JPH058808A - Article warehousing/delivery method - Google Patents

Abstract

PURPOSE:To provide an article warehousing/delivery method to warehouse the same kind of articles so that a first in and first out system can be carried out easily as well as to deliver articles in order from the article which is warehoused first. CONSTITUTION:In the case when no preset article is stored in an automatic warehouse 10, or in the case when the same kind of article as those to be warehoused are stored only in No.1 rack 11, the article are warehoused preferentially in the No.1 rack 11, and in the case when the same kind of articles as those to be warehoused are also stored in No.2 and No.3 racks 12 and 13, the articles are determined to be warehoused in the common storage unit of the No.1 rack or in the No.2 and 3 racks 12 and 13.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a storage method and a storage method for storing and storing articles using storage facilities such as automatic warehouses, and in particular, dedicated storage for storing preset articles. The present invention relates to loading and unloading of articles by using a storage facility including a main storage facility having a department and a common storage unit for storing an arbitrary item, and an auxiliary storage facility having a common storage unit.

[0002]

2. Description of the Related Art Japanese Patent Publication No. 59-28481 and the like are known as prior arts concerning a method of storing and leaving articles. The conventional technique described above will be described in Japanese Patent Publication No. 59-284.
No. 81 gazette divides the luggage storage compartments of the three-dimensional storage shelf into a loading / unloading zone and an inventory zone, and uses a stacker crane during the idle time, such as nighttime when the loading / unloading work is stopped It describes a method of loading and unloading in a three-dimensional automated warehouse in which luggage is transferred between a zone and an inventory zone and then loaded and unloaded.

[0003]

However, the above-mentioned conventional techniques have the following problems.

That is, in the loading and unloading method in the three-dimensional automatic warehouse described in Japanese Patent Publication No. 59-28481, the luggage storage section group of the three-dimensional storage shelves is divided into a loading / unloading zone and an inventory zone.
It is possible to transfer goods from the stock zone to the combined storage / unloading zone for efficient loading and unloading, but with a dedicated storage unit for storing preset items and a common storage unit for storing arbitrary items. There is no description, and no suggestion, is made to store an article in a storage facility including a main storage facility having a storage unit and an auxiliary storage facility having a common storage unit, or to leave an item from the storage facility. Further, the above-mentioned publication is a technical disclosure for efficiently loading and unloading articles in one storage facility, and there is no problem in the case where articles of the same type are loaded in order from the one loaded first (first-in first-out method), There is no description and no suggestion of first-in first-out when articles are taken out from only one of the plurality of storage facilities.

Therefore, it is an object of the present invention to use a storage facility having a main storage facility having a dedicated storage unit and a common storage unit and an auxiliary storage facility having a common storage unit to easily first-in first-out products of the same type. Thus, it is to provide a warehousing and unloading method for warehousing as described above and for warehousing in order from the first warehousing.

[0006]

The present invention according to claim 1 provides a main storage facility (No. 1 rack) for storing pre-registered articles (PFC registered articles) and an auxiliary storage facility (No. 2/3). A storage method (goods storage) for storing goods in a storage facility (automatic warehouse) equipped with a rack), in which the above-mentioned registered goods are stored in the main storage facility.
Are stored so that a certain amount of each of the registered articles is secured.

The present invention according to claim 2 is the method of the present invention according to claim 1, wherein the main storage facility further stores a dedicated storage section for storing the registered articles and the registered articles or other items. And a common storage unit for storing the articles, and the auxiliary storage facility has a common storage unit.

The present invention according to claim 3 is the method according to the present invention according to claim 2, wherein the goods to be stored are the registered goods and are not in stock in the storage facility, or If the goods are stored only in the main storage facility, the above-mentioned goods are preferentially received into the above-mentioned main storage equipment, and the goods to be received are the above-mentioned registered goods and also exist in the above-mentioned auxiliary storage equipment. Is to store the article in the common storage unit of the main storage facility or the auxiliary storage facility.

The present invention according to claim 4 provides the invention according to claims 1 to 3.
In the method of the present invention according to any one of the items 1 to 3, the main storage facility further has a dedicated outlet (PFC) for delivering the pre-registered article.

According to a fifth aspect of the present invention, a main storage facility having a dedicated storage unit for storing pre-registered items and a common storage unit for storing arbitrary items, and an auxiliary storage facility having the common storage unit In the method of issuing an article to issue an article from a storage facility comprising: an article of the same type that has been stored before the article stored in the common storage section of the main storage facility is in the auxiliary storage facility, and If there is free space in the dedicated storage section of the main storage facility, the same type of goods in the auxiliary storage facility should be transferred to the dedicated storage section of the main storage facility and then delivered. Is.

According to a sixth aspect of the present invention, there is provided a method of moving an article between a main storage facility having a dedicated outlet for storing a pre-registered article and an auxiliary storage facility. When there is a vacancy in the dedicated storage section of the storage facility, if the oldest storage item (the date it was stored) is in the auxiliary storage facility, move the oldest item to the dedicated storage section of the main storage facility. It was done.

[0012]

According to the method of loading and unloading articles of the present invention, the same type of product can be obtained by using the storage facility including the main storage facility having the dedicated storage unit and the common storage unit, and the auxiliary storage facility having the common storage unit. It is easy to put in the goods in the first-in first-out manner, and the goods that have been first received are delivered in order.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a layout drawing showing the layout of the first floor of a distribution center having an automated warehouse (storage facility) to which the present invention is applied, FIG. 2 is a layout drawing showing the layout of the second floor and third floor, and FIG. 3 is the present invention. FIG. 4 is a block diagram showing a control system of the physical distribution system, FIG. 5 is a schematic diagram showing a storage frame of an automatic warehouse, FIG. 6 is a flow chart showing a storage process flow, and FIG. 7 is an overflow. 9 is a flow chart showing a calculation processing flow, FIG. 8 is a flow chart showing a warehousing setting processing flow, and FIG.
6 is a flowchart showing an automatic inventory transfer processing flow.

(Automatic Warehouse) The automatic warehouse 10 has a first rack 11 having racks each having a plurality of stages and a plurality of rows.
(Main storage equipment) No. 2 and No. 3 racks 12, 13 (auxiliary storage equipment) are arranged in parallel, and each rack 11, 12, 13
An individual stacker crane 14 is attached to each of the above.

Description of first floor layout (see FIG. 1) The warehouse building 101 adjacent to the automated warehouse 10 is a three-story building, and the automated warehouse 10 and the warehouse building 101 form a distribution center 10.
0 is configured. On the first floor of the warehouse building 101, a loading / unloading conveyor 15 for transferring the articles loaded on the pallets and stored in the carton to and from the forklift, and a loading / unloading section for delivering the articles to the stacker cranes 14 of the racks 11 to 13. A conveyor 16, a delivery conveyor 17 that receives articles from the stacker cranes 14 of the racks 11 to 13, and a traverser 18 that transfers articles between the branch ends of the loading / unloading conveyor 15 and all the conveyors 16 and 17 are installed.

On the first floor, 23 independent pallet flow conveyors (PFC) 19 for each of the 23 product types are provided for picking and picking 23 A-managed products to be described later.
(A controlled product picking equipment) is installed.

In addition, on the first floor, a pallet rack 20 (BC managed product picking equipment) is divided for each type of BC managed product in order to pick a BC managed product to be described later.
Is installed.

Further, on the first floor, a packing area 21 is set.

Description of the layout of the second and third floors (see FIG. 2) The layout of the second and third floors of the warehouse building 101 is the same.
On the 2nd and 3rd floors, a loading / unloading conveyor 22 and a loading / unloading conveyor 22 for transferring articles to / from a forklift.
To the stacker crane 14 of each rack 11 to 13 to transfer the articles from the stacker crane 14 of each rack 11 to 13 to the loading / unloading conveyor 22 to transfer the articles to the loading / unloading conveyor 22 and the loading / unloading conveyor 22. A traverser 25 for transferring articles between the conveyors 23, 24 is installed.

On the second and third floors, an overflow area 26 (another storage means) for storing overflow products, which will be described later, is set.

(Physical Distribution System and Control System) Physical distribution system using the automated warehouse 10 (see FIG. 3) A specified number of articles in the container received by the truck or the like at the distribution center 100 are placed for each product type. In particular, it is possible to configure a pallet of a unit that is full, and the pallets are stored in the racks 11 to 13 of the automated warehouse 10 in units of the full pallet.

In this embodiment, there is only one type of packing for a full pallet. For example, the pallet packing is divided into tall ones (high loads) and low ones (low loads), and the automatic warehouse 10 is used.
Two types of racks may be prepared for each load.

The articles stored in the automated warehouse 10 are stored in any of the racks 11 to 13 or the overflow area 2 in accordance with the "automatic warehouse control concept" described later.
Stored in 6. The articles stored in the overflow area 26 are then re-stored in the racks 11 to 13.

Then, the racks 11 to 13 of the automated warehouse 10
Among the goods stored in, the A controlled products are directly delivered to the pallet flow conveyor 19 in the full pallet unit by the stacker crane 14 of the No. 1 rack 11 and picked in carton units from the pallet flow conveyor 19 and the BC controlled products are The stacker cranes 14 and 14 of the No. 2 rack 12 and No. 3 rack 13 leave the pallet in a full pallet unit through the delivery conveyor 17, the traverser 18, and the loading / unloading conveyor 15, and are supplied to the pallet rack 20 by the forklift, and then the pallet. Picked from the rack 20 in carton units. The picked A managed product and the BC managed product are shipped by a truck or the like through the packing area 21.

Control System of Automatic Warehouse 10 (See FIG. 4) The control system of the automatic warehouse 10 is composed of a host CPU 31, a physical distribution CPU 32, and a control CPU 33.

The host CPU 31 performs business information processing by transmitting order information data to the physical distribution CPU 32 and receiving delivery results from the physical distribution CPU 32.

The physical distribution CPU 32 transmits arrival schedule data, article code, etc. to the control CPU 33, and the control CPU 33
By receiving the warehousing performance data, inventory data, etc. from 33, a warehousing schedule plan, a picking plan, and a replenishment plan are created.

The control CPU 33 uses the key board of the control CPU 33, the first floor entry setting terminal, the second floor re-entry terminal, and the third floor re-entry terminal to carry out the articles in and out of the racks 11 to 13 by the conveyor controller 34. Controls the conveyors 15, 16, 17, 22, 23, 24 and the traversers 18, 25, and the crane controller 35 controls the stacker cranes 14.

(Concept of control of automated warehouse) Storage frame of automated warehouse 10 (see FIG. 5) The automated warehouse 10 uses the No. 1 rack 11 as main storage equipment,
The No. 2 and No. 3 racks 12 and 13 are used as auxiliary storage facilities.

The No. 1 rack 11 is an A-managed product-dedicated storage unit dedicated to each A-managed product (PFC-registered product) stored on the pallet flow conveyor 19 and a A-managed product. If so, A can store any variety
It has a common storage section for managed items.

The No. 2 and 3 racks 12 and 13 store a BC managed product common storage unit capable of storing any BC managed product, and any ABC managed product. And an ABC managed product common storage unit.

In the present embodiment, the top 23 products from the ones with the largest shipments are A-managed products, and the other products are BC-managed products. Generally, A-managed products are products with the cumulative shipment quantity from the higher-ranking products arranged up to 80% of the total, and B-managed goods are those with the cumulative shipment quantity of the remaining 15%. , C controlled products are the lower 5% of products.

Here, the number of storage frames of each managed product in the automatic warehouse 10 is determined in consideration of the minimum storage quantity of each product in the automatic warehouse 10. Minimum required storage quantity is 1
This is a quantity that is sufficient for the shipment quantity per day or one day.

Overflow processing When there is an incoming quantity exceeding the total number of racks in the automated warehouse 10, some types of A managed products and BC managed products are limited and overflowed into the overflow area 26 on the second or third floor. .

The overflow processing is specifically
This is performed by the flow of FIGS. 7 and 8 described later.

Automatic warehouse priority storage of BC managed products No. 2 and 3 racks 12 and 13 are shared with a BC managed product common storage unit.
Although the BC managed product common storage unit is provided, the ABC managed product common storage unit can preferentially store BC managed products that are stored in excess of the number of storage frames of the BC managed product common storage unit. This is because it is necessary to store all the BC managed products in the No. 2 and 3 racks, so that the A managed products cannot be stored in the BC managed product common storage unit. In addition, many kinds of BC
If the managed products overflow, the product type setting for re-stocking will occur frequently and it will be troublesome in operation. Therefore, as a general rule, store the BC managed products in the rack and use the A managed products that have few types and are easy to manage. It overflows.

The minimum inventory of the No. 1 rack of the A-managed products and the automatic inventory movement The respective varieties of the A-managed products are sequentially replenished and delivered to the pallet flow conveyors 19 provided for the respective varieties along the No. 1 rack 11. It Therefore, it is necessary to store a fixed amount of all the A-managed products in the No. 1 rack 11 at all times. For this reason, the A-managed product frame (dedicated storage unit) is set to 1
For example, 10 pallets (10 shelves) per item in No. rack 11
All other storage units (shelf) of the No. 1 rack 11 are designated as A managed common storage units as described above.
The managed items are allowed to be stored. Then, when the number of stored items in No. 1 rack 11 of a product with A management products is only 4 pallets, the inventory is automatically transferred from No. 2 and No. 3 racks 12, 13 to No. 1 rack 11 in units of 6 pallets.

Here, it is the maximum quantity (estimated value or measured value) of the shipment quantity of one time or one day that the dedicated storage section of the A controlled product is set to 10 pallets per kind, as described above.
The pallet is the average quantity (actual value) of the shipment quantity of one time or one day or the quantity that does not run out of stock before the inventory is moved from the No. 2 and No. 3 racks 12 and 13.

Also, the movement in units of 6 pallets is 2
・ Outgoing conveyors 17 and 24 (2 racks 12 and 13 (2
This is because the amount of pallets that can be stored at one time on the pallets x 2 lines) and the storage conveyors 16 and 23 (2 pallets) of the No. 1 rack 11 are stored.

The automatic inventory movement is specifically performed by the flow of FIG. 9 described later.

Inventory Management Method The inventory management of the articles stored in the racks 11 to 13 of the automatic warehouse 10 is carried out on a first-in, first-out basis (on the basis of the date of receipt in the automatic warehouse 10) in units of lots on the receipt date. The quality of each item is maintained.

Crane loading / unloading priority processing The loading / unloading function of the stacker crane 14 in each of the racks 11 to 13 is as follows: (a) Pallet flow conveyor 1 for A controlled products
9), (b) A-managed products, BC-managed products to the overflow area 26, and BC-managed products to the pallet rack 20, (c) A-managed products' automatic inventory transfer, (d) A
There are functions of new storage of managed products and BC managed products, and restocking from the overflow area 26.

In the present embodiment, if the stacker crane 14 services each work evenly, each work will be delayed, so that the number of processing lots is limited and the centralized processing is performed from the highest priority. . That is, the priority order shall be lower in the order of (a) → (b) → (c) → (d), and the number of processed lots shall be 1 pallet for (a) and 1 lot for (b). There are 10 pallets, 6 pallets for (c) and 1 pallet for (d).

(Specific Example of Physical Distribution Processing) (1) Storage Processing (See FIG. 6) The storage processing of the goods in the automated warehouse 10 is performed as follows, for example.

The control CPU 33 receives the arrival schedule data (container code, article name, quantity) from the physical distribution CPU 32, for example, by the day before the arrival, and writes this in the warehousing schedule file.

When the operator starts up the control CPU 33 before the start of storage (the morning of the day), the control CPU 33 enters the overflow calculation process of FIG.
Perform overflow calculation for each managed product and create an overflow list.

The operator determines the articles to be overflowed, the quantity, etc. on the basis of the above-mentioned overflow list, and registers and sets the overflow articles in the control CPU 33. The control CPU 33 writes this overflow registration data (container code, article name, quantity, overflow area floor) in the scheduled storage file.

The operator makes the following storage settings (a) and (b) for the control CPU 33 based on the scheduled storage file written in the control CPU 33.

(A) By operating the first floor warehousing setting terminal of the control CPU 33, the "planned warehousing menu screen" is opened, and the container code for warehousing is entered and the "menu screen for each container" is opened. On this "container-specific menu screen", the names of articles and the number of cartons contained in the container are displayed.

(B) If the pallet packing of the article to be stored in (a) above is a full pallet (a pallet on which a prescribed number of cartons of articles are loaded), enter the article name and the number of pallets.

On the other hand, if the pallet packing of the goods to be stored in (a) above is a fractional pallet (a pallet that does not reach the specified number of cartons for a full pallet), the name of the article and the number of cartons are input, and then automatically. It should be stored outside the rack and overflow area of the warehouse 10.

In the automatic warehouse 10, even if the quantity actually carried in is larger than the planned quantity to be stored, or the article actually carried in is not scheduled, it can be stored. Further, since the expected arrival quantity and the record of receipt are displayed on the first floor receipt setting terminal, the operator can perform the receipt inspection based on the receipt schedule information and the receipt record information.

With the above-mentioned storage setting, the control CPU 3
3 enters the warehousing setting process of FIG. 8 described later, and drives the conveyor control device 34 and the crane control device 35.

At this time, the control CPU 33 executes the following (a)-
Carry out control of (d).

(A) In response to a branch request signal indicating that the pallet has reached the branch end of the loading / unloading conveyor 15, the stacker crane 14 of any of the racks 11 to 13 is allocated as follows.

The A controlled product is preferentially allocated to the stacker crane 14 of the No. 1 rack 11, and the BC managed product is allocated to only the stacker crane 14 of the No. 2 and 3 racks 12 and 13.
However, one of the stacker cranes 14 is down, and the storage conveyors 16, 2 corresponding to the stacker crane 14 concerned.
3 failure or full, or the stacker crane 14 concerned
When the rack corresponding to No. 1 is full, another empty stacker crane 14 is reserved.

(B) Inventory of A controlled product is rack No. 1 and 2
Not in 2, 13 but 10 in stock for the corresponding product in rack No. 11.
If the number of pallets is less than the number of pallets (including the case where the number of stocks is 0), the pallets wait for allocation to the No. 1 rack 11. In other words, the type with A-controlled products is rack No. 2 and rack 1.
Not in 2, 13 and 10 pallets in the same rack in No. 1 rack 11 (less than the number of dedicated storage frames for A-managed products)
In this case, even if the products are stored in the No. 2 and No. 3 racks 12 and 13, the movement command to the No. 1 rack 11 is immediately applied.
The stacker crane 14 of the rack No. 11 is in a standby state or waits for the warehousing conveyor 16 of the rack No. 11 to become empty.

The BC controlled products are the No. 2 and No. 3 racks 12 and 13.
To evenly stock the product. In other words, for the BC controlled product, the same product type is used for the No. 2 and No. 3 racks 12 and 13 so that the shipping work does not stop even if one of the stacker cranes 14 of the No. 2 and No. 3 racks 12 and 13 goes down. Stock in equal amounts.

(C) The control CPU 33 allocates (searches) shelves from the empty shelves near the loading station of the storage conveyor 16 (the leading end conveyor of the storage conveyor 16) for the stored goods in the rack, and outputs an operation command to the stacker crane 14. To do.

If the pallet flow conveyor 19 is out of stock when the A-managed product is stored in the No. 1 rack 11, it is directly delivered to the pallet flow conveyor 19.

(D) For the overflow product, the control CPU 33 confirms the establishment of the conveyor shipping operation condition on the overflow area floor, and outputs the operation command of the stacker crane 14.

When the overflow sub-conveyors on the 2nd and 3rd floors are filled with overflow products, the stacker crane 14
Since the operation command cannot be output to, wait as it is.

When the second floor and the third floor are being used as a re-stocking line for overflow products, the stocking work may be stopped and overflowing may be performed after the setting contents are processed.

The receipt record data (container code, article name, number of receipt records for each storage location) of the completed container is stored in the floppy disk (F) from the memory of the control CPU 33.
D) is written and sent to the physical distribution CPU 32. Logistics CP
U32 updates the inventory based on the receipt result data.

(2) Overflow calculation process (see FIG. 7) The above-described overflow calculation process and overflow item setting registration in the above (1) warehousing process are performed as follows.

First, in step S1, the number of empty shelves (rack with no articles) in the A management article dedicated storage section of the first rack 11 is calculated. That is, the number of products (number of actual shelves) in the dedicated storage unit of the No. 1 rack 11 is checked for each A-managed product, and the number of empty shelves in the dedicated storage unit of the No. 1 rack 11 is obtained for each product type. Then, the number of empty shelves obtained as described above is totaled to obtain the number of empty shelves in the dedicated storage section of the first rack 11. Then, the total number of empty shelves obtained as described above is summed, and the first rack 1
The number of empty shelves in the dedicated storage unit 1 (total number of empty shelves in the dedicated storage unit) is obtained.

Subsequently, in step S2, the number of empty shelves in the A-managed product common storage section of the first rack 11 is determined as follows.

That is, the total number of empty shelves in the No. 1 rack 11 dedicated storage section for A-managed items and the common storage section for A-managed items (total rack number for No. 1 rack) is checked from the empty rack file, and total empty rack for No. 1 rack is checked. It is calculated by subtracting the total number of empty shelves for exclusive use of the A controlled product obtained as described above from the number.

In step S3, it is judged whether or not there is an arrival today (whether or not there is a scheduled arrival data), and if there is, an expected arrival number is summed for each A-managed product and BC-managed product (step S3-1). If not, the planned arrival number is set to 0 (step S3-2), and the process proceeds to step S4.

In step S4, the number of BC managed products that should overflow is calculated.

The quantity of BC managed goods that cannot be filled in the empty racks of the No. 2 and 3 racks 12 and 13 is set as the quantity to be overflowed. If there is no quantity to overflow and all BC managed products are stored, if there are empty shelves in the BC managed product common storage section, the number of empty shelves will be used as the rack allowance for BC managed products.
Re-stocking of overflows of C controlled products is possible. Less than,
The details will be described.

First, from the planned arrival quantity of BC controlled products,
If the value obtained by subtracting the number of empty shelves of No. 3 racks 12 and 13 is a positive number, all or some of the BC controlled products are No. 2 and 3 racks 1.
This means that there are no empty shelves to be stored in Nos. 2 and 13, and the value of the difference is taken as the overflow number of BC managed products. In this case, the number of A-managed products that can be stored in the No. 2 and No. 3 racks 12 and 13 (possible storage amount) is zero.

If the value obtained by subtracting the number of empty shelves of No. 2 and No. 3 racks from the planned quantity of BC controlled goods received is 0 or a negative value, B
With the number of overflows of C controlled products as 0, the number of surplus racks for storing BC managed products is calculated. That is, the number of spare racks for storing BC managed products (the number of BC managed product racks)
Is based on the number of BC controlled product storage frames (the number of shelves in the BC managed product common storage section), and the current number of BC managed products in the No. 2 and 3 racks and the BC.
Calculate by subtracting the planned arrival number of managed products.

If the BC management product rack surplus number is a negative value, the BC management product rack surplus number is set to 0, and the number of A management products that can be stored in the No. 2.3 racks 12 and 13 is calculated.
If it is 0 or a positive value, the number of racks for BC managed products is used as it is, and the No. 2 and 3 racks 12, 1 for A managed products are used.
Calculate the number of items that can be stored in 3.

The number of A-managed products that can be stored in the No. 2 and No. 3 racks 12 and 13 is determined by the number of empty shelves in the No. 2 and No. 3 racks 12 and 13 from the expected number of BC-managed products to be received and the number of BC-managed product rack margins. Pull and ask. The above contents are shown below as equations (1) and (2).

BC managed product rack surplus number = Number of BC managed product storage frames-Number of BC managed product inventory-Number of expected BC managed product arrivals (1) Number of A managed products that can be stored in the No. 2 and 3 racks = Number of empty racks of No. 2 and 3 racks-Number of BC controlled products to be received-Number of BC managed product rack margins (2) When BC managed product rack margin number <0 → BC managed product rack margin number = 0 BC management When the number of spare parts in the rack is ≧ 0 → B obtained from Eq. (1)
Use the number of racks for C controlled products.

If the BC management product overflows, the A management product cannot be stored in the No. 2 and No. 3 racks 12 and 13. If there are empty shelves in the common storage area for ABC managed goods even if all BC managed goods are stored, the number of empty shelves is 2 for A managed goods.
It is the number that can be stored in the No. 3 rack. Then, if the number of A-managed products that are expected to arrive is greater than the total number of A-managed products that can be stored in the No. 2 and 3 racks and the number of empty shelves in the A-managed product common storage unit, overflow the A-managed products. Re-stocking of overflow products is possible. In step S5, the number of overflows of the A-managed product is calculated by the following procedure.

The overflow number is the number of A-managed products that can be stored in the No. 2 and No. 3 racks and the number of empty shelves in the common storage section of the No. 1 rack, which is obtained from the planned arrival quantity of the A-managed products (step S4). To obtain. If the number of overflows is a positive number (there is no empty shelf to store all or some of the A-managed products), the number of racks that can store A-managed products (the number of racks available for all 1, 2, and 3 racks) Is set to 0 and the overflow number is 0 or a negative value, the overflow number is set to 0 (no need for overflow) and the rack margin number of the A-managed product is obtained. The number of spare racks for A-managed products is calculated from the sum of the number of A-managed products that can be stored in No. 2 and No. 3 racks obtained in step S4 and the number of empty shelves in the common storage section of No. 1 rack. To obtain.

In step S6, a BC managed product or A
Whether or not the managed product needs to overflow is determined by checking the presence or absence of the overflow number obtained in step S4 and step S5. If there is an overflow number, an overflow list is output (step S6-
1) If there is not, "No overflow" is displayed on the screen of the control CPU 33 (step S6-
2).

The contents of the overflow list include the number of overflows, the types of goods to be received and the quantity to be received, and the amount of inventory of each kind in the automated warehouse. The operator determines the articles to be overflowed, the quantity, and the like based on the overflow list, and sets and registers the overflow articles.

At this time, when the overflow setting is performed, the operator should limit the number of products to be stored in all racks of the automatic warehouse 10 to a part of the products rather than overflowing all or most of the products to be stored. There are the following advantages in operation.

(A) The number of overflow product types may be set small.

(B) The frequency of restocking of overflow products may be low.

Therefore, it is preferable to set the same product type as the product that has overflowed the previous time or already (the product that is in stock in the overflow area 26) as the product to be overflowed this time.

When overflow setting is performed,
It is preferable that the operator sets items that are not required for the time being to be stored in the overflow area 26, and that necessary items (items with a small inventory) be stored in the racks 11 to 13 preferentially.

In steps S7 to S9, the planned arrival quantity is smaller than the stockable quantity and the overflow area 26
If there is any article in the above, the number of the above-mentioned articles stored in the above-mentioned overflow area 26 that can be stored in each rack 11 to 13 is calculated, and an overflow re-stocking list is output.

That is, it is always checked whether or not there is an article in the overflow area 26, and if there is no article, the processing ends, and if there is, it is determined whether or not there is a rack margin number.

If there is a rack surplus number, the overflow restocking list is output, and if not, the process ends.

The contents of the overflow re-entry list are the rack surplus number, the overflow area stock type, the quantity and the location of the overflow area, and the automatic warehouse stock quantity,
For example, the date of receipt

The operator determines the articles to be re-stocked, the quantity, etc. based on the overflow re-stocking list, and sets the re-stocking of the overflowed articles from the re-stocking setting terminal provided on the floor of the corresponding overflow area.

At this time, when the overflow re-entry setting is performed, the operator leaves the articles that are not necessary for the time being in the overflow area 26 and preferentially stores the necessary articles (items with a small inventory) into the racks 11 to 13. It is preferable to set.

(3) Goods Receipt Setting Process (See FIG. 8) In the aforementioned (1) Goods Receipt Process, the aforementioned goods receipt setting process is performed as follows.

The pallet arrives at the branch end of the loading / unloading conveyor 15 which receives the loading instruction data (step S
1) and the following processing is performed to determine the receiving destination.

In step S2, it is determined whether or not the article should overflow (the article for which overflow is set). If it is an overflow product, step S10
Then, the stacker crane 14 to be used is determined (the stacker crane 14 to be used is determined to be the one that is not in operation, the one that has few operation reservations, etc.). If it is not an overflow product, the process proceeds to step S3.

In step S3, it is determined whether the stored product is an A-managed product. If it is not an A controlled product, step S9
Proceed to and decide to store in the No. 2 and No. 3 racks 12 and 13. If it is an A controlled product, the process proceeds to step S4.

In step S4, it is determined whether the same stocked goods are in stock in the No. 2 and No. 3 racks 12 and 13, and if there are stocks in the No. 2 and No. 3 racks 12 and 13, the process proceeds to step S6. If there is no stock, the process proceeds to step S5.

In step S5, rack No. 1 11
Is less than the required number of shelves (10 racks per product type in this embodiment as described above) in the A-managed product dedicated storage section of the first rack, and if less than the required number of shelves, step S
The process proceeds to 7 and it is decided to store the No. 1 rack 11 in the storage section dedicated to the A controlled product. If the number of shelves is equal to or larger than the required number, the process proceeds to step S6.

At step S6, A of rack No. 1 11
It is determined whether or not there is an empty shelf in the managed article common storage unit, and if not, the process proceeds to step S9, and if there is, to step S8.

At step S8, A of rack No. 1 11
It is decided to store in the managed goods common storage section.

As described above, step S7, step S
When the storage location is determined in each of 8, step S9, and step S10, the control CPU 3 in step S11.
3 outputs a warehousing command to the conveyor controller 34, and the warehousing goods are designated as warehousing locations (No. 1 rack 11, No. 2 rack 1).
Start toward the racks 11 to 13) where the stacker cranes 14 used for moving to the No. 2 and No. 3 racks 13 or the overflow area 26 exist.

The pallet to which the warehousing instruction is output in step S11 is conveyed to the loading station of the designated warehousing conveyor 16. When the pallet arrives at the loading station, the control CPU 33 determines the receiving shelf and outputs the crane operation data to the crane controller 35, and the control CPU 33 updates the inventory file and the shelf file (step S12).

The stacker crane 14 puts the pallets on the loading station into the designated shelves or puts them out to the designated overflow floor.

(4) Outgoing process for BC managed product An outbound process for replenishing the pallet rack 20 with a BC managed product is performed as follows, for example.

The operator controls the control CPU 3 based on the delivery instruction list output (printed) from the physical distribution CPU 32.
The delivery setting is made according to 3.

The control CPU 33 checks the inventory of the No. 2 and No. 3 racks 12 and 13 of the automatic warehouse 10 when the delivery is set, and if the inventory is insufficient, displays a shortage alarm on the screen.

The control CPU 33 writes the delivery setting data (delivery floor, article name, number of pallets) in the delivery setting file.

The control CPU 33 is the conveyor control device 3
4. Control the crane controller 35 to execute the above-mentioned shipping setting data. At this time, the control CPU 33 reserves the stacker crane 14 attached to the rack storing the oldest storage date pallet for each storage date lot. When the oldest storage date pallets are in a plurality of racks, the empty stacker crane 14 is reserved.

(5) Outgoing Processing of A-Managed Articles Outgoing processing for replenishing the pallet flow conveyor 19 with A-managed articles is performed as follows, for example.

When the control CPU 33 detects that the A-managed product is empty in the pallet flow conveyor 19, it allocates the rack of the oldest storage pallet in the first rack 11 and issues an operation command for the stacker crane 14 to the crane controller 35. Output.

When the number of pallets on the oldest storage day in the No. 1 rack 11 becomes 4 pallets, the control CPU 33 will
6 if the oldest storage date pallet is in racks 3 and 4
For each pallet, the No. 2 and No. 3 racks 12 of the pallet,
An inventory transfer plan file from 13 to the No. 1 rack 11 is created.

As a general rule, the conveyor used when moving the A-managed products stored in the No. 2 and No. 3 racks 12 and 13 to the No. 1 rack 11 is the one arranged on the second floor. If the one on the second floor is in the shipping operation, the one on the third floor is used.

Here, the above-mentioned automatic inventory movement is performed as follows (see FIG. 9).

In step S1, if the pallet flow conveyor 19 is unloaded and the pallet flow conveyor 19 detects an empty load (empty detection), the process proceeds to step S2. Repeat S1.

At step S2, the control CPU 33
Examines the articles registered there from the pallet flow conveyor 19 for which there was an empty detection,
Pallet flow conveyor 1
In order to carry out the goods to 9, the shelving location is given to the crane controller 35, and a goods issue instruction is outputted.
Takes out the instructed article.

The control CPU 33 updates that the contents of the shelf location for which the delivery instruction has been issued is an empty shelf with an empty shelf file, and A of the first rack 11 is stored in the A managed product common storage section of the first rack 11. It is checked whether or not there is a cargo stored in the storage section for exclusive use of managed products that has been stored on the same day as the one stored on the latest day (step S3).

If step S3 is affirmative, the process proceeds to step S4, and the data is moved from the A-managed product common storage section of the No. 1 rack 11 to the A-managed product dedicated storage section of the No. 1 rack 11 (the shelves being stored). The location remains the same).

If step S3 is negative, the process proceeds to step S5, where the loads stored in the A-managed product common storage section of the No. 1 rack 11 are stored in the ABC-managed product common storage section of the No. 2 and 3 racks 12 and 13. Check to see if there was one that was put in first. If not, the process proceeds to step S4, and the one that is stored next to the latest storage date in the A managed product dedicated storage unit of the No. 1 rack 11 from the A managed product common storage unit of the No. 1 rack 11 Move to the storage area dedicated to managed items (moving only data).

In step S5, the No. 1 rack 11 is stored in the ABC controlled product common storage section of the No. 2 and No. 3 racks 12 and 13.
If there is a product that has been stored before the load stored in the A-managed product common storage section, the process proceeds to step S6, and the articles are moved from the No. 2 and No. 3 racks 12 and 13 to the No. 1 rack 11. That is, after the control CPU 33 automatically designates the conveyor to be used for movement (the conveyor on the second floor has priority, and if the conveyor on the second floor is working, the conveyor on the third floor is selected), and then the control CPU 33 moves the inventory. 2.3 by instructing
The corresponding articles stored in the ABC managed product common storage unit of racks Nos. 12 and 13 are unloaded and stored in the A managed product dedicated storage unit of rack No. 11. In this case, A of rack 1
Even if the product is stored in the managed goods storage, it will not be updated again. That is, the warehousing date is the day when the warehousing was first performed via the automated warehouse 10, and is the same.

It should be noted that although the movement of each pallet is described in step S6, the present invention is not limited to this embodiment, and in the case of "YES" in step S5, a plurality of pallets may be moved simultaneously. For example, if the empty shelves for 6 pallets are not moved until the A management product dedicated storage section of the No. 1 rack 11 is moved, and 6 pallets are moved simultaneously when 6 pallets are generated, conveyors can be operated simultaneously for multiple pallets, etc. , Work efficiency is improved.

In the automatic warehouse 10, the control CP
U33 is based on the warehousing information and warehousing information in each of the racks 11 to 13 and the overflow area 26,
The inventory files in each of these storage locations are constantly updated and grasped.

Further, in the automated warehouse 10, the common storage section of the No. 1 rack 11 may store the A-managed products or the products other than the A-managed products.

According to the article loading and unloading method according to the above-described embodiment, the No. 1 rack 11 (main storage facility) having the A-managed product dedicated storage part and the A-managed product common storage part, and the ABC-managed product common storage part. Automated warehouse 10 (storage facility 10) equipped with No. 2 and 3 racks 12 and 13 (auxiliary storage facility)
Using, the articles of the same type (A-managed article) can be put in first and put in easily so that the goods can be put in first, and the goods can be put out in order from the first article.

[0123]

As described above, according to the method of loading and unloading articles of the present invention, the storage provided with the main storage facility having the dedicated storage unit and the common storage unit and the auxiliary storage facility having the common storage unit. By using the facility, it is possible to store articles of the same type in a first-in, first-out manner so that the articles can be stored in order from the first-stored article.

[Brief description of drawings]

FIG. 1 is a layout diagram showing a first floor layout of a distribution center having an automatic warehouse (storage facility) to which the present invention is applied.

FIG. 2 is a layout diagram showing a second floor and third floor layout.

FIG. 3 is a flowchart showing a physical distribution system to which the present invention is applied.

FIG. 4 is a block diagram showing a control system of a physical distribution system.

FIG. 5 is a schematic diagram showing a storage frame of an automated warehouse.

FIG. 6 is a flowchart showing a warehousing process flow.

FIG. 7 is a flowchart showing an overflow calculation processing flow.

FIG. 8 is a flowchart showing a warehousing setting processing flow.

FIG. 9 is a flowchart showing an automatic inventory movement processing flow.

[Explanation of symbols]

10 Automatic warehouse (storage facility) 11 No. 1 rack (main storage equipment) No. 12, 13 No. 2 and 3 racks (auxiliary storage equipment)

Claims (6)

[Claims] 1. A method of storing an article into a storage facility including a main storage facility for storing a pre-registered article and an auxiliary storage facility, wherein the registered product is stored in the main storage facility. An article storage method, characterized in that a storage space is stored so as to secure a fixed amount for each registered article. 2. The main storage facility comprises a dedicated storage unit for storing the registered items and a common storage unit for storing the registered items or other items, and the auxiliary storage unit is a common storage unit. The method of storing an article according to claim 1, further comprising: 3. If the goods to be stored are the above-mentioned registered goods and are not in stock in the above-mentioned storage facility, or if they are in stock only in the above-mentioned main storage facility, then the above-mentioned article is said If the goods to be stored preferentially are stored in the above-mentioned registered auxiliary storage equipment and the above-mentioned goods are stored in the common storage section of the main storage equipment or the auxiliary storage equipment. The method of storing an article according to claim 2, wherein the article is stored. 4. The article storage method according to claim 1, wherein the main storage facility has a dedicated outlet for delivering the pre-registered article. 5. Articles are stored from a storage facility including a main storage facility having a dedicated storage unit for storing pre-registered items and a common storage unit for storing arbitrary items, and an auxiliary storage facility having a common storage unit. In the shipping method of the goods to be shipped,
If there is an item of the same type that has been stored before the item stored in the common storage section of the main storage facility in the auxiliary storage facility and there is empty space in the dedicated storage section of the main storage facility. A method of delivering an article, wherein the article of the same type in the auxiliary storage facility is transferred to the dedicated storage section of the main storage facility and then delivered. 6. A method for moving goods between a main storage facility having a dedicated outlet for storing pre-registered goods and an auxiliary storage facility, wherein the dedicated storage section of the main storage facility is vacant. If the oldest article is stored in the auxiliary storage facility, the oldest article is moved to the dedicated storage section of the main storage facility.