Abstract: A method and system for opportunistically picking order items during decant processes. An order management system determines which items required for a pending order are depleted within a decant function or storage system and orders replenishment, such as inbound vendor cases containing the depleted required items, to the decant function. Operators at decant workstations pick the required items from the inbound vendor cases into order containers while simultaneously decanting any remaining, non-required vendor items into inventory containers. The order containers and the inventory items are stored in a storage system until all required items for an order are present therein. Once all required items are present, the items are released to a downstream picking workstation, sorter, and/or packing station. The method with opportunistic decant may enable minimized facility space requirements, labor reductions, and resource reductions while improving facility throughput.

Abstract: A system and method is provided for controlling an automated warehouse or order fulfillment facility. The system includes a sequencing tower, which functions as a buffer for inbound items and shipping containers, and various pick/decant workstations which are connected between the sequencing tower and an automated storage and retrieval system (ASRS). The sequencing tower is adapted for receiving, storing, and releasing newly erected shipping containers and inbound vendor cases. The pick/decant workstations function as a hub between the sequencing tower and the ASRS, where operators at the pick/decant workstations pick order items to shipping containers to fulfil orders or pick inbound/vendor items to inventory containers to be stored in the ASRS. The system and methods synchronize the sequencing tower and ASRS to release items to arrive at the workstations simultaneously to optimize efficiency and throughput of the facility.