System and method for preparing and delivering orders

Abstract

A system and method for preparing and delivering product orders, such as consumer products, and is applicable in the field of B-to-C (business-to-consumer) marketing of such products (foodgeneral merchandiseDIY, etc.), and more particularly according to a Drive marketing mode. The products are distributed into at least two different categories based on their nature. For each product category, an order preparation zone is provided, including: one or more storage and preparation zones for products to be withdrawn, one or more storage and reconciliation zones for storing containers containing the withdrawn products, including at least one device for supplying complete orders for that product category, a conveying system for conveying empty or full containers from the storage and preparation zone(s) for products to be withdrawn toward the storage and reconciliation zone(s), and vice versa.

Claims

1. A method for preparing and delivering product orders, the method comprising: distributing products of a first storage category into a first storage and order preparation zone of a warehouse, and distributing products of a second storage category into a second storage and order preparation zone of the warehouse based on storage conditions for the products, the first storage and order preparation zone and the second storage and order preparation zone having different storage conditions; in response to an order, carrying out order preparation steps in each of the first and second storage and order preparation zones for preparing products of the first and second storage categories, respectively, said order preparation steps comprising: withdrawing products of the first storage category from a first storage location in the first storage and preparation zone and placing the withdrawn products of the first storage category in containers in the first storage and preparation zone, and withdrawing products of the second storage category from a second storage location in the second storage and preparation zone and placing the withdrawn products of the second storage category in containers in the second storage and preparation zone, reconciling the products of the first storage category contained in the containers in at least one first storage and reconciliation zone using at least one device for providing complete orders for the first storage category, and reconciling the products of the second storage category contained in the containers in at least one second storage and reconciliation zone using at least one device for providing complete orders for the second storage category, using a conveying system to convey empty or full containers from the first storage and preparation zone toward the first storage and reconciliation zone, and vice versa, and using a conveying system to convey empty or full containers from the second storage and preparation zone toward the second storage and reconciliation zone, and vice versa.

2. The method as recited in claim 1 wherein, for at least one of the order preparation zones, the device for supplying complete orders for the corresponding product category includes at least one rotating cabinet.

3. The method as recited in claim 1 wherein, for at least one of the order preparation zones, the device for supplying complete orders for the corresponding product category includes at least one gripping device for the containers.

4. The method as recited in claim 3 wherein, for at least one of the order preparation zones, the device for supplying complete orders for the corresponding product category includes at least one rotating cabinet.

5. The method as recited in claim 3 wherein the gripping device is a gripping robot able to move along three axes.

6. The method as recited in claim 5 wherein, for at least one of the order preparation zones, the device for including complete orders for the corresponding product category includes at least one rotating cabinet.

7. The method as recited in claim 1 further comprising, for at least one of the order preparation zones, a system for managing and optimizing the locations of the containers and able to steer the device for supplying complete orders for the corresponding product category.

8. The method as recited in claim 7 further comprising for at least one of the order preparation zones, one or more empty container storage zones.

9. The method as recited in claim 7 wherein the system for managing and optimizing the locations of the containers is computerized.

10. The method as recited in claim 1 further comprising, for at least one of the order preparation zones, one or more empty container storage zones.

11. The method as recited in claim 1 further comprising a zone for withdrawing orders to be delivered, the device for supplying complete orders by product category communicating with the zone for withdrawing orders.

12. The method as recited in claim 11 wherein the device for supplying complete orders from each product category is arranged so as to limit the movements necessary for an operator to deliver the order to a customer.

13. The method as recited in claim 12 wherein the zone for withdrawing orders to be delivered is arranged so as to limit the movements necessary for an operator to deliver the order to a customer.

14. The method as recited in claim 1 further comprising a product inventory management and optimization system.

15. The method as recited in claim 1 further comprising an automatic order distributor.

16. The method as recited in claim 1 wherein the conveyance system is configured to allow containers to be conveyed automatically in front of the storage and preparation zones for products to be withdrawn for the order, and stopping those containers in front of those zones, and to allow the containers to pass in front of the storage and preparation zones for products to be withdrawn not affected by the order without stopping in front of those zones.

17. The method as recited in claim 1 wherein the positioning of the containers in the storage and reconciliation zone is managed by a position management system, such that the containers of a same order are positioned in a stack or close to each other.

18. The method as recited in claim 17 wherein the position management system for the containers uses downtime to reorganize the positioning of the containers of a same order so as to group them together and bring them close to a device for providing the complete orders, so as to allow time-optimized delivery of the order to the customer.

19. The method as recited in claim 18 wherein at the beginning of each of the preparation steps, a number of containers necessary for the corresponding product category is determined at the beginning of the preparation step.

20. The method as recited in claim 19 wherein a number of empty containers necessary for the corresponding product category is provided and conveyed over a circuit allowing the containers to pass in front of all of the storage and preparation zones for the products to be withdrawn for the order and to stop in front of those zones, and to pass in front of all of the storage and preparation zones for products to be withdrawn that are not affected by the order without stopping in front of those zones.

21. The method as recited in claim 20 wherein the provision of empty containers is done automatically by a gripping robot able to move along three axes, and in that the conveying circuit is an automatic conveying circuit.

22. The method as recited in claim 1 wherein said at least two different categories are chosen from: dry products, cold products, and frozen products.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) Other features and advantages of the invention will appear more clearly upon reading the following description of preferred alternative embodiments of the system and implementation of the method, which are provided as non-limiting examples in reference to the appended drawing, which diagrammatically shows a top view of one example system according to the invention.

(2) This FIGURE diagrammatically shows one example of a system for preparing and delivering orders of the Drive type, for consumer products distributed into three categories based on the nature of the products: dry products, cold products, frozen products.

DETAILED DESCRIPTION

(3) The system comprises a warehouse 13 in which the products available for sale are stored, and in which the method is implemented, in particular mechanized order preparation.

(4) A space 14 is provided to allow customers to park their vehicle when picking up their order.

(5) In this FIGURE, the flows of products and containers are shown by arrows 18 or 19, depending on whether the containers are conveyed automatically or by operators.

(6) The shipment of the product by truck is done in the zone 17.

(7) Each customer order is recorded, sequenced and split by the computer management system for the warehouse so that all of the products in it are assigned to one or more preparation containers, such as tubs. More specifically, one or more preparation containers are assigned for dry products, one or more preparation containers are assigned for cold products, and one or more preparation containers are assigned for frozen products. Each order can therefore be made up of one or more types depending on the number, nature and volume of the items in question.

(8) When processing of an order is launched, i.e., when the decision is made to begin preparing an order, the order is assigned the number of tubs needed to contain it in its entirety, for each of the categories in question (dry products, cold products, frozen products).

(9) This is followed by launching the processing of each order for each of the categories, as described below.

(10) Dry Product Storage and Preparation Zone 1a, 1b

(11) The products or items available for sale are stored in furniture in a sequenced manner allowing them to be picked up manually by an operator 15.

(12) Products with a strong rotation, i.e., frequently ordered by customers, are stored in the storage and preparation zones 1b for quick handling by operators 15.

(13) Products with a lower rotation are stored in the storage and preparation zone 1a.

(14) The empty tubs, provided by a provision device 16 when an order is launched, as will be explained below, are conveyed automatically on a conveying system 4 of the collector circuit 4 or conveyor 4 type.

(15) This collector circuit is designed to be steered to allow the tubs to pass in front of all of the storage and preparation zones 1a, 1b.

(16) For each storage and preparation zone 1a, 1b, the tubs in question, i.e., designed to contain the items stored and withdrawn in those zones, are provided by an operator 15. The latter deposits the item(s) from his sector in each tub.

(17) These storage or preparation zones 1a, 1b, or preparation stations 1a, 1b, are arranged so as to have the best ergonomics for the operator 15 relative to the arrangement of the products, and to thereby limit the operator's movements. Furthermore, the tubs being prepared stay on the conveyor 4 in order to minimize carrying heavy loads.

(18) The tubs not affected by a zone pass through without stopping in the zone.

(19) The tubs prepared in each zone continue to travel, optionally stopping at the following zone.

(20) At the end of preparation, after passage in all of the affected zones or stations 1a, 1b, the full tubs are conveyed to the order storage and reconciliation zone 6.

(21) Dry Product Order Storage and Reconciliation Zone 6

(22) This order storage and reconciliation zone 6 comprises a gantry robot 16 moving along three axes, steered by location management and optimization software, to provide complete orders for the dry product category.

(23) When the system is initialized, this zone 6 is made up of stacks of empty tubs designed to supply the order preparation process. Subsequently, the empty tubs are stored in a zone 2 inside the order storage and reconciliation zone 6, also covered by a gantry robot 16.

(24) A device for gripping the tubs, placed at the end of the robot 16, makes it possible to form stacks and/or to move at will in the action area of the robot.

(25) When an order is launched, as explained above, the robot 16 delivers the empty tubs, preferably by unit, to the collector and conveying circuit 4 for order preparation, based on demand.

(26) When the tubs or containers are done being prepared, i.e., when they are full or there are no more products to add, they return to the entry to the order storage and reconciliation zone 6.

(27) These containers are then stored, for example on the ground, as close as possible to the output zone 11, or withdrawal zone 11 for orders to be shipped or delivered.

(28) Initially, each location intended to receive the containers in the zone 6 corresponds to one order. When an order is made up of several tubs, the subsequent tubs are placed on the first one so as to form a stack of tubs corresponding to the same order. Ultimately, the storage consists of stacks of full tubs each corresponding to a customer order.

(29) In order to optimize the storage and retrieval process, the system can also stack several orders to increase the storage capacity.

(30) Likewise, when the system is not addressed by high-priority actions such as removing or delivering an order to the withdrawal zone 11, the arrival of a full tub in the zone 6, the exit of an empty tub toward the storage and preparation zones 1a, 1b, it reorganizes the stored tubs so as to bring the orders closer to the exit interface made up of the withdrawal zone 11, bringing the empty tubs closer to the empty tub exit onto the conveyor circuit 4, to stack or unstack orders to optimize retrieval times based on the volume to be stored.

(31) When the customer arrives to take delivery of his order by entering the space 14, the device 16 for providing complete orders automatically delivers all of the tubs from his order using an ergonomic interface (placement on a cart, for example) toward the withdrawal zone for orders to be delivered 11. This action takes priority over the rest of the actions of the gantry robot 16 (taking out empty tubs, entry of prepared orders, reorganization of the inventory, etc.).

(32) Once the tubs have been emptied of its items, they are reintegrated into inventory for a new cycle.

(33) Cold Product Storage and Preparation Zone 7

(34) The products available for sale are stored on pallets in a sequenced manner allowing them to be picked up manually by an operator 15, in the storage and preparation zone 7.

(35) The empty tubs, provided to an operator, are manually withdrawn when a cold product order is launched, for example by means of a withdrawal order on the operator's mobile terminal.

(36) The products are withdrawn by the operator manually based on the list displayed on his mobile terminal, in one or more containers. The containers, duly filled, are then manually arranged and stored in a storage and reconciliation zone for the cold products corresponding to a sub-zone of the cold product storage and preparation zone 7.

(37) Cold product order storage and reconciliations zone

(38) This storage and reconciliation zone comprises a rotating cabinet 8 allowing completed orders to be provided for the cold product category.

(39) This rotating cabinet 8 allows the storage and fast retrieval of orders for cold product thus prepared. The entry point for this cabinet 8 is situated inside the cold product storage and preparation zone 7, while the exit point communicates with the withdrawal zone 11 for orders to be delivered.

(40) In order to preserve the cold chain, a flap opens when there is a request to remove tubs from the zone. In all other cases, the flap remains closed.

(41) When a customer arrives to take delivery of his order, all of the tubs or containers comprising his order are automatically provided at the withdrawal zone for orders to be delivered 11.

(42) Frozen Product Storage and Preparation Zone 9

(43) The frozen products available for sale are stored on pallets in a sequenced manner allowing them to be picked up manually by an operator in the zone 9.

(44) The empty tubs, provided to the operator, are withdrawn manually when an order for frozen products is launched, for example using a withdrawal order on the operator's mobile terminal.

(45) The products are withdrawn by the operator manually based on the list displayed on his mobile terminal, in one or more containers. The containers, duly filled, are then manually arranged and stored in a storage and reconciliation zone for the frozen products corresponding to a sub-zone of the frozen product storage and preparation zone 9.

(46) Storage in this zone is done at a location determined by the warehouse inventory management software and indicated using labels. This location is stored for future retrieval.

(47) Frozen product order storage and reconciliations zone

(48) This storage and reconciliation zone comprises a device 10 for providing completed orders for the frozen product category, which may be a static cabinet 10, for example a simple shelf 10.

(49) Each box of this cabinet 10 is identified by a unique inventory number, i.e., on the side of the storage and preparation zone 9, and identified by lighted protective glass on the side of the withdrawals zone 11.

(50) No tub movement occurs once the operator has deposited it in a location.

(51) The entry point of that static cabinet 10 is therefore situated in the frozen zone 9 or the storage and preparation zone 9 for frozen products to be withdrawn, behind that cabinet 10.

(52) The outlet of that static cabinet 10 communicates with the withdrawal zone for orders to be delivered or shipped 11, via glass doors making it possible to preserve the cold chain.

(53) When a customer arrives in the area 14 to take delivery of his order, the location of the tubs to be withdrawn is indicated, by means of the lighted protective glass on the static cabinet 10.

(54) Withdrawal Zone for Orders to be Delivered 11

(55) This zone 11 is a recovery zone for tubs making up a complete order, for delivery to the customer.

(56) When the latter indicates his presence and parks his vehicle in the space 14 provided to that end, the system provides all of the containers making up the order, with all products combined.

(57) In a single trip, an operator can therefore collect all of those tubs, starting with the dry products, and deliver to the end customer in a very short amount of time.

(58) The system can be automated, so as to allow the provision of orders to customers without operator intervention. In this configuration, the system comprises an automatic distributor suitable for removing orders 24 hours a day, 7 days a week, which may for example be situated at the outlet 12 of the withdrawal zone 11 for withdrawing orders to be delivered.

(59) It is recalled that the entire description above is provided as an example and is not limiting with respect to the invention.