has a SKU, a quantity, and an expiration date. The RF-based bossie receiving program prompts for the UPC code, expiration date, and number of bossies (the default is one bossie). The computer suggests an appropriate date code based on the type of SKU (current date plus the SKU&#39;s shelf life). 
     ENTERING ORDERS 
     The system includes order-handling capabilities. Orders 383 can be received via the Ethernet connection, DOS-formatted floppy disks, or manual entry. The exact contents of orders are not known, and will be agreed upon during the design phase of the project. 
     Using the order editor program, orders can be created, modified, or deleted. Deletion of an order is preceded by a verification step. Orders can be scheduled and activated for picking. Orders can be unscheduled, if desired. 
     ORDER PICKING 
     Products are picked by pick zone 367. A pick zone is a path that an order picker walks while picking product. Each pick zone is a list of storage zones 329. 
     Multiple pick zones can be defined and modified. A pick zone may combine storage zones in multiple areas, such as the floor 385 and the pallet rack 323, if desired. 
     When an order picker begins picking, he tells the computer which pick zone he&#39;ll be working in. When orders are activated, the computer directs the order pickers along their pick zones, displaying the proper quantities for them to pick on their handheld RF data terminals 387. 
     Typically, an order-picking screen displays the following information: 
     Order number 
     SKU to pick 
     Quantity to pick (stacks/cases/units, or bossies) 
     Picking Location 
     The order-picking screen the prompts for the following information: 
     Quantity actually picked (stacks/cases/units, or bossies) 
     Actual Picking Location 
     All information is verified for suitability. 
     The computer knows the schedule of orders and each order picker&#39;s progress along the zone. After an order picker picks the desired quantities and places them on conveyor 389, he confirms the entry into the RF data terminal. The computer then directs him to the next pick location, and displays the next product and quantity to pick. If he picks the item short, he enters this into the RF data terminal. In any case, the computer immediately deducts the proper quantity from inventory and credits the order. 
     The computer minimizes the path that the order picker walks while picking. When an order picker begins picking an order, the computer locates all requests for the order which require product from that pick zone. It then searches for the storage zones of the oldest expiration date of each product, and sorts the final list by the picking path. 
     When the last item for an order has been picked, the computer automatically prints an Checker Report 391 on the printer 393 in the dock office. 
     PICKING FROM THE PALLET RACKS 
     Picking from the pallet racks 323 is done in a similar manner. The pallet positions 377, which can be picked from are assigned to a pick zone, and material which is picked is deducted from the pallet. 
     A &#34;Move Pallet&#34; transaction is supplied which facilitates moving a pallet from a storage position 377 in the pallet rack 23 to a picking position 395 or 397. 
     PICKING BOSSIES 
     Picking from the bossies is done in a similar manner. Instead of being prompted for stacks, cases, or units, however, the order picker is prompted for the number of bossies. 
     CHECKING AND SHIPPING ORDERS 
     Product which is picked passes by an order checker 399. The order checker is given a Checker Sheet 391 which lists all product for the order, grouped by pick zone. The order checker verifies that the quantities are correct, and then releases the product to the dock for loading onto the truck. The product is released via a PLC control screen 401 that is placed at the release gate 403. The order checker enters into this control screen the number of stacks to release. The PLC releases the specified number of stacks and then closes the gate, permitting the order checker to check another conveyor line while the stacks are traveling to the dock. The order checker determines the number of stacks to release by counting them as he checks them. 
     Palletized product 327 and bossies 331 also appear on the Checker Sheet, and can be checked at the order checker&#39;s convenience. 
     When all product for an order has been checked, the order checker steps into the dock office and uses one of the client PCs 405 to print a bill of lading. 
     ADJUSTMENTS TO INVENTORY 
     Adjustments to inventory can be entered at any client PC. That can be necessary when receiving returns or after taking a physical inventory. 
     ADJUSTMENTS TO ORDERS 
     Adjustments to orders can be entered at any client PC. That can be necessary when last-minute changes to orders are received. Inventory can be either added to an order or returned to stock. 
     Additions to an order can be received even while the order is being picked. The computer will, in real time, even direct an order picker to move backward along the pick zone to retrieve newly-requested material. 
     If an addition to an order is received after an order is picked, however, the order must be rescheduled. 
     HISTORICAL TRACKING 
     The system maintains the following historical information: 
     1. Receipts. 
     2. Adjustments to inventory. 
     3. Orders and shipments. 
     4. Order picking information. 
     5. Alarms. 
     Each of these is maintained for up to 400 days. 
     REPORTS 
     A variety of reports are included with the system. All reports can be directed to either the user&#39;s screen or a printer. Reports can be scheduled to run automatically at specified times and days of the week. The reports include: 
     Maintenance reports: 
     SKU Definitions 
     Storage Zones 
     Pick Zones 
     Current inventory reports: 
     Inventory Summary 
     Inventory By Location 
     Pallets By Product 
     Expired Inventory 
     Mixed Storage Zones 
     Mixed Pallets 
     Expected Shortages 
     Historical reports: 
     SKU Movement 
     Picking Activity By Zone 
     Picking Activity By Order 
     Shipments 
     Receipts 
     Daily Case Summary 
     Alarms 
     SYSTEM ADMINISTRATION 
     The system contains utilities for performing the following functions: 
     1. Starting up and shutting down the entire application, or individual programs within it. 
     2. Backing up the database to tape. 
     3. Restoring the database from tape. 
     4. Scheduling daily database backups to occur at a specified time. The system supports on-line backups of the database, permitting full 24-hour operation of the warehouse. 
     5. Accessing the database performance/resource monitor. 
     6. Monitoring the overall system performance. 
     These utilities are menu-driven, requiring no knowledge of the operating system. 
     Remaining system administration tasks are performed directly through the computer&#39;s operating system, using the programs supplied by the computer vendor. 
     While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention.