Description:FIELD OF INVENTION

[001] The present invention relates to a system and method for creating pre-sorted pick task with orders of single destination based group. Particularly, the present invention relates to a method for pre-sorting orders based on single destination based group, thereby eliminating sortation of packages post packaging at sortation center so as to save time and efforts of workers and lowering the risk of damage to packages due to squeezing and mishandling of packages during sortation.

BACKGROUND OF THE INVENTION

[002] Fulfillment center (FC) is one of the major section of supply chain that functions as a hub for all logistics processes required to provide a product from a seller to a customer. The fulfillment center regulates entire order fulfillment process, starting from picking and processing of the order to packaging and shipping. The fulfilment center primarily involves three stages through which a customer shipment passes. Such stages involve inventory, packaging, and sorting. Items for sale are stored in inventory. Customers place order on the inventory from all serviceable destinations. The ordered items are reserved at available shelf locations within the fulfillment center. Depending on the size of fulfillment center, the inventory area is divided into a number of smaller zones to minimize picker travel. The item is picked from its zone after shipment creation and sent for packaging. The packaging stage involves attaching shipping label and customer invoice to package after the product is packed in a robust secondary packaging. The sortation stage involves sorting shipments by destination line haul lanes and stages the shipments until line haul vehicle arrives.

[003] Some of the conventional type of order picking includes wave picking, batch picking, and discrete picking. The wave picking involves dividing processing hours of the fulfillment center into time durations called waves. Each wave is allocated to pick orders belonging to a pre-decided destination or a set of destinations. In case, orders of a destination or a set of destinations is greater than the capacity of that destination then there may be delay in delivering excess orders to the customer and in case orders of a destination or a set of destinations is lower than the capacity of that destination then there may be wastage of resources of the fulfillment center. Furthermore, as the number of destinations is large, dividing processing time of the fulfillment center to multiple dedicated time slots for each destination is not feasible. Post wave change, the sortation center needs to switch over its infra and map it to the destination or group of destinations of the next wave, which may result in loss of time and in turn capacity for sortation center.

[004] Batch picking involves clubbing orders into batches depending on the inventory storage location of the ordered items. The clubbing is agnostic of destinations of the ordered items and focusses primarily on picker’s travel optimization and utilization of capacity of the fulfillment center. However, batch picking does not allow users to segregate orders by destination as it may require sortation. Moreover, batch picking is not a suitable picking strategy for orders with large SKU (stock keeping units) volume or large sized orders.

[005] Discrete picking involves picking items of individual orders in one pick task. Furthermore, discrete picking is suitable only for small warehouses that deals with small orders. Moreover, discrete picking is labor-intensive and limited to picking one customer order at a time.

[006] All the conventional picking methods allow creation of pick task having orders of multiple destinations during a time window or only one destination during a time window. As the pick list is created agnostic of destinations of shipments, the shipments of multiple customers from multiple destinations is picked in a same tote and handed over to the sortation center in any sequence of distribution. Thus, the shipments at sortation center requires sortation which may be time-consuming and may result in damage to the package due to rough handling during sortation.

[007] There are several patent application that provides a system and method for creating pick task for picker so as to manage orders for deliveries. One such WIPO Patent Application WO2022/008980 discloses a computerized systems and methods for package delivery to fulfill customer orders. The cited prior art establishes a computerized systems to pick, pack and sort customer orders and then put them in a container that can further be loaded into vehicles. However, the cited prior art fails to address the processing of multiple customer orders in a single time. The cited prior art recommends an additional sortation process which increase the time and efforts of the workers.

[008] In order to overcome the problem associated with above stated prior arts, there is a need for the development of an efficient system and method for creating pre-sorted pick task for pickers capable of handling multiple customer orders at a same time and eliminating sortation post packaging, thereby saving time and efforts of the worker.

OBJECTIVE OF THE INVENTION
[009] In order to overcome the problem associated with above stated prior arts, there is a need for the development of an efficient system and method for creating pre-sorted pick task for pickers and eliminating sortation post packaging, thereby saving time and efforts of the worker.

[0010] The primary objective of the present invention is to provide a system and method for creating pre-sorted pick task with orders of single destination based group.

[0011] Another objective of the present invention is to provide a system and method for pre-sorting of orders based on single destination based group, thereby eliminating sortation of packages at sortation center so as to save time and efforts of the workers and lowering the risk of damage to packages due to squeezing and mishandling of packages during sortation.

[0012] Another objective of the present invention is to ensure that each pick task involves items of single destination based group.

[0013] Another objective of the present invention is to provide a system and method capable of handling multiple customer orders at a same time.

[0014] Another objective of the present invention is to create pick tasks for multiple destinations simultaneously while ensuring that each pick task includes items of order of single destination based group.
[0015] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

BRIEF DESCRIPTION OF DRAWINGS
[0016] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:

[0017] Figure 1 illustrates a flowchart depicting four primary stages involved in creating pre-sorted pick task with orders of single destination based group;

[0018] Figure 2 illustrates a flowchart depicting a method for processing orders and creating pre-sorted pick task with orders of single destination group; and

SUMMARY OF THE INVENTION
[0019] The present invention provides a system and method for creating pre-sorted pick task with orders of single destination based group. The method for creating pre-sorted pick task with orders of single destination based group comprises: (a) uploading the destination based groups by a user in a software module (104) installed in a computing device (102); (b) receiving orders of customers from multiple destinations by the computing device (102); (c) assigning a group number to each destination based group by the user via the computing device (102); (d) segregating orders separately based on destination by a processor (106) integrated in the computing device (102); (e) segmenting orders in picking zone as per the shelf location of the ordered item in an inventory; (f) creating a picklist comprising of a pick task for each picking zone, having items belonging to the single destination based group by the software module (104); (g) transmitting the picklist to an automatic storage and retrieval system (ASRS) (108) for picking items from each location in a single barcoded tote; (h) picking ordered items by the ASRS (108) from the inventory; (i) placing of picked items by the ASRS (108) into a single barcoded tote; (j) transporting the barcoded tote to a carton packaging machine (112) via a motorized roller conveyor (MRC) (110); (k) scanning the barcode attached on tote bag by a barcode reader (114) installed at entry point of a carton packaging machine (112); (l) sending details of all shipments (address, customer details and products to be packed) to be created for the items present in the scanned tote to a processing unit (116) of the carton packaging machine (112), so as to analyze dimensions of all products in the tote bag; (m) sending the dimensions of all products to be packed to the computing device (118) of the carton packaging machine (112); (n) placing of each product one-by-one on an infeed conveyor (120) of the carton packaging machine (112) till each tote bag gets empty; (o) scanning barcode of each product by a camera (122) installed on the infeed conveyor (120) of the carton packaging machine (112); (p) passing the products through the carton packaging machine (112) for packing of the products via the infeed conveyor (120); (q) packaging of each product as per its size by the packing machine; (r) pasting of shipping label and invoice on each product by a print and apply machine (124); (s) scanning the shipping label by the camera (122) and transmits the details to the processing unit (116) of the carton packaging machine (112), to obtain the picklist id and group number of shipment; (t) diverting all shipments having products picked in the same picklist id and same destination group number to the same branch of infeed conveyor (120), so as to collect the shipments of same picklist group and destination group into a gunny bag with a RFID; (u) repeating step (s-t) until all products of the picklist are packed in a same gunny bag; and; v) discharging the gunny bag having shipments of same picklist group and destination group onto a gunny bag belt conveyor (126) to move the gunny bag through an RFID tunnel toward a vehicle dispatch area.

[0020] The system for creating pre-sorted pick task with orders of single destination based group comprises of: a computing device; a processor integrated in the computing device; a software module installed in the computing device of the system; an automatic storage and retrieval system (ASRS) communicably connected to the computing device; a motor roller conveyor (MRC) communicably coupled to the ASRS to receive a single barcoded tote; a carton packaging machine (CPM) is configured to receive tote bag from the MRC, a print and apply machine configured to receive packed products via the infeed conveyor via gunny bag conveyor belt transmit shipments from the infeed conveyor to a vehicle dispatch area through a RFID tunnel. The CPM provided in the system comprises of: an infeed conveyor to receive all products of the tote bag one by one onto an infeed conveyor; a barcode reader installed at the entry point of the carton packaging machine to scan the barcode on the tote; a camera integrated on the infeed conveyor; a processing unit to receive all shipment details of the tote from the barcode reader and the camera; a computing device to receive dimensions of all products of the tote from the processing unit; a packing machine communicably connected to the computing device; a print and apply machine configured to receive packed products via the infeed conveyor; a gunny bag conveyor belt transmit shipments from the infeed conveyor to a vehicle dispatch area through a RFID tunnel.

DETAILED DESCRIPTION OF THE INVENTION
[0021] The following description describes various features and functions of the disclosed system with reference to the accompanying figures. In the figures, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system can be arranged and combined in a wide variety of different configurations, all of which have not been contemplated herein.

[0022] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0023] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0024] The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustrative purpose only and not for the purpose of limiting the invention.

[0025] It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

[0026] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, steps, components or groups thereof. The equations used in the specification are only for computation purpose.

[0027] Accordingly, the present invention relates to a system and method for creating pre-sorted pick task with orders of single destination based group. Particularly, the present invention relates to a method for pre-sorting orders based on single destination based group, thereby eliminating sortation of packages post packaging at sortation center so as to save time and efforts of workers and lowering the risk of damage to packages due to squeezing and mishandling of packages during sortation.

[0028] In a preferred embodiment, the system (100) is configured to provide pre-sorting of shipment based on an automated packaging of the orders of single destination. The system provides automated packaging and pre-sortation of the shipments. A plurality of conveyor belts are installed in the system for managing the transportation and packaging of the shipments, by enabling the transport of shipments from an automatic storage and retrieval system (ASRS) (108) for packaging to the vehicle dispatch area for delivery. The system comprises of the ASRS (108); a carton packaging machine (112) integrated with an infeed conveyor (120), a barcode reader, processing unit (116) of the carton packaging machine, and automated packaging unit; a print and apply machine connected to the end point of the carton packaging machine; one or more RFID attached gunny bags for collecting the shipments placed on the infeed conveyor (120) of the carton packaging machine (112).

[0029] In an embodiment, the system (100) for creating automated pre-sortation pick task with orders of single destination based group comprises of the following components:

[0030] (a) Computing device (102): A computing device (102) is configured to receive orders from multiple destinations and enables the user to perform actions such as segregating and sorting of orders as per the destination based groups. In an exemplary embodiment, the computing device (102) may include such as, but not limited to, a computer, laptop, and the like.

[0031] (b) Processor (106): A processor (106) is integrated in the computing device (102). The processor (106) is configured to segregate the orders received by the computing device (102) separately based on destination. In an embodiment, the segregated orders are segmented in picking zone as per the shelf location of the ordered item in an inventory.

[0032] (c) Software module (104): A software module (104) is installed in the computing device (104) of the system (100). The software module (104) is uploaded with a plurality of destination based groups provided by the user for generating a destination based pick list for orders belonging to a single destination based group. In an embodiment, the software module creates a pick task for each picking zone that comprises of items belonging to a single destination based group.

[0033] (d) Automatic storage and retrieval system (108): An automatic storage and retrieval system (ASRS) (108) is communicably connected to the computing device (102). The ASRS (108) is configured to receive picklist created by the software module (104), for each picking zone for picking items from each location into a single barcoded tote. The ASRS (108) is configured to pick ordered items from the inventory and transfer the items into a single barcoded tote.

[0034] In an exemplary embodiment, the ASRS (108) is a computer aided system for retrieving or storing items into a tote, thereby helping to speed up manufacturing and shipping tasks. The ASRS (108) runs along a track and deliver items or move them between racking systems, thereby automating the process of picking high volume loads rapidly and accurately into the tote bag.

[0035] (e) Motorized Roller Conveyor (110): A motorized roller conveyor (MRC) (110) is communicably coupled to the ASRS (108) to receive single barcoded tote bag onto the roller conveyor (110) from the ASRS (108).

[0036] (f) Carton packaging machine (112): A carton packaging machine (112) is configured to receive tote bag from the MRC (110). The carton packaging machine (112) comprises of: a barcode reader (114) installed on the entry point to scan the barcode on the tote bag; an infeed conveyor (120) to receive all products of the tote bag one by one; a camera (122) installed on the infeed conveyor (120) and a packing machine; a processing unit (116) to receive all shipment details of the tote bag from the barcode reader (114) and the camera (122); a computing device (118) to receive dimensions of all products of the tote from the processing unit (116); and a packing machine communicably connected to the computing device (118).

[0037] In an embodiment, MRC (110) is configured to transport the barcoded tote bag to a carton packaging machine (112). The barcode reader (114) installed at entry point of the carton packaging machine (112) scans the barcode attached to tote bag and sends the details of all shipments (address, customer details and products to be packed) to be created for the items present in the scanned tote to a processing unit (116) of carton packaging machine (112) so as to analyze dimensions of all products in the tote bag. The processing unit (116) transmits the dimensions of all products to be packed to the computing device (118) of carton packaging machine (112). The products are loaded/placed one-by-one on infeed conveyor (120) of carton packaging machine (112) till each tote bag get empty. The camera (112) installed on infeed conveyor (120) of carton packaging machine (112) is configured to scan barcode of each product, which are then passed through the packing machine for packing of the products.

[0038] (g) Print and apply machine (124): The packed products on the infeed conveyor (120) passes through a print and apply machine (124) for pasting shipping label and invoice on the packet of each product.

[0039] The camera (122) installed on the infeed conveyor (120) further scans the shipping label pasted on the packet of each product and transmits all details to the processing unit (116) of the carton packaging machine (112), which creates a picklist id and group number of shipment. The infeed conveyor (120) connected to the processing unit (116) of the carton packaging machine (112) diverts all shipments, one after the other, having products picked in the same picklist id and having the same destination based group number to the same branch of infeed conveyor (120) to collect the shipments of same picklist group and destination group into a gunny bag configured with a RFID.

[0040] (h) Gunny Bag conveyor belt (126): A gunny bag conveyor belt (126) is communicably coupled to the infeed conveyor (120) wherein the infeed conveyor (120) discharges the gunny bag having shipments of same picklist group and destination group onto the gunny bag conveyor belt (126) to move the gunny bag through a RFID tunnel toward a vehicle dispatch area.

[0041] In an embodiment, the RFID tunnel provides fast and accurate automatic reading of RFID tags attached on each gunny bag through the gunny bag conveyor belt (126), which further dispatches the gunny bag to a vehicle dispatch area.

[0042] In an embodiment, as shown in Figure 1, the method for creating pre-sorted pick task with orders of single destination based group involves four stages including pick task creation, picking, packaging, and line haul. The method eliminates sortation stage for sorting shipments/packages post packaging at the sortation center, thereby saving time and efforts of the workers along with lowering the risk of damage to packages due to squeezing and mishandling of packages during sortation.

[0043] Referring to Figure 2, the automated method for creating pre-sorted pick task with orders of single destination based group comprises of the following steps:

(a) uploading the destination based groups by a user in a software module (104) installed in a computing device (102);
(b) receiving orders of customers from multiple destinations by the computing device (102);
(c) assigning a group number to each destination based group by the user via the computing device (102);
(d) segregating orders separately based on destination by a processor (106) integrated in the computing device (102);
(e) segmenting orders in picking zone as per the shelf location of the ordered item in an inventory;
(f) creating a picklist comprising of a pick task for each picking zone, having items belonging to the single destination based group by the software module (104);
(g) transmitting the picklist to an automatic storage and retrieval system (ASRS) (108) for picking items from each location in a single barcoded tote;
(h) picking ordered items by the ASRS (108) from the inventory;
(i) placing of picked items by the ASRS (108) into a single barcoded tote;
(j) transporting the barcoded tote to a carton packaging machine (112) via a motorized roller conveyor (MRC) (110);
(k) scanning the barcode attached on tote bag by a barcode reader (114) installed at entry point of a carton packaging machine (112);
(l) sending details of all shipments (address, customer details and products to be packed) to be created for the items present in the scanned tote to a processing unit (116) of the carton packaging machine (112), so as to analyze dimensions of all products in the tote bag;
(m) sending the dimensions of all products to be packed to the computing device (118) of the carton packaging machine (112);
(n) placing of each product one-by-one on an infeed conveyor (120) of the carton packaging machine (112) till each tote bag gets empty;
(o) scanning barcode of each product by a camera (122) installed on the infeed conveyor (120) of the carton packaging machine (112);
(p) passing the products through the carton packaging machine (112) for packing of the products via the infeed conveyor (120);
(q) packaging of each product as per its size by the packing machine;
(r) pasting of shipping label and invoice on each product by a print and apply machine (124);
(s) scanning the shipping label by the camera (122) and transmits the details to the processing unit (116) of the carton packaging machine (112), to obtain the picklist id and group number of shipment;
(t) diverting all shipments having products picked in the same picklist id and same destination group number to the same branch of infeed conveyor (120), so as to collect the shipments of same picklist group and destination group into a gunny bag with a RFID;
(u) repeating step (s-t) until all products of the picklist are packed in a same gunny bag; and
(v) discharging the gunny bag having shipments of same picklist group and destination group onto a gunny bag belt conveyor (126) to move the gunny bag through an RFID tunnel toward a vehicle dispatch area.

[0044] In an embodiment, the RFID tunnel provides fast and accurate automatic reading of RFID tags attached on each gunny bag through the gunny bag conveyor belt (126), which further dispatches the gunny bags to a vehicle dispatch area.

[0045] In an alternate embodiment, a picklist may be provided to an ASRS (108) for manually picking the items directly into a tote. A handheld device (108) may receive the picklist generated at step (f) and provide instructions to the picker regarding the ordered items, which may further be picked from an inventory by the picker.

[0046] In an embodiment, the present invention enables creation of pick tasks of multiple destinations simultaneously, ensuring that each pick task involves ordered items of a single destination based group.

[0047] In an exemplary embodiment, the tote used in the present invention for packing the ordered items may include such as, but not limited to, hard crates so as to ensure protection to the items inside the tote from the damage.

[0048] In an alternate embodiment, the system is configured to provide pre-sorting of shipment based on a semi-automated packaging of the orders of single destination. The system for semi-automated packaging of orders further comprises of:

[0049] (I) Handheld device (128): The handheld device (128) is configured to receive the destination based picklist generated by the software module (104) and provide instructions to the picker regarding the ordered items to be picked from an inventory. In an exemplary embodiment, the handheld device (108) may include such as, but not limited to, mobile device, Ipad, and the like.

[0050] (II) Scanner (130): The scanner (130) is communicably coupled to the software module (104) installed in the computing device (102). The scanner (130) is configured to scan barcode of each tote.

[0051] As per an alternate embodiment, a method for creating semi-automated pre-sorted pick task with orders of single destination based group comprises of the following steps:

(a) uploading the destination based groups by a user in a software module (104) installed in a computing device (102);
(b) receiving orders of customers from multiple destinations by the computing device (102);
(c) assigning a group number to each destination based group by the user via the computing device (102);
(d) segregating orders separately based on destination by a processor (106) integrated in the computing device (102);
(e) segmenting orders in picking zone as per the shelf location of the ordered item in an inventory;
(f) creating a picklist comprising of a pick task for each picking zone, having items belonging to the single destination based group by the software module (104);
(g) generating a destination based pick list for orders belonging to a single destination based group by the software module (104);
(h) transmitting the pick list to a handheld device (128) of a picker over a wireless network;
(i) picking ordered items by the picker from an inventory;
(j) packing ordered items in a tote;
(k) transporting the tote to a packing station;
(l) scanning barcode of the tote by the packer via a scanner (130);
(m) scanning barcode of each item inside the tote by the packer via the scanner (130);
(n) prompting shipping details of the item to the packer by the software module (104);
(o) verifying quality attributes, packs item(s) and its invoice by the packer through the handheld device (128);
(p) packing the item and putting a shipping label and customer invoice on each package by the packer;
(q) putting each package in a separate tote by the packer;
(r) repeating steps (m-q) until all items of the tote picked by the packer are packed and put in the same tote;
(s) consigning the entire tote to a sortation center by the packer;
(t) receiving the tote by the sortation center;
(u) packing the packages of the entire tote in a single gunny bag;
(v) sealing the gunny bag; and
(w) loading the gunny bags directly in line haul vehicle or staging the gunny bags till vehicle arrives.

[0052] In an embodiment, as shown in Table 1, the destination based groups are created by permutation of destination based pin-codes, mode of transport and logistic partner. The destination based pin-codes may include a single pin-code or a group of pin-codes served by a single last mile hub (delivery hub) or a group of pin-codes served by multiple delivery hubs but belonging to the same line haul lane. Each combination of destination based pin-code, mode of transport, and logistic partner is assigned a specific group number by a user via the computing device (102). For instance, a group including a combination of pin-code-11001, mode of transport-air, and logistic partner- Ekart is assigned a group number A by the user; a group including a combination of a set of pin-codes-560102, 560103, 560100, mode of transport-surface and logistic partner-Ekart is assigned a group number B by the user; a group including a combination of pin-code-11001, mode of transport-air and logistic partner- Delhivery is assigned a group number C by the user; a group including a combination of pin-code-11001, mode of transport-air and logistic partner- Delhivery is assigned a group number C by the user; and a group including a combination of pin-code-11001, mode of transport-surface and logistic partner- Ekart is assigned a group number D by the user. The flexibility of selecting destination based pin-codes is entirely dependent on the user.

Destination Mode of Transport Logistics partner Group number
110001 Air Ekart Group A
560102 Surface Ekart Group B
560103 Surface Ekart Group B
560100 Surface Ekart Group B
110001 Air Delhivery Group C
110001 Surface Ekart Group D

Table 1
[0053] In an embodiment, in order to ensure that the items of one pick list provided to the picker remains together until loaded in destination line haul vehicle, the capacity booking of the fulfilment center remained unchanged and all new orders were accommodated in next time duration and the location selection in inventory also remained unchanged while creating a picklist.

[0054] In an embodiment, the system ensures sufficient orders per destination so that the batch size picked by a picker in one travel is not reduced, thereby maintaining cost of operating and ensuring that the picking strategy is within acceptable guardrails.

[0055] The present invention exhibits a number of advantages:

1. The present invention eliminates sortation stage post packaging of items, thereby reducing time and efforts of the workers.
2. The present invention eliminates sortation thereby reducing the damage to the items while sorting the items due to rough handling or squeezing of items. This elimination of sortation stage reduces touch points of the items due to which separate hard packing of each item can be avoided, thereby saving cost and efforts of the packer.
3. The present invention aims to reduce packaging since elimination of sortation reduces touching of the shipments/packages, rough handling and squeezing of the shipment/package, resulting in low risk of handling damages.
4. The strength of packaging can be reduced or avoided as the picked tote are transported to the destination.

[0056] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
, Claims:WE CLAIM:
1. A method for creating pre-sorted pick task with orders of single destination based group, comprising:
(a) uploading the destination based groups by a user in a software module (104) installed in a computing device (102);
(b) receiving orders of customers from multiple destinations by the computing device (102);
(c) assigning a group number to each destination based group by the user via the computing device (102);
(d) segregating orders separately based on destination by a processor (106) integrated in the computing device (102);
(e) segmenting orders in picking zone as per the shelf location of the ordered item in an inventory;
(f) creating a picklist comprising of a pick task for each picking zone, having items belonging to the single destination based group by the software module (104);
(g) transmitting the picklist to an automatic storage and retrieval system (ASRS) (108) for picking items from each location in a single barcoded tote;
(h) picking ordered items by the ASRS (108) from the inventory;
(i) placing of picked items by the ASRS (108) into a single barcoded tote;
(j) transporting the barcoded tote to a carton packaging machine (112) via a motorized roller conveyor (MRC) (110);
(k) scanning the barcode attached on tote bag by a barcode reader (114) installed at entry point of a carton packaging machine (112);
(l) sending details of all shipments (address, customer details and products to be packed) to be created for the items present in the scanned tote to a processing unit (116) of the carton packaging machine (112), so as to analyze dimensions of all products in the tote bag;
(m) sending the dimensions of all products to be packed to the computing device (118) of the carton packaging machine (112);
(n) placing of each product one-by-one on an infeed conveyor (120) of the carton packaging machine (112) till each tote bag gets empty;
(o) scanning barcode of each product by a camera (122) installed on the infeed conveyor (120) of the carton packaging machine (112);
(p) passing the products through the carton packaging machine (112) for packing of the products via the infeed conveyor (120);
(q) packaging of each product as per its size by the carton packaging machine (112);
(r) pasting of shipping label and invoice on each product by a print and apply machine (124);
(s) scanning the shipping label by the camera (122) and transmits the details to the processing unit (116) of the carton packaging machine (112), to obtain the picklist id and group number of shipment;
(t) diverting all shipments having products picked in the same picklist id and same destination group number to the same branch of infeed conveyor (120), so as to collect the shipments of same picklist group and destination group into a gunny bag with a RFID;
(u) repeating step (s-t) until all products of the picklist are packed in a same gunny bag; and
(v) discharging the gunny bag having shipments of same picklist group and destination group onto a gunny bag belt conveyor (126) to move the gunny bag through an RFID tunnel toward a vehicle dispatch area.

2. The method as claimed in claim 1, wherein the pick tasks are created for multiple destinations simultaneously, ensuring that each pick task involves ordered items of a single destination based group.

3. The method as claimed in claim 1, wherein each tote contains ordered items of single destination based group.

4. The method as claimed in claim 1, wherein the pre-sorted pick task with orders of single destination based group is created by a semi-automatic method, comprising steps of:
(a) uploading the destination based groups by a user in a software module (104) installed in a computing device (102);
(b) receiving orders of customers from multiple destinations by the computing device (102);
(c) assigning a group number to each destination based group by the user via the computing device (102);
(d) segregating orders separately based on destination by a processor (106) integrated in the computing device (102);
(e) segmenting orders in picking zone as per the shelf location of the ordered item in an inventory;
(f) creating a picklist comprising of a pick task for each picking zone, having items belonging to the single destination based group by the software module (104);
(g) generating a destination based pick list for orders belonging to a single destination based group by the software module (104);
(h) transmitting the pick list to a handheld device (128) of a picker over a wireless network;
(i) picking ordered items by the picker from an inventory;
(j) packing ordered items in a tote;
(k) transporting the tote to a packing station;
(l) scanning barcode of the tote by the packer via a scanner (130);
(m) scanning barcode of each item inside the tote by the packer via the scanner (130);
(n) prompting shipping details of the item to the packer by the software module (104);
(o) verifying quality attributes, packs item(s) and its invoice by the packer through the handheld device (128);
(p) packing the item and putting a shipping label and customer invoice on each package by the packer;
(q) putting each package in a separate tote by the packer;
(r) repeating steps (m-q) until all items of the tote picked by the packer are packed and put in the same tote;
(s) consigning the entire tote to a sortation center by the packer;
(t) receiving the tote by the sortation center;
(u) packing the packages of the entire tote in a single gunny bag;
(v) sealing the gunny bag; and
(w) loading the gunny bags directly in line haul vehicle or staging the gunny bags till vehicle arrives.

5. The method as claimed in claim 1, wherein the destination based groups are created by permutation of destination based pin-codes, mode of transport and logistic partner.

6. The method as claimed in claim 1, wherein the destination based pin-codes include a single pin-code or a group of pin-codes served by a single last mile hub (delivery hub) or a group of pin-codes served by multiple delivery hubs but belonging to the same line haul lane.

7. A system for creating pre-sorted pick task with orders of single destination based group as claimed in claim 1, comprising:
• a computing device (102);
• a processor (106) integrated in the computing device (102);
• a software module installed in the computing device (104) of the system (100);
• an automatic storage and retrieval system (ASRS) (108) communicably connected to the computing device (102);
• a motor roller conveyor (MRC) (110) communicably coupled to the ASRS (108) to receive a single barcoded tote;
• a carton packaging machine (CPM) (112) is configured to receive tote bag from the MRC (110), said CPM (112) comprises of:
o an infeed conveyor (120) to receive all products of the tote bag one by one onto an infeed conveyor (120);
o a barcode reader (114) installed at the entry point of the carton packaging machine (112) to scan the barcode on the tote;
o a camera (122) integrated on the infeed conveyor (120);
o a processing unit (116) to receive all shipment details of the tote from the barcode reader (114) and the camera (122);
o a computing device (118) to receive dimensions of all products of the tote from the processing unit (116);
o a packing machine communicably connected to the computing device (118);
• a print and apply machine (124) configured to receive packed products via the infeed conveyor (120);
• a gunny bag conveyor belt (126) transmit shipments from the infeed conveyor (120) to a vehicle dispatch area through a RFID tunnel;
wherein,
I. the computing device configured to receive orders from multiple destinations and enables the user to perform actions such as segregating and sorting of orders as per the destination based groups;
II. the processor (106) configured to segregate the orders received by the computing device (102) separately based on destination.
III. the software module (104) configured to create a pick task for each picking zone that comprises of items belonging to a single destination based group;

IV. the ASRS (108) configured to receive picklist created by the software module (104),so as to pick items from each location into a single barcoded tote;
V. the MCR (110) configured to receive single barcoded tote bag from the ASRS (108);
VI. the camera (122) configured to scan barcode of each product and pass through the packing machine for packing of the products;
VII. the processing unit (116) receive shipment details from the barcode reader (114), so as to analyze dimensions of all products in the bag and transmit the dimensions to the computing device (118);the infeed conveyor (120) passes the packed products through the print and apply machine (124), so as to paste shipping label and invoice on the packet of each product;
VIII. the gunny bag conveyor belt (126) receives shipments of same picklist group and destination group from the infeed conveyor (120) to move the gunny bag through the RFID tunnel toward the vehicle dispatch area.

8. The system as claimed in claim 7, wherein the system (100) comprises a handheld device (108) and a scanner (110) for manual pre-sorted pick task with orders of single destination based group.

9. The system as claimed in claim 8, wherein the handheld device (103) is configured to receive the destination based picklist generated by the software module (104).

10. The system as claimed in claim 8, wherein the scanner (110) is communicably coupled to the software module (104) to scan barcode of each item by a packer.