DE102019124303B4 - Kitting procedure - Google Patents

Abstract

Method for kitting for assembling kits with components and parts that are required for the manufacture of a specific product or a specific assembly, wherein the components and parts are stored in single-variety storage containers (L) in a warehouse and are removed from storage for assembling the kit and transported to a goods-to-person station (11; 101; 101B) via stationary conveyors (17, 18, 19; 117, 118, 119), wherein all storage containers (L) with the components or parts contained in the kit are provided in a sequence at the goods-to-person station (11; 101; 101B) simultaneously by means of the conveyors (17, 18, 19; 117, 118, 119) in order to enable an operator (12; 102) to reload all components or parts of the kit into a kit container (K), characterized in that the Goods-to-man station (11; 101; 101B) has a conveyor loop (16; 116) in which the storage containers (L) are conveyed in a circle until kitting is completed, wherein the conveyor loop (16) is arranged within the working area (13; 113) of the goods-to-man station (11; 101; 101B).

Description

The invention relates to a method and a system for kitting according to claim 1.

Kitting is the process of assembling components and parts required for the production of a specific product or assembly. The individual components are assembled together and distributed or delivered in groups. The subsequent assembly process for the individual components is already taken into account during the assembly process.

In contrast to order picking, a selected group of components is assembled, not based on a broad range of items based on a random customer order, but rather specifically resulting from the product or assembly to be manufactured. Each kit is therefore predefined by the corresponding product or assembly. Only the number of kits is determined (e.g., depending on the product or assembly to be replaced or repaired). Typically, the kit is not assembled specifically for each customer.

This allows the subsequent assembly process to be more efficient and flexible. It also saves space in the assembly area and reduces the risk of confusion between components with similar appearance.

US 5,472,309 A Describes an integrated warehouse system for storing and retrieving goods, as well as preparing the goods for their final disposal. The warehouse system comprises numerous modular components that can be added to or subtracted from the system to meet specific storage needs. Inventoried goods stored in containers are stored on a rotating storage carousel. Several workstations, each with associated temporary storage queues, are integrated into the carousel to facilitate high-volume handling operations. Containers delivered from the storage carousel are placed in the temporary queue, where they are held until an operator is ready to work with the goods stored within. The container is then delivered to a work area where the operator performs the required task. The containers can then be delivered either to another suitable workstation or back to the storage carousel.

US 10 074 073 B2 describes a method for managing a warehouse system, which includes receiving a work request that identifies a warehouse item and selecting a work station from a plurality of work stations at which the work request is to be fulfilled. The method also includes moving a storage container that stores the identified warehouse item to the selected work station and moving a storage container that stores a warehouse item associated with the received work request to the selected work station. The storage containers are moved using mobile shelves in which the storage containers are stored. The mobile shelves are lifted, moved, and set down by intelligent robots. This type of movement requires a lot of free space for the robots to move and also sufficient space at the work station for the mobile shelves.

In contrast, the object of the present invention is to provide a kitting method that is more space-saving and at the same time more efficient.

This object is achieved by the method recited in claim 1. Advantageous embodiments emerge from the subclaims and the description.

According to the invention, it has been recognized that if all the single-variety storage containers with the components contained in a kit are provided in a sequence at a goods-to-person station at the same time by means of a conveyor, it is possible to increase efficiency by quickly providing all components via conveyors, since the conveyors can generally move storage containers faster than the robots via mobile shelves and at the same time to save space, since the conveyors only take up installation space once but can transport a wide variety of storage containers to and from the workstation or goods-to-person station.

In other words, all components and parts required for the manufacture of a specific product or assembly are made available at the goods-to-person station at the same time in the predetermined order (sequence) for assembling the kit.

Preferably, especially for kits with few components and parts, all storage containers are simultaneously within direct access (work area) for the kitter (operator of the goods-to-person station). This results in a particularly efficient and accelerated process. In other words, at the goods-to-person station, all storage containers with the components or parts contained in the kit are simultaneously within the operator's access area. It is particularly preferred when the kitter is presented with three storage containers at the same time.

For kits with many components and parts (e.g., 4-8), all storage containers will be available at the goods-to-person station at the same time. However, due to workspace constraints, they will only be presented one after the other, so that the kitter only has access to the practical number of storage containers. Since the order or sequence must be maintained during kitting anyway, the subsequent conveyance (later presentation) of the additional storage containers plays no role in the kitting process itself. Thus, despite a compromise regarding the number of storage containers presented (or station size), it is an efficient way to assemble even larger kits, since the storage containers are available at the goods-to-person station and are always presented when needed.

According to the invention, the goods-to-person station has a conveyor loop in the work area in which the storage containers are conveyed in a circle until kitting is completed.

In order to ensure a sequential supply of storage containers, to enable follow-up orders for other kits, etc., the conveyor loop at the goods-to-person station can have a parallel buffer section.

When kits are assembled with a large number of components and parts (e.g., > 8 - 22), a space problem arises when storing all the storage containers at the goods-to-person station. To solve this, the conveyor loop at the goods-to-person station can be shortened (double loop). In other words, the conveyor loop now has a cross conveyor section that connects the conveyor loop sections (loop sides) in a shortcut. The resulting configuration is roughly in the shape of an "8." This increases the length of the conveyor loop without requiring additional space.

Depending on the operating mode and storage container quantities, it may therefore be useful for both filled storage containers and empty storage containers to use the abbreviation.

Accordingly, it is also advisable to remove fully filled kit containers from the conveyor loop as quickly as possible to free up space. Therefore, they will always be removed directly from the conveyor loop, especially directly to a lift that distributes the finished kits throughout the warehouse.

Alternatively, at the goods-to-person station, fully filled kit containers and storage containers can be removed via the same conveyor lines.

At the goods-to-person station, large or bulky components and parts and/or outer packaging can be provided on one (or more) pallet locations. In other words, parts and components that are too large and/or heavy for the storage containers are provided separately on pallets. The same applies to outer packaging, e.g., boxes in which the kit is assembled. These are usually placed as the first "part" in the kit container, and then all "other" actual kit parts (or components) are assembled inside them. It goes without saying that, if necessary, multiple pallets containing such parts and/or components and/or outer packaging or intermediate shelves, etc., can be provided on pallets at the kitting station.

At the goods-to-person station, emptied storage containers are exchanged for filled ones at a targeted rate. This is easily possible thanks to the conveyor technology used, which allows for individual removal and exchange. For this purpose, a buffer line can be arranged parallel to the presentation arrangement for the storage containers, allowing for individual control.

The described kitting procedures and kitting workstations allow for efficient kitting to stock - called kit to stock - or kitting on demand or just in time - called kit to order.

The kits may also include, in addition to the components and parts required to manufacture a specific product or assembly, special tools and/or special screws, etc.

The method according to the invention is particularly suitable for the external supply of replacement or repair kits to workshops and repair or maintenance teams. This particularly applies to the automotive and truck sectors, where many prefabricated assemblies are used.

• 1 eine schematische Draufsicht auf einen Kittingarbeitsplatz zur Durchführung eines Verfahrens in einer ersten Variante;
• 2 eine schematische Draufsicht auf einen Kittingarbeitsplatz zur Durchführung des erfindungsgemäßen Verfahrens in einer zweiten Variante;
• 3 eine schematische Draufsicht auf einen Kittingarbeitsplatz zur Durchführung des erfindungsgemäßen Verfahrens in einer dritten Variante;
• 4. eine schematische Draufsicht auf den Kittingarbeitsplatz aus 3 bei der Durchführung des erfindungsgemäßen Verfahrens in einer vierten Variante;
• 5 eine schematische Draufsicht auf den leicht abgewandelten Kittingarbeitsplatz aus 3 bei der Durchführung des erfindungsgemäßen Verfahrens in einer fünften Variante; und
• 6 eine schematische perspektivische Ansicht auf einen ganzen Kittingbereich mit leicht abgewandelten Kittingarbeitsplätzen aus 5 im Zusammenspiel mit weiterer Fördertechnik zeigt.

Further details of the invention emerge from the following description of embodiments with reference to the drawing, in which

• 1 a schematic plan view of a kitting workstation for carrying out a method in a first variant;
• 2 a schematic plan view of a kitting workstation for carrying out the inventive according to the invention in a second variant;
• 3 a schematic plan view of a kitting workstation for carrying out the method according to the invention in a third variant;
• 4 . a schematic plan view of the kitting workstation 3 when carrying out the method according to the invention in a fourth variant;
• 5 a schematic plan view of the slightly modified kitting workstation from 3 when carrying out the method according to the invention in a fifth variant; and
• 6 a schematic perspective view of an entire kitting area with slightly modified kitting workstations from 5 in interaction with other conveyor technology.

In the 1 A schematic plan view of a kitting workstation 1 for carrying out the method according to the invention in a first variant is shown. This kitting workstation is designated as a whole by 1.

In the work area 3 of the operator or kitter 2, up to three single-type storage containers L01, L02, L03 are presented simultaneously in a row 6 for direct access. Next to it, at the corner, a kit container K to be filled is provided in a target location 5, which is supplied with empty containers via a separate target or kit container supply 4.

Behind row 6 of storage containers 01, 02, 03 there is a buffer line 7 parallel to it, which allows a targeted and individual supply and disposal of the spaces in row 6, for example if a storage container becomes empty during kitting.

For the supply of storage containers, the buffer section 7 is connected to a corresponding conveyor 8, which specifically brings storage containers L of the same type from a warehouse (not shown).

For the removal of filled kit containers K or emptied storage containers L, the buffer section 7 is connected at the end facing the destination location 5 to a corresponding conveyor 9, via which the destination location 5 itself is also connected.

At workstation 1, up to three source or storage containers L are available to the worker or kitter at the same time. Kits manufactured at this workstation 1 may therefore typically consist of up to three components or parts from the storage containers L. Worker 2 therefore places the components or parts into the kit container K in the correct order 01, 02, 03..., and this is then transported away via conveyor 9. The worker then begins with the next kit container.

If the kit changes, the storage containers L also change.

If a storage container L becomes empty during kitting before the kitting order (number of kits) is completed, the now empty storage container is transported to the warehouse (not shown) (shuttle warehouse) and replaced with a new, full storage container. This container is ready in time on buffer line 7 of workstation 1 and takes the place in row 6 of the emptied and removed storage container.

If the kit only needs to be manufactured once, the production of larger kits is also conceivable at this workstation 1. In this case, the corresponding storage container L is removed immediately after access, as if it were emptied. This makes room for a possible additional storage container L, e.g., L04, as a successor container.

In addition, bulky components or parts as well as outer packaging can be provided on a pallet or space P at the station.

In the 2 A schematic plan view of a kitting workstation for carrying out the method according to the invention is shown in a second variant. This kitting workstation is designated as a whole by 11. In this variant, up to eight storage containers are available to the worker 12. However, only five are shown here.

In the work area 13 (partial leg of loop 16, see below) of the operator or the assembler 12, several single-type storage containers L are simultaneously presented frontally for direct access. The remaining storage containers L are located on a conveyor loop or loop 16 arranged within the work area 13.

Next to it, around the corner, a kit container K to be filled is provided in a target location 15, which is supplied with empty containers via a separate target or kit container supply 14.

For the supply of storage containers L, the loop 16 is connected to a corresponding conveyor 18, which specifically brings storage containers L of the same type from a warehouse (not shown).

For the removal of filled kit containers K or emptied storage containers L, the loop 16 is connected to a conveyor 19.
Since the destination 5 itself is also connected to Loop 16, it can be disposed of accordingly.

A buffer section 17 is provided parallel to loop 16 between the connection of conveyors 18 and 19. This buffer section is used, as before, to hold the targeted replenishment without obstructing the conveyor flow on loop 16. Alternatively or additionally, containers can be buffered on conveyor 18.

The incoming conveyor 18 is supplied by a container lift 20, which is connected to or extends from a shuttle storage (not shown). Similarly, the outgoing conveyor 19 leads to a container lift 21, which is also connected to or extends from a shuttle storage (not shown).

If the lifts 20, 21 are located in shelves of an aisle of the shuttle warehouse, it is advisable if the distance between the conveyors 18, 19 corresponds to the shelf distance.

At workstation 11, the operator preferably has access to up to eight storage containers L. Similar to the smaller workstation 1, orders with up to eight components or parts from storage containers L, or even larger orders with a production quantity of only one kit, can be manufactured.

After the worker has removed the required number of components for the current kit from the corresponding storage container L and activated the container change, the storage container is changed, i.e., conveyed further in loop 16. This allows the worker to concentrate entirely on one storage container L during kitting, and the removal process is further simplified.

Alternatively, the worker could also remove the relevant components or parts from several storage containers, e.g. three, and these could then be transported further as a group.

The container change can also be time-controlled, i.e. after a specified personal “processing time”.

The container change itself is logically performed in the "shadow" of the processing time. This allows the operator to add the next component or part to the kit without waiting.

Even with kits containing only two components, the storage container must continue to move in one variant after removal.

Empty storage containers L are disposed of via the conveyor loop 16 and immediately replaced with the appropriate replenishment container. Finished kit containers K are also disposed of via loop 16.

After the kitting order is completed, all storage containers L are disposed of together with the (last) kit container and immediately replaced by the next order. At this point, the next order is already ready on buffer line 17 of workstation 11 according to its sequence with storage containers L*.

The one in the 3 to 5 Workstation 101 shown is in principle a variant of workstation 11. Corresponding parts are therefore designated by reference numerals increased by 100.

The main differences to workstation 11 are, in addition to the size of the conveyor loop 116, that it has a cross connection as a shortcut 122 and that the buffer section is designed as a buffer section 117 of the incoming conveyor 118. In addition, there is the possibility (cf. 5 ) pallet spaces must be provided.

Workstation 101 offers various operating modes to efficiently supply storage containers for a wide range of four to 22 storage containers L in order to carry out the corresponding kitting, which is described below using the 3 - 5 is explained.

All operating modes are linked by the basic functionality of workstation 101. As with workstation 11, storage containers L are delivered to worker 102 via a circulating conveyor loop 116. This allows the worker 102 to remove the required components from the respective container L0X in their work area 103 and add them to the respective kit K at location 105. The supply and removal are carried out analogously to the above.

The difference in the operating modes for workstation 101 now consists in reducing the duration of the cycles if necessary in order to achieve sufficiently fast access to the circulating storage containers L even when there are few storage containers L, or to provide sufficient conveyor length for many storage containers L.

When kitting with few storage containers L (as in 3 shown), the storage containers L use a shorter circulation route, which is made possible by the use of the abbreviation 122. The Loop or conveyor loop 116 is therefore deliberately shortened.

In this configuration, more buffer spaces are available for replenishment containers or storage containers L* of a possible next order. In addition to the currently circulating order with storage containers L01...L05 and a replenishment container L01n for storage container L01, the illustration also shows another order with five containers L* and another order L** on buffer section 117.

The replenishment container L01n waits before the shortcut directly at the circulating storage containers L to replace the emptying storage container L01.

In the operating mode (as in 4 shown) with more than eight and less than 19 storage containers L, the storage containers L circle around the outer loop 116 of the workstation 101.

The shortcut 122, which is used for orders with few or very many components (see below) from storage containers L, is not used in this operating mode. Replenishment containers are located at the buffer locations within loop 116 on the feed buffer section 117.

When kitting (cf. 5 ) with 19 to 22 components or parts from storage containers L, both the outer circulation of the loop 116 and the abbreviation 122 are used for circulating the storage containers L.

In this operating mode, as in the operating mode with 9 to 17 components from storage containers L, the buffer section 117 located in loop 116 is available for buffering the storage containers L.

In this operating mode, storage containers L must be split during circulation and later reunited. The sequence must (and will) be maintained during reunification.

In addition, the workplace 101B includes the 5 another provision of pallets P. As previously described, kitting workstations 1 and 101, as well as 101B, have, in addition to the container connection described above, a connection to a pallet conveyor system 125 at location P. Thus, the worker has access not only to the respective storage container L or kit container K, but also to a number of source pallets. This allows bulky components or parts, as well as outer packaging, to be provided at the workstation on one or more pallets P1, ... PX.

6 shows possibilities to equip an entire kitting area with slightly modified kitting workstations 101B from 5 in conjunction with other conveyor technology.

The four kitting workstations 101B shown are arranged approximately in a square when viewed from above and share lifts 121, 122 in pairs. These lifts therefore serve as a supply for one workstation and as a discharge for the other workstation.

At the same time, the respective supply lift 121, 122 for the workstations serves not only as a supply for storage containers L, but also for the supply 114 with empty kit containers K to be filled. Depending on the arrangement, two adjacent workstations can share a supply 114 (see left workstations).

In 6 The right half of the figure also shows the pallet conveyor system 125 in area P for the provision of several pallets P1, ... PX. The pallet conveyor system 125 includes, among other things, simple reversible pallet conveyors 126 at locations P3 and P4 and also more complex infeed and outfeed conveyor systems 127 at locations P1 and P2.

List of reference symbols

1, 11, 101, 101B

Kitting workstation

2, 12, 112

worker

3, 13, 113

Workspace

5, 15, 115

Destination

16, 116

Loop or conveyor loop

2, 12, 102

puttyer, worker

20, 120

Container lift

21, 121

Container lift

4, 14, 114

Kit container supply

5, 15, 105

Destination

6

Row

7, 17, 117

Buffer section

8, 18, 118

Sponsors

9, 19, 119

Sponsors

K

Kit container

L, L1...Lx, L*, L**

storage containers

P

Pallet area

P1... Px

Places

7, 17, 117

Buffer section

122

abbreviation

125

Pallet conveyor technology

126

pallet conveyor

127

Infeed and outfeed conveyor technology

Claims (9)

A kitting method for assembling kits with components and parts required for the manufacture of a specific product or assembly, wherein the components and parts are stored in single-variety storage containers (L) in a warehouse and are removed for assembly of the kit and transported to a goods-to-person station (11; 101; 101B) via stationary conveyors (17, 18, 19; 117, 118, 119), wherein all storage containers (L) with the components or parts contained in the kit are provided in a sequence at the goods-to-person station (11; 101; 101B) simultaneously by means of the conveyors (17, 18, 19; 117, 118, 119) to enable an operator (12; 102) to reload all components or parts of the kit into a kit container (K), characterized in that the goods-to-person station (11; 101; 101B) has a conveyor loop (16; 116) in which the storage containers (L) are conveyed in a circle until kitting is completed, the conveyor loop (16) being arranged within the working area (13; 113) of the goods-to-person station (11; 101; 101B). Procedure according to Claim 1 , characterized in that at the goods-to-person station (11; 101; 101B) large or bulky components and parts and/or outer packaging are provided on a pallet location (P). Procedure according to Claim 1 or 2 , characterized in that at the goods-to-person station (11; 101; 101B) storage containers (L) emptied by kitting are specifically exchanged with filled storage containers. Method according to one of the preceding claims, characterized in that at the goods-to-person station (11; 101; 101B) all storage containers (L) with the components or parts contained in the kit are simultaneously within the access area (13; 113) of the operator. Method according to one of the preceding claims, characterized in that at the goods-to-person station (11; 101; 101B) fully filled kit containers and storage containers are conveyed away via the same conveyor lines (17, 18, 19; 117, 118, 119). Procedure according to Claim 1 , characterized in that the conveyor loop (13; 113) has a parallel buffer section (17; 117) at the goods-to-person station (11; 101; 101B). Method according to one of the preceding Claims 1 or 6 , characterized in that the conveyor loop (13) has a shortcut (122) at the goods-to-person station (11; 101; 101B). Procedure according to Claim 7 , characterized in that both filled storage containers and empty storage containers use the abbreviation (122). Method according to one of the Claims 6 until 8 , characterized in that fully filled kit containers (K) are always transported directly from the conveyor loop (13; 113), in particular are conveyed directly to a lift (21; 121).

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