System and method for partial order filling

A method for distributing a plurality of items, using a material handling system, in accordance with a plurality of separate requests for specific quantities of said items, comprising the steps of:

• receiving said requests by a processor within said material handling system;
• receiving a plurality of said items, each item being provided in a predetermined quantity;
• automatically assembling said requested items in transport units, contained within a work area of said material handling system for placement in said transport units in accordance with said requests, said requests including quantities of said items less than said predetermined quantity;
• and
• planning the distribution of said plurality of items by sequentially ordering said items to cause the predetermined quantity corresponding to the greatest number of requests for the item to be received in the work area first.

A method of distributing items, based on a plurality of separate requests for said items, comprising the steps of:

• providing said items in a predetermined quantity;
• controlling the distribution of said items to place quantities of said items, less than said predetermined quantity, in transport units, contained in a work area of a material handling system, each said transport unit being associated with one of said requests;
• ordering a sequence of said items in predetermined quantities to cause the predetermined quantity corresponding to the greatest number of requests for the item therein to enter the work area first;
• and
• automatically placing said items into said transport units.

A material handling system for distributing a plurality of items in accordance with a plurality of separate requests for specific quantities of said items, comprising:

• means for receiving said requests;
• means for receiving a plurality of said items, each item being provided in a predetermined quantity;
• means for automatically assembling said requested items in transport units contained within a work area of said material handling system for placement into said transport units in accordance with said requests, said requests including quantities of said items less than said predetermined quantity;
• means for planning the distribution of said plurality of items by sequentially ordering said items to cause the predetermined quantity corresponding to the greatest number of requests for the item to be received in the work area first, said means for planning including:
• means for assigning specific quantities of said items to corresponding ones of said transport units:
• means for combining quantities for said items within at least two of said plurality of separate requests;
• means for comparing the combined quantity for said item with said predetermined quantity of the item;
• means for tracking the transport units, from oldest to newest, based on the length of time said transport units have been in the work area;
• and
• means for comparing the first sequential predetermined quantity of items with said assigned specific quantity for said item, corresponding to said oldest transport unit.

A method for distributing a plurality of items, using a material handling system, in accordance with a plurality of separate requests for specific quantities of said items, comprising the steps of:

• receiving said requests by a processor within said material handling system;
• receiving a plurality of said items, each item being provided in a predetermined quantity;
• automatically assembling said requested items in transport units, contained within a work area of said material handling system for placement in said transport units in accordance with said requests, said requests including quantities of said items less than said predetermined quantity;
• and
• planning the distribution of said plurality of items by sequentially ordering said items to cause the predetermined quantity corresponding to the greatest number of requests for the item to be received in the work area first, said step of planning including the steps of:
• assigning specific quantities of said items to corresponding ones of said transport units;
• combining quantities for said items within at least two of said plurality of separate requests;
• comparing the combined quantity for said item with said predetermined quantity of the item;
• tracking the transport units, from oldest to newest, based on the length of time said transport units have been in the work area;
• and
• comparing the first sequential predetermined quantity of items with said assigned specific quantity for said item, corresponding to said oldest transport unit.

A method of distributing items, based on a plurality of separate requests for said items, comprising the steps of:

• providing said items in a predetermined quantity;
• controlling the distribution of said items, by combining quantities for said items within at least two of said plurality of separate requests and comparing the combined quantity for said item with said predetermined quantity of the item to place quantities of said items, less than said predetermined quantity in transport units, contained in a work area of a material handling system, each said transport unit being associated with one of said requests, said step of controlling further including tracking the transport units, from oldest to newest, based on the length of time said transport units have been in the work area and comparing the first sequential predetermined quantity of items with the requirements for said item, corresponding to said oldest transport unit, any other successive transport units in the work area and any additional transport units, corresponding to said item, assignable to the work area;
• ordering a sequence of said items in predetermined quantities to cause the predetermined quantity corresponding to the greatest number of requests for the item therein to enter the work area first;
• and
• automatically placing said items in said transport units, according to said combined requests, when said combined quantity is greater than or equal to said predetermined quantity.