Abstract
A method (Fig 1) and associated system 100A for replenishing and picking inventory in a forward pick area 104 of a warehouse 102 is disclosed. System 10A comprises an automated tote exchanger 124 and a controller 100 that receives a replenishment instruction based on at least one inventory stock keeping unit/SKUs from a management server 108 and communication network 112. Motion of storage totes 116A-C, filled with inventory items, on conveyor 114 from bulk storage area 106 to at least one induction point /aisle in area 104 is followed by the direction of an automated range tote to person bot 118A-B to collect filled totes from conveyor 114 and store load on a multi-level flow rack 120A-B also in forward pick area 104. An order signal is communicated, including a pick order an route / location sequence to at least one operator device 126A-B and a ranger assist bot 122A-B when a new order is received from management server 108. Ranger assist bots 12A-B are then directed towards a drop-off location and auto tote exchanger 124. The fulfilled order tote is collected from ranger assist bot 122A-B and automatically exchanged with an empty tote from the multi-level takeaway conveyor 28. Fig 1