DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of Invention:
A SYSTEM AND METHOD FOR SMART STOCK REORGANIZATION

APPLICANT:
ARAPL RAAS PRIVATE LIMITED
An Indian entity
having address as:
Gat No.1209, Village Wadki,
Pune-412308, Maharashtra, India
The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from the Indian patent application, having application number 202321005556, filled on 27th January 2023, incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure relates to a supply chain, manufacturing, and logistics automation equipment systems, and more particularly to the integration of technologies, such as robotics and intelligent control systems, to automate various aspects of warehouse operations, including the smart reorganization of inventory storage items using a robotic system.
BACKGROUND
This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to help provide the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
In logistics facilities, such as distribution centres or warehouses, goods stock is stored for retrieval by a pick worker. Each type of stock item is known as a Stock Keeping Unit (SKU), and each SKU has a specific location in which it is kept. This stock can be stored openly on shelving racks, or in compartmentalized containers, such as boxes or cartons. Generally, stock of the same SKU is placed in a single carton also known as single SKU cartons. Also, many times, stock of different SKUs is also placed in a single carton also known as multi-SKU cartons. When the warehouse receives an order from a customer for an item, the customer ordered item is then picked from the single SKU carton corresponding to SKU of the customer ordered item manually by a warehouse person. Once the stock of the single SKU cartons is below a predefined threshold value, the warehouse person needs to refill the single SKU cartons from the multi-SKU carton. Typically, the warehouse person needs to walk through the entire inventory storage of the central warehouse to find both multi-SKU carton and single SKU carton and perform manual decanting of items from the multi-SKU cartons to the single SKU cartons. In another scenario, at any point in time it may happen that orders for a particular SKU item are not received for certain number of days (e.g., 30-40 days) and a single SKU carton for that SKU item has stock below the predefined threshold value (say 1 or 2 items) left in the SKU carton. Over a period of time, around 20-30% of total inventory cartons are having very low sale and low quantity lying in the carton, this is resulting in occupying precious inventory space of the warehouse. Typically, since these SKUs are saleable stocks, they are discarded only after their expiry. Moreover, in cases like shoes and apparel which do not have any expiry, the area occupancy by these unsold items results in even more burning problem. Therefore, such kind of items in the single-SKU cartons for 2-3 SKUs needs to be reorganized in the multi-SKU cartons. Manual reorganization activity on the regular basis requires the warehouse person to walk through the entire inventory storage of the central warehouse for finding and manual decanting of items from the one or more single-SKU cartons to a multi-SKU carton, which is time consuming and cost burning activity of warehouse operation. There are numerous issues associated with aforementioned manual way of reorganizing of stock such as:
a. Manually tracking of stock quantities of the single SKU cartons is a time-consuming task.
b. Manually picking the single SKU cartons and the multi-SKU cartons from the inventory storage is time-consuming and a difficult task. As manually searching for cartons at inventory storage requires plenty of time.
c. Manually picking of items from the multi-SKU cartons and transfer to the single SKU cartons or vice versa is time-consuming and a difficult task involving lot of manpower cost and time.
d. The warehouse person can only pick items in the inventory storage shelves up to a height of 2 metres, which increases the size requirement of the inventory storage.
e. Manual collection of specific cartons from the inventory storage can inevitably entail a risk of human error.
f. High number of warehouse persons are required for manual moving of cartons.
g. Operational Inefficiency: Manual processes in order fulfilment and inventory maintenance result in slower operations, causing delays in order processing.
h. Inventory Space Inefficiency: Around 20-30% of total inventory cartons have very low sales and quantities, occupying valuable warehouse space. This inefficiency is exacerbated by the presence of saleable items that are not discarded until expiry.
Therefore, there is a long-felt need for a method and a system that overcomes at least the issues/challenges related to the manual stock reorganization and facilitating smart stock reorganization of inventory storage items using a smart robot.
Recognizing these challenges, there exists a longstanding need for a method and system that addresses the inefficiencies associated with manual stock reorganization. A proposed solution involves the introduction of a smart robotic system to facilitate automated stock reorganization in warehouse inventory. This system aims to comprehensively enhance warehouse operational efficiency by streamlining SKU retrieval, replenishment, and reorganization, reducing reliance on manual labour, and minimizing operational costs. The proposed automated stock reorganization system eliminates the manual burden on pickers by introducing a seamless process driven by smart robotics and intelligent control systems, in contrast to the traditional approach, where pickers physically fetch and transport multi SKU cartons, the present invention utilizes an autonomous robotic system guided by a Warehouse Control System (WCS).
The implementation of an automated stock reorganization system within inventory storage promises to revolutionize warehouse operations, providing a solution that optimizes space, reduces operational costs, and enhances the overall efficiency of SKU organization and retrieval. This background lays the foundation for an invention, outlining the inventive aspects of the automated stock reorganization system with smart robotics.
SUMMARY
This summary is provided to introduce concepts related to a system and a method for smart stock reorganization of inventory storage items, and the concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in classifying or limiting the scope of the claimed subject matter.
In an implementation of the present disclosure, a system and a method for automated stock reorganization in a warehouse inventory items of a central warehouse are disclosed. The system may comprise a memory and a processor coupled with the memory. The processor may be configured to execute programmed instructions stored in the memory. The system may comprise an intelligent warehouse management system (IWMS), one or more user devices, and one or more smart robots connected via a communication network. The IWMS may be coupled to the memory and the processor, to enable the automated stock reorganization operations. Implemented within a centralized warehouse, the system may include both an inventory storage and a dedicated reorganization zone. The inventory storage features multiple compartments that may be designed for storing one or more cartons. Each carton from the one or more cartons possibly associated with a unique carton identifier. Correspondingly, each compartment may be identified with a specific compartment identifier, potentially ensuring systematic inventory organization. The reorganization zone may be equipped with a set of bins designed for the temporary housing of one or more cartons during the reorganization process. Operationalizing the system may involve one or more smart robots specialized in executing automated stock reorganization operations within the centralized warehouse. The IWMS play a pivotal role, systematically checking the count of items in each carton within the inventory storage and comparing it against a predefined stock quantity threshold for precise inventory management. The smart robots may be configured to receive transport instructions from the IWMS when the item count in a carton falls below the predefined stock quantity threshold. These instructions may guide the robots to pick up the identified cartons from the plurality of compartments in the inventory storage and transport them to the set of bins in the reorganization zone for decanting. The decanting of items at the reorganization zone may be performed either automatically through one or more smart robots, or manually by a person. Once the decanting operation is complete, the smart robots may place the processed cartons (Residual cartons) back into the plurality of compartments in the inventory storage. Importantly, the IWMS may be updated with the mapping of residual carton identifiers to compartment identifiers, potentially ensuring an accurate and real-time record of carton locations within the inventory storage.
In one implementation, a method for automated stock reorganization facilitated by an Intelligent Warehouse Management System (IWMS) and one or more smart robots may be characterized by a sequence of operations. The method may commence with the continuous monitoring of the item count within each carton among the one or more cartons situated in the inventory storage of a centralized warehouse. The inventory storage may be structured with a plurality of compartments, each designed to store one or more cartons, with each carton possibly associated with a unique carton identifier, and each compartment linked to a corresponding compartment identifier. Following the monitoring phase, the method may include a comparison step where the monitored item count in each carton is assessed against a predefined stock quantity threshold. Subsequently, the method includes a step to identify one or more cartons where the item count falls below the established stock quantity threshold. Upon identification, the IWMS may send one or more transport instructions to the designated smart robots. These instructions may guide the robots in transporting the identified cartons to a reorganization zone within the centralized warehouse. The reorganization zone may be equipped with a set of bins designed for temporarily accommodating one or more cartons during the reorganization process. Further, the method may enable one or more smart robots to execute a series of actions, including picking the identified cartons from the plurality of compartments within the inventory storage. Subsequently, the smart robots may place the picked cartons into the set of bins within the reorganization zone, facilitating the decanting of items from the cartons at the reorganization zone. After the decanting operation is complete, the smart robots then may place the processed cartons back (Residual cartons) into the plurality of compartments within the inventory storage. The disclosed method may present an efficient and automated approach to stock reorganization, utilizing intelligent monitoring, robotic assistance, and a reorganization zone to enhance the overall operational efficiency of a centralized warehouse.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF DRAWINGS
The detailed description is described with reference to the accompanying figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer to the like features and components.
Figure 1 illustrates a system for automated stock reorganization, in accordance with an embodiment of the present subject matter;
Figure 2 illustrates the estate architecture of a central warehouse comprising an inventory storage and a reorganization zone in accordance with an embodiment of the present subject matter;
Figure 3 illustrates a decision-making flow diagram (300) within the system (100) to be performed for automated stock reorganization, in accordance with an embodiment of the present subject matter; and
Figure 4 illustrates a flowchart describing the method (400) for automated stock reorganization, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
Before the present system and method are described, it is to be understood that this disclosure is not limited to the system and its arrangement as described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. The present disclosure overcomes one or more shortcomings of the prior art and provides additional advantages discussed throughout the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the versions or embodiments only and is not intended to limit the scope of the present application.
The terms “comprise”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system or method. In other words, one or more elements in a system or apparatus preceded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
Referring to Figure 1, a system (100) for automated stock reorganization in a warehouse inventory, is illustrated in accordance with an embodiment of the present subject matter. The system (100) may comprise an intelligent warehouse management system (IWMS) (102), a user device (104), and one or more smart robots (106). The central warehouse may be divided into two sections namely an inventory storage and reorganization zone. The details of the sections are given in subsequent paragraphs with reference to Figure 2. The IWMS (102), the user device (104) and one or more smart robots (106) may communicate to send or receive data with each other through a network (108).
The network (108) facilitating communication within the disclosed system may encompass various types of communication infrastructures, offering a broad spectrum of possibilities. It may include a cable network, enabling data transmission through physical cables like coaxial or fibre-optic cables. Alternatively, a wireless network may be employed, utilizing technologies such as Wi-Fi, Bluetooth, Zigbee, or other wireless protocols for seamless data exchange without the need for physical connections. Moreover, the system might integrate with a telephone network, covering diverse technologies like Analog, Digital, POTS, PSTN, ISDN, and xDSL. This versatility ensures compatibility with different telecommunication standards, providing adaptability to varying network environments. Additionally, a cellular communication network may be part of the network configuration, incorporating various generations of mobile communication technologies, ranging from CDMA and GSM to the latest advancements like 5G and potentially 6G. A radio network might be utilized, allowing communication through radio waves, suitable for specific applications like radio broadcasting or dedicated radio communication systems. The Internet, as a global network connecting devices worldwide, could be integrated into the system, facilitating broader connectivity and access to a vast array of resources. Local Area Networks (LANs) may be deployed for communication confined within a specific geographic area, while Wide Area Networks (WANs) could extend the reach to cover broader geographical regions. Additionally, short-range communication networks, such as Near Field Communication (NFC) or Radio-Frequency Identification (RFID), may find application in specific contexts, providing close proximity data exchange capabilities. It's important to note that the network (108) used for communication is not rigidly bound by the mentioned examples. A person skilled in the art may explore and implement other communication means tailored to the specific requirements and advancements in the field, ensuring flexibility and adaptability to emerging technologies.
The system (100) comprises a memory and a processor coupled with the memory. The processor may be configured to execute programmed instructions stored in the memory. The IWMS (102) may be configured to enable the automated stock reorganization operations of the centralized warehouse (200). The IWMS (102) may be coupled with the memory and the processor. This processor is intricately designed to execute meticulously crafted instructions stored in the memory for controlling and tracking the smart robot for automatically picking and transferring cartons from the inventory storage to the reorganization zone of the warehouse and vice versa. These instructions serve the pivotal purpose of not only controlling but also diligently tracking the smart robot's (106) activities within the warehouse, orchestrating the seamless movement of cartons between the inventory storage (201) and the reorganization zone(202), and vice versa.
The IWMS (102) is highly versatile in its implementation, manifesting through a combination of hardware, software, or a harmonious blend of both. The system's adaptability extends to various forms, including computer programs, mobile applications, or "apps," deployable either on-premises through corresponding computing terminals or in a virtualized environment leveraging cloud infrastructure. The IWMS (102) unfolds as a collection of micro-services or independent computer programs, capable of autonomous functioning while collaboratively contributing to the holistic system. The IWMS (102) may also interact with a third-party or external computer system. Internally, the IWMS (102) may be the central processor of all requests for transactions by the various actors or users of the system. A critical aspect of the IWMS (102) is that it is able to concurrently and instantly complete an online transaction by a system used in conjunction with other systems.
The processor, in one embodiment, may comprise a standard microprocessor, microcontroller, central processing unit (CPU), distributed or cloud processing unit, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions and/or other processing logic that accommodates the requirements of the present invention. The memory, in another embodiment, may include any computer-readable medium or computer program product known in the art including, for example, volatile memory, such as static random-access memory (SRAM) and dynamic random-access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, Solid State Disks (SSD), optical disks, magnetic tapes, memory cards, virtual memory and distributed cloud storage. The memory may be removable, non-removable, or a combination thereof. The memory may include routines, programs, objects, components, data structures, etc., which perform particular tasks or implement particular abstract data types. The memory may include programs or coded instructions that supplement applications and functions of the system (100). In one embodiment, the memory, amongst other things, serves as a repository for storing data processed, received, and generated by one or more of the programs or the coded instructions. In yet another embodiment, the memory may be managed under a federated structure that enables adaptability and responsiveness of the system (100). In one embodiment, the IWMS (102) utilizes the processor for executing the programmed instructions stored in the memory.
In one embodiment, the smart robots (106) may include a set of components, including a motorized base, one or more shelves, a manipulator, an extendable lift, a processor, a memory, a communication module, and a power storage unit. The shelves, designed for efficient picking and placement of cartons, may have an adjustable height within the range of 500 to 3700 mm. The embodiment envisions the smart robot (106) as a line-tracing robot, showcasing its potential to autonomously follow predefined paths. To enhance navigation within the central warehouse, the motorized base may be equipped with a LIDAR system. This advanced system may utilize laser emissions to analyze reflections, effectively mapping the surrounding area and identifying safe navigable pathways while avoiding obstacles. Underneath the motorized base are casters, drive wheels, and motors enabling the smart robots (106) to traverse the x-y spatial planes within the central warehouse. The extendible lift, which may be coupled to motors at the base in some embodiments or driven independently in others, is a collapsible framework capable of expanding to varying heights. Its fully collapsed state positions about one foot above the motorized base, while in its fully expanded form, it may rise over four meters above the base. The extendible lift may be powered pneumatically or through other mechanical means.
Additionally, the smart robots (106) may integrate one or more optical sensors, such as a camera, for scanning machine-readable codes. The IWMS (102) may play a pivotal role in controlling and coordinating the operation and movement of the smart robots (106). The communication module embedded within the smart robot (106) may facilitate seamless information exchange with the IWMS (102), contributing to the synchronized functioning of the entire automated stock reorganization system. One or more smart robots (106) may comprise multiple storage racks for carrying multiple cartons simultaneously. The IWMS (102) may take charge of controlling the smart robot's (106) operation and movement. The communication module embedded in the smart robots (106) may facilitate seamless information exchange with the IWMS (102), ensuring real-time coordination and responsiveness during various tasks within the warehouse. The integration of advanced robotic capabilities underscores the potential efficiency and precision that may be achieved in the automated stock reorganization of a warehouse inventory system.
In another embodiment, the user device (104) may represent a diverse spectrum of portable electronic devices, including but not limited to cellular devices, mobile devices, tablets, PDAs, laptops, netbooks, smart books, and similar gadgets. The installation of an application associated with the IWMS (102) on the user device (104) may broaden its functionality. Equipped with a communication module, the user device (104) may establish effective communication channels with the IWMS (102). Moreover, the user device (104) may feature one or more optical sensors, possibly in the form of a camera, enhancing its capability to scan machine-readable codes. This enhanced functionality may position the user device (104) as a versatile tool for interaction and information retrieval within the automated stock reorganization system.
The incorporation of various types of portable electronic devices into the system adds versatility, as users may utilize devices that best suit their preferences or are readily available to them. The application on the user device (104) enhances the user's interaction with the IWMS (102), allowing for seamless communication and information exchange. The inclusion of optical sensors further augments the user device's (104) utility in tasks requiring visual data capture, such as scanning machine-readable codes during the stock reorganization process. This comprehensive integration of user devices in the warehouse ecosystem may contribute to enhanced efficiency and user experience.

In one embodiment, as depicted in Figure 2, the architectural layout of a central warehouse (200) is detailed in accordance with the present subject matter. The central warehouse (200) may be configured with an estate architecture featuring essential components, primarily the inventory storage (201) and a dedicated reorganization zone (202). This architectural configuration aims to optimize the organization and retrieval of goods within the warehouse space.

The inventory storage (201) may serve as the core storage facility within the central warehouse (200). This main storage area may be designed to house a multitude of stock cartons, each representing a Stock Keeping Unit (SKU). The SKUs, corresponding to specific stock items, may be carefully organized within the inventory storage (201). The specific location assigned to each SKU may ensure efficient retrieval when required. Notably, the storage methodology may encompass both open shelving racks and compartmentalized containers, such as boxes or cartons, offering flexibility in accommodating diverse types of goods. Within the inventory storage (201), the SKUs may be systematically arranged to streamline the retrieval process. The shelving racks and containers may provide distinct locations for each SKU, contributing to an organized and accessible inventory. This organization may facilitate the swift identification and retrieval of goods, minimizing operational delays and optimizing overall warehouse efficiency. In the context of inventory management, the use of shelving racks or compartmentalized containers may ensure a tailored approach to various stock items, accommodating their varied storage requirements. This adaptability may be a key feature, allowing the central warehouse (200) to efficiently manage a wide range of goods, from diverse industries or product categories.
In one embodiment the reorganization zone (202) may serve as a dedicated area within the central warehouse (200) designed for efficient manual reorganization of stock. This zone may act as a staging area where the smart reorganization system, including the smart robot (106), may facilitate the transfer of goods between single-SKU cartons and multi-SKU cartons. The system may intelligently identify the need for reorganization based on stock levels, ensuring optimal space utilization, and reducing the manual effort involved in the process.
Further, the estate architecture of the central warehouse (200) may be strategically designed to encompass the inventory storage (201) and reorganization zone (202), collectively providing a comprehensive framework for automated stock reorganization. The storage flexibility, coupled with a dedicated reorganization zone (202), may lay the foundation for an automated system that may significantly enhance the overall operational efficiency of the central warehouse (200).
In another embodiment, inventory storage (201) may be designed to accommodate diverse storage needs efficiently. The stock management system may employ a practice wherein stock of the same Stock Keeping Unit (SKU) is typically stored in a designated carton, referred to as a single-SKU carton. Additionally, to optimize space utilization, there may be a provision for placing stock of different SKUs together in a single carton, commonly known as multi-SKU cartons.
Further, the inventory storage (201) may be organized with a systematic arrangement, featuring a set of racks and corresponding compartments designated for storing the SKU cartons. Within this setup, each compartment may be exactly identified and mapped to a compartment identifier, which may be further associated with a compartment machine-readable code. This code affixed to every compartment within the inventory storage (201), may take various forms, such as a linear barcode, a radio frequency identification (RFID) tag, a Quick Response (QR) code, an optical label, or similar identification technologies.
The incorporation of machine-readable codes, including barcodes, RFID tags, QR codes, or optical labels, may serve a crucial role in enhancing the efficiency of stock management. These codes may enable swift and accurate identification of each compartment within the inventory storage (201), allowing for seamless tracking and retrieval of SKU cartons. The use of advanced identification technologies may contribute to the overall automation of the stock management system, reducing the margin of error and expediting the retrieval process. This embodiment may highlight the versatility of inventory storage (201), which may accommodate both single-SKU cartons and multi-SKU cartons. The incorporation of machine-readable codes may ensure a structured and technologically advanced approach to inventory organization, fostering an environment conducive to streamlined stock retrieval and management within the central warehouse.
In one embodiment, the racks of the inventory storage (201) may feature adjustable heights, providing flexibility for storage conditions. The height adjustment may extend up to 4 meters or more, allowing for tailored configurations based on the characteristics of stored items. However, the decision to set rack heights at or above 4 meters may depend on factors such as the nature of the inventory, space optimization goals, and accessibility considerations. The flexibility in rack height may offer versatility in accommodating diverse stock cartons within the inventory storage (201).
In another embodiment, the reorganization zone (202) may be strategically positioned within the central warehouse (200), serving as a specialized area dedicated to the systematic reorganization of cartons sourced from the inventory storage (201). The reorganization process within this zone may involve the selective picking of items from multi-SKU cartons and their transfer to single-SKU cartons, or vice versa, depending on the dynamic operational requirements. The reorganization zone (202) may act as a dynamic hub, allowing for efficient adjustments to the inventory structure. The reorganization zone (202) may comprise a set of racks with a set of bins for storing the cartons. Each bin of the reorganization zone (202) may correspond to a bin identifier mapped to a bin machine-readable code. The bin machine-readable code may be pasted to each bin of the reorganization zone (202). The racks of the reorganization zone (202) may be of a height up to 2 meters. Storage at 2-meter racks may be easy for the pick worker for accessing cartons for reorganization.
For enhanced tracking and management, each compartment of the inventory storage (201) and bin of the reorganization zone (202) may be assigned a unique machine-readable code, which may include a linear barcode, RFID tag, QR code, optical label, or similar identification technologies. This embodiment leverages advanced labelling methods, providing a robust system for accurately monitoring and organizing inventory items throughout the central warehouse (200).
In an embodiment emphasizing ergonomic considerations, the racks within the reorganization zone (202) may be designed with a height limitation, possibly up to 2 meters. This intentional design choice may cater to the convenience of pick workers, ensuring that the racks are easily accessible during the reorganization process. The adjustable height feature, maybe up to 2 meters, aligns with a focus on creating a workspace that promotes efficiency and minimizes physical strain for the pick worker, potentially contributing to an optimized reorganization workflow.
The method steps performed for the automated stock reorganization in a warehouse inventory may be described in detail with reference to Figure 3 in subsequent paragraphs.
Now referring to Figure 3, a decision-making diagram (300) within the system (100) to be performed for the smart reorganization of stock of inventory storage (201) is illustrated, in accordance with an embodiment of the present subject matter.
In step 301, the IWMS (102) may continuously monitor stocks at the inventory storage (201) while receiving an order from a customer and while delivering the customer-ordered items from the Inventory storage (201). Generally, the items from the single-SKU cartons of the Inventory storage (201) may be used to fulfil customer orders. In another embodiment, the IWMS (102) may be configured to continuously monitor the order details of each SKU present in the inventory storage (201), to identify low-selling SKUs.
In step 302, the IWMS (102) may check the stock quantity remaining in the single-SKU cartons stored in the inventory storage (201). The processor of the IWMS (102) may be configured to store a stock quantity threshold in the memory. The processor may be configured to compare the stock quantity remains of the single-SKU cartons with the stock quantity threshold. Further, the processor may be configured to identify the single-SKU cartons with stock quantity less than the stock quantity threshold. In another embodiment, the IWMS (102) may check the stock quantity remaining along with order details in the single-SKU cartons stored in the inventory storage (201), for identifying low-selling SKUs. The low-selling SKUs may be identified based on calculating the day difference between the current day and the day on which the last order for that particular SKU was received by the IWMS (102). The IWMS (102) may be configured to store a predefined low-selling day threshold in the memory. Further, the IWMS (102) may be configured to compare the calculated day difference for that particular SKU with the predefined low-selling day threshold, to identify the low-selling SKU. Based on the disclosed steps, the IWMS (102) may be configured to identify one or more low-selling SKU items and to identify one or more single SKU cartons with low stock quantity of the identified low-selling SKU items. In another embodiment, the IWMS (102) may be configured to identify one or more multi-SKU cartons having the identified low-stock SKU items.
In step 303, the IWMS (102) may be configured to send one or more transport instructions to one or more smart robots (106) for picking the identified single SKU cartons having low-stock SKU items from the inventory storage (201) and for transferring the identified single-SKU cartons to the reorganization zone (202) of the central warehouse (200). The IWMS (102) may further be configured to send one or more transport instructions to one or more smart robots (106) for picking one or more multi-SKU cartons having low-stock SKU items from the inventory storage (201) and for transferring the one or more multi-SKU cartons to the reorganization zone (202) of the central warehouse (200). In one implementation, one or more transport instructions may correspond to an immediate instruction, needs to be followed by the one or more smart robot (106) on urgent basis. In another implementation, one or more transport instructions may correspond to the scheduled instructions for future processing by the one or more smart robots (106). The multi-SKU cartons may correspond to the SKU for which the single-SKU cartons with stock quantity less than the stock quantity threshold have been identified. The IWMS (102) may also send the shortest travelling path (along with the scheduling instructions) to reach the inventory storage (201) and to reach the reorganization zone (202). In an exemplary embodiment, one or more transport instructions comprise one of the carton identifiers, the bin identifier, the compartment identifier, location (geo-spatial) coordinates of the plurality of bins at reorganization zone (202), location (geo-spatial) coordinates of the plurality of storage compartments at the inventory storage (201), a shortest travelling path or a combination thereof. The instructions from the IWMS (102) to one or more smart robots (106) may contain positional information about the identified single-SKU cartons and the identified multi-SKU carton. While sending instructions to the smart robots (106), the IWMS (102) may be configured to ensure that the task instructions are balanced across days of a month to ensure day-wise workload balance for the pick worker.
In another embodiment, the IWMS (102) may be configured to send scheduling instructions to the smart robots (106) for picking the identified single-SKU cartons having low-selling SKU items with low stocks from the inventory storage (201) and for transferring the identified single-SKU cartons to the reorganization zone (202) of the central warehouse (200). The IWMS (102) may further be configured to send scheduling instructions to the smart robots (106) for picking one or more multi-SKU cartons having item stock less than the stock quantity threshold, from the inventory storage (201) and for transferring one or more multi-SKU cartons to the reorganization zone (202) of the central warehouse (200). In another embodiment, the IWMS (102) may be configured to send instructions to the smart robot (106) for picking one or more empty cartons and for transferring one or more empty cartons to the reorganization zone (202). The IWMS (102) may also send the shortest travelling path (along with the scheduling instructions) to reach the inventory storage (201) and to reach the reorganization zone (202). The instructions from the IWMS (102) to the smart robots (106) may contain positional information about the identified single-SKU cartons, multi-SKU cartons or empty cartons.
In step 304, the smart robot (106) may deliver the single-SKU cartons with fewer stock and multi-SKU cartons in the reorganization zone (202). The smart robot (106) may move towards the inventory storage (201). The smart robot (106) may first scan the machine-readable code of each carton, at the inventory storage (201) to verify the instructions (Carton Identifier, Compartment Identifier) received from the IWMS (102). In one embodiment, after successful verification, the smart robot (106) may pick the single-SKU cartons from the compartment of the inventory storage (201) and move towards the reorganization zone (202). In another embodiment, the smart robot (106) may pick the single SKU cartons from the compartment of the inventory storage (201), based on geospatial coordinates received from the IWMS (102). The smart robot (106) may utilize an optimized path to reach the reorganization zone (202). In another embodiment, after successful verification, the smart robot (106) may pick the multi-SKU carton from the compartment of the inventory storage (201) and move towards the reorganization zone (202). In the next step, the smart robot (106) may pick the single SKU cartons and the multi-SKU cartons from the inventory storage (201) and move towards the reorganization zone (202). Further, the smart robot (106) may drop the single SKU cartons and multi-SKU cartons at the reorganization zone (202). In another embodiment, the smart robot (106) may drop one or more empty cartons into the reorganization zone (202). For dropping the cartons at the reorganization zone (202), the smart robot (106) may scan the bin machine-identifier associated with bins of the reorganization zone (202) to identify empty bins. After identification of the empty bin at the reorganization zone (202), the smart robot (106) may place the cartons in the identified empty bin. After placement, the smart robot (106) may send location mapping information (carton identifier, bin identifier) to the IWMS (102). In another embodiment, the smart robot (106) may drop the single SKU cartons, multi-SKU cartons, and empty cartons at the reorganization zone (202), based on geospatial coordinates received from the IWMS (102).
In step 305, a pick worker may manually decant the stocks at the reorganization zone (202) of the central warehouse (200). The pick-worker is a person who manually picks the items from the multi-SKU cartons and transfers the items to the single-SKU cartons at the reorganization zone (202) or vice versa. The pick-worker may have the user device(104). An API (or an application) associated with the IWMS (102) may be installed on the user device (104). The pick worker may be prompted with details about the reorganization of the single-SKU carton and multi-SKU carton placed at the reorganization zone (202). The pick-worker may manually decant the stock by transferring the stock from the multi-SKU carton to the single SKU carton or vice versa.
In another embodiment, the pick worker may manually decant the stock by transferring the low-selling stocks from the single-SKU carton to the multi-SKU carton or vice versa. In an alternative embodiment, the pick worker may reorganize the stock by transferring the low-selling stocks from the single-SKU carton to the empty cartons placed in the reorganization zone (202). The pick worker, after stock reorganization, may put the multi-SKU cartons and the single-SKU cartons back in the set of bins of the reorganization zone (202). The pick worker may map the location of the cartons (single-SKU and multi-SKU) with a set of bins of the reorganization zone (202). The mapping may comprise scanning, by the user device (104), the machine-readable code associated with the carton and the bin of the reorganization zone (202). The user device (104) may send the location mapping information to the IWMS (102).
In step 306, the IWMS (102) may send scheduling instructions with the shortest travelling path to the smart robot (106) for picking the cartons (single-SKU and multi-SKU) from the reorganization zone (202) and placing the cartons back in the inventory storage (201). The smart robot (106) may scan the machine-readable code associated with each carton, to identify cartons corresponding to the instructions from the IWMS (102). After successful identification, the smart robot (106) may pick up the carton from the reorganization zone (202) and move towards the inventory storage (201) of the central warehouse (200). In another embodiment, the smart robot (106) may pick up the carton from the reorganization zone (202), based on geospatial coordinates received from the IWMS (102). The smart robot (106) may scan the compartment machine-readable code of the inventory storage (201) to identify an empty compartment and place the cartons (multi-SKU and single-SKU) in the respective empty compartment of the inventory storage (201). After placement, the smart robot (106) may map the location of the cartons (single-SKU and multi-SKU) with a set of compartments of the inventory storage (201). The mapping may comprise scanning, the machine-readable code associated with the carton and the machine-readable code associated with the compartment of the reorganization zone (202). The smart robot (106) may send the location mapping information to the IWMS (102). In another embodiment, the smart robot (106) may place the cartons (multi-SKU and single SKU) in the compartment of the inventory storage (201), based on geospatial coordinates received from the IWMS (102).
Now referring to Figure 4, a method to be performed for the smart reorganization of stock of inventory storage (201) is illustrated, in accordance with an embodiment of the present subject matter.
Step(401) (Monitoring): The method may begin with the monitoring of item counts within cartons stored in the inventory storage (201) of the centralized warehouse (200). Each carton may be associated with a unique carton identifier, and the inventory storage comprises a plurality of compartments, each may be associated with a compartment identifier.
Step (402) (Comparing): The monitored item counts may then be compared with a predefined stock quantity threshold.
Step (403) (Intelligent Identification): Smart algorithms are employed to intelligently identify one or more cartons with items that count below the predefined stock quantity threshold. This proactive identification minimizes the likelihood of stockouts and reduces manual intervention.
Step (404) (Sending Transporting to Reorganization Zone): The IWMS (102) may send one or more transport instructions to one or more smart robots (106). These instructions may guide the smart robots (106) in transporting the identified cartons to a reorganization zone (202) within the centralized warehouse (200). The reorganization zone (202) may be equipped with a set of bins for temporarily carrying the cartons during the reorganization process.
Step (405) Picking and Placing (406) for Decanting: The smart robots (106) are configured to pick the identified cartons from the plurality of compartments within the inventory storage (201). Subsequently, the robots may place the picked cartons into the set of bins within the reorganization zone (202) for decanting of the items stored in the cartons.
Step (407) (Returning to Inventory Storage): After completing the decanting operation, the smart robots (106) may place the cartons back into the plurality of compartments within the inventory storage (201).
The embodiments illustrated above, especially related to a system and method for the smart stock reorganization may provide, but are not limited to, the following technical advancements:
• Automated tracking of the number of quantities left in the single SKU carton or the multi SKU carton at the inventory storage
• Reduction in manpower for picking and transferring the single SKU cartons and multi-SKU cartons from the inventory storage to the reorganization zone.
• Needs less area to store the cartons at inventory storage as smart robot can pick the cartons at high shelving racks up to 4 meters or more.
• Increase accuracy of picking of cartons and eliminate the risk of human errors
• Smart robot can work 24 hours without rest.
• Save time for picking and transferring the cartons from the reorganization zone to the inventory storage, and vice versa, due to automated robotic transportation and time management by the IWMS.
• Achieve high precision and accuracy
Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in art would understand that certain modifications could come within the scope of this disclosure.
The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments
,CLAIMS:We Claim:
1. A system (100) for automated stock reorganization in a warehouse inventory, characterized in that, the system (100) comprises:
a memory;
a processor coupled to the memory, wherein the processor is configured to execute programmed instructions stored in the memory;
an Intelligent Warehouse Management System (IWMS) (102) coupled with the memory and the processor, wherein the IWMS (102) is configured to enable the automated stock reorganization operations;
a centralized warehouse (200), wherein the centralized warehouse (200) comprises an inventory storage (201) and a reorganization zone (202),
wherein the inventory storage (201) comprises a plurality of compartments for storing one or more cartons, wherein each carton from the one or more cartons is associated with a corresponding carton identifier, wherein each compartment from the plurality of compartments is associated with a corresponding compartment identifier,
wherein the reorganization zone (202) comprises a set of bins for temporarily carrying one or more cartons,
one or more smart robots (106) for performing automated stock reorganization operations in the centralized warehouse (200);
wherein the IWMS (102) is configured to check the count of items in each carton from the one or more cartons placed in the inventory storage (201), wherein the IWMS (102) is configured to compare the count of items in each carton with a predefined stock quantity threshold;
wherein one or more smart robots (106) are configured to:
receive one or more transport instructions, from the IWMS (102), wherein one or more transport instructions correspond to instructions for transporting one or more cartons from the plurality of compartments of the inventory storage (201) to the set of bins of the reorganization zone (202) for temporarily carrying one or more cartons, wherein the one or more transport instructions from the IWMS (102) is received in case of count of items in carton placed in the inventory storage (201) is less than the predefines stock quantity threshold;
pick the one or more cartons from the plurality of compartments of the inventory storage (201);
place the one or more picked cartons in the set of bins of the reorganization zone (202) for decanting of the items placed in the cartons at the reorganization zone (202);
place the one or more cartons, after decanting operation, from the set of bins of the reorganization zone (202) back to the plurality of compartments of the inventory storage (201), and
update the IWMS (102) with mapping of carton identifier with compartment identifier of the inventory storage on which the one or more cartons have been placed.
2. The system (100) as claimed in claim 1, wherein the set of bins in the reorganization zone (202) is associated with a corresponding bin identifier.

3. The system (100) as claimed in claim 2, wherein the compartment identifier corresponds to a compartment machine-readable code; wherein the carton identifier corresponds to a carton machine-readable code; wherein the bin identifier corresponds to a bin machine-readable code; wherein each of the compartment machine-readable codes, carton machine-readable code and bin machine-readable codes correspond to one of a linear barcode, a radio frequency identification (RFID) tag, a Quick Response (QR) code, an optical label or a combination thereof.

4. The system (100) as claimed in claim 1, wherein one or more cartons comprise a carton including one or more items with a single Stock Keeping Unit (SKU), wherein one or more cartons comprise a carton including one or more items with multiple-SKUs.

5. The system (100) as claimed in claim 4, wherein one or more transport instructions correspond to instructions for picking one of the cartons having items with a single-SKU, the carton having items with multiple-SKUs, or a combination thereof.

6. The system (100) as claimed in claim 1, wherein one or more transport instructions are instructions scheduled for future processing by the one or more smart robots (106); wherein one or more transport instructions comprise one of the carton identifier, the bin identifier, the compartment identifier, geo-spatial coordinates of the set of bins, geo-spatial coordinates of the plurality of compartments, a shortest travelling path, or a combination thereof.

7. The system (100) as claimed in claim 1, wherein the IWMS (102) is configured to check order details of the items stored in one or more cartons in the inventory storage (201) to identify low selling items, wherein the low selling items are identified by comparing number of days for which the items not ordered with a predefined low selling day threshold.

8. The system (100) as claimed in claim 7, wherein the IWMS (102) is configured to send one or more transport instructions to the one or more smart robots (106) for transporting one or more cartons containing the low selling items.

9. The system (100) as claimed in claim 1, wherein the decanting operation at the organization zone (202) corresponds to the decanting of items from multiple-SKUs cartons to single-SKU cartons, or vice versa; wherein the decanting operation at the organization zone (202) is performed either automatically through the one or more smart robots (106), or manually by a person.

10. The system (100) as claimed in claim 1, wherein the system (100) comprises one or more user devices (104), wherein the one or more user devices (104) is configured to input, into the IWMS (102) mapping of carton identifier with either the bin identifier or the compartment identifier; wherein the one or more user devices (104) is used during the manual decanting operation for mapping of carton identifier with the bin identifier of the reorganization zone (202).

11. The system (100) as claimed in claim 1, wherein the plurality of compartments of the inventory storage (201) and the set of bins of the reorganization zone (202) are different and placed at different locations in the warehouse.

12. A method (400) for automated stock reorganization by an Intelligent Warehouse Management System (IWMS) (102) using one or more smart robots (106), characterized in that, the method (400) comprising:
monitoring (401), count of items in each carton of one or more cartons placed in an inventory storage (201) of a centralized warehouse (200), wherein the inventory storage (201) comprises a plurality of compartments for storing one or more cartons, wherein each carton from the one or more cartons is associated with a corresponding carton identifier, wherein each compartment from the plurality of compartments is associated with a corresponding compartment identifier;
comparing (402), the monitored count of items in each carton with a predefined stock quantity threshold;
identifying (403), one or more cartons with the count of items less than the stock quantity threshold;
sending (404), one or more transport instructions to the one or more smart robots (106) for transporting the identified one or more cartons to a reorganization zone (202) of the centralized warehouse (200), wherein the reorganization zone (202) comprises a set of bins for temporarily carrying one or more cartons;
enabling one or more robots (106) to:
pick (405) the one or more cartons from the plurality of compartments of the inventory storage (201);
place (406) the one or more picked cartons to the set of bins of the reorganization zone (202) for decanting of the items placed in the cartons at the reorganization zone (202); and
place (407) the one or more cartons, after the decanting operation, from the set of bins of the reorganization zone (202) back to the plurality of compartments of the inventory storage (201).

13. The method (300) as claimed in claim 11, wherein the method (400) comprises receiving, by the IWMS (102), mapping information of carton identifier with compartment identifier of the inventory storage (201) on which the one or more cartons have been placed.

14. The method (400) as claimed in claim 11, wherein identifying cartons with item count less than the stock quantity threshold corresponds to identifying cartons having single Stock Keeping Unit (SKU) items less than the stock quantity threshold, wherein identifying cartons with item count less than the stock quantity threshold corresponds to identifying carton having multiple SKU items less than the stock quantity threshold.

15. The method (400) as claimed in claim 11, wherein the decanting operation at the organization zone (202) corresponds to the decanting of items from multiple-SKUs cartons to single-SKU cartons, or vice versa; wherein the decanting operation at the organization zone (202) is performed either automatically through the one or more smart robots (106), or manually by a person.

Dated this 27th day of January 2023