SYSTEM AND METHOD FOR DEMONSTRATING OPERATIONS AT A DISTRIBUTION CENTER

Abstract

An interactive gaming system offer training and education to users in the distribution center, such as employees and field workers, about optimal distribution operations. The system includes a pre-marked surface that resembles a game board. The pre-marked surface can represent a workflow in a distribution center, warehouse, or other type of storage facility. The pre-marked surface can also include a plurality of zones that represent sub-processes or sub-workflows in the distribution center that make up the entire workflow. The system can also include instruction instruments, such as cards, that, when selected by users at the pre-marked surface, provide instructions and/or prompts indicating actions that the users can take to demonstrate distribution operations in the distribution center.

Description

TECHNICAL FIELD

This document generally describes devices, systems, and methods related to demonstrating operations at a distribution center, such as by gamifying the distribution operations.

BACKGROUND

Distribution centers, warehouses, or other types of storage facilities can be used in supply chains to facilitate movement and storage of items. Various processes can be performed in a distribution center as distribution operations in order to move the items around the distribution center. For example, processes can be performed to unload items from trucks when the items arrive at the distribution center. Processes can be performed to move the items to storage locations in the distribution center after being unloaded from the trucks. Processes can be performed to retrieve one or more of the items from storage when the one or more items are ready to be shipped/delivered to a customer. Processes can also be performed to prepare the retrieved items for outbound shipment. Other processes can also be performed as part of the distribution operations in the distribution center.

The distribution operations can be performed based on decisions made by employees and workers in and out of the distribution center. The decisions made by such employees and workers can be used to complete the distribution operations using warehouse equipment, including but not limited to forklifts, robots, and other vehicles (autonomous, semi-autonomous, non-autonomous). The distribution operations may also be performed by autonomous and/or semi-autonomous vehicles in the distribution center. The decision made by one employee or human worker in and out of the distribution center may affect the decision of another employee or human worker. Thus, a coordination between decisions made by different employees and human workers may be important in optimizing or improving the operations at the distribution center.

SUMMARY

The document generally describes systems, methods, and technology for demonstrating operations in a distribution center. More specifically, the document provides interactive gaming techniques that offer training and education to users in the distribution center, such as employees and field workers, about optimal distribution operations. The disclosed system can include a pre-marked surface that resembles a game board. The pre-marked surface can be provided in various forms. For example, the pre-marked surface can be provided on a surface of a board or plate. Alternatively, the pre-marked surface can be provided at a tabletop or a surface of other suitable devices. The pre-marked surface can represent a workflow in a distribution center, warehouse, or other type of storage facility. The pre-marked surface can also include a plurality of zones (e.g., sub-sections) that represent sub-processes or sub-workflows in the distribution center that make up the entire workflow. The disclosed system can also include instruction instruments, such as cards, that, when selected by users at the pre-marked surface, provide instructions and/or prompts indicating actions that the users can take to demonstrate and/or mimic distribution operations in the distribution center. The disclosed system may also include modular pieces, such as stackable bricks (e.g., Lego® bricks), that represent various warehouse components, such as items (e.g., goods), pallets, warehouse or distribution center equipment (e.g., material handling equipment), cages, cases, etc. The users can perform actions with the modular pieces, based on the selected instruction instrument(s).

Multiple users take part in performing operations in the workflow of the distribution center that is represented by the pre-marked surface. As a result, the users can simulate task performance and decision-making at each process, sub-process, and/or sub-workflow of the workflow. For example, each zone of the pre-marked surface can be assigned at least one user, who is tasked with performing operations that correspond to processes/workflows performed in that zone in an actual distribution center. For example, the zones can represent inbound, warehousing or storing, picking, packing, and outbound stages of the workflow in the actual distribution center. The users can perform tasks using the modular pieces in each of the zones, such as building or taking apart pallets of items, transporting items or pallets on conveyor belts, delivering pallets to shipment areas for various stores, etc., to achieve an instruction, mission, or goal that may be indicated on a card or other instruction instrument that is selected by at least one of the users. However, actions taken can also be based on the users' own decisions and judgment. The actions of each user also can impact actions of other users and/or downstream sub-processes and/or sub-workflows of the distribution center's workflow. Throughout the demonstration of the workflow as described above and herein, the users can identify various issues that may occur in real-world distribution operations based on the actions they take, and learn how to resolve those issues (e.g., bottlenecks, bullwhip effect of sub-optimal inventory management, operational constraints, increasing outputs through level scheduling workloads). As a result, the users can learn how to efficiently handle operations in a distribution center workflow without having to experience or test the operations at an actual, real-world distribution center.

One or more embodiments described herein can include a system for demonstrating distribution operations at a distribution center. The system includes a pre-marked surface representing a workflow for the distribution center, the pre-marked surface defining a plurality of sections that represent the distribution operations at the distribution center and are configured to be assigned to a plurality of users who demonstrate the distribution operations; a plurality of instruction instruments configured to be randomly selected by the plurality of users, each instruction instrument being configured to initiate one of the plurality of users to perform an action at one of the plurality of sections that is assigned to the one of the plurality of users, the action being configured to cause another of the plurality of users to take an action at another of the plurality of sections; and a plurality of modular pieces representing components at the distribution center and configured to, based on selection of the plurality of instruction instruments, be interlocked with each other at the plurality of sections and delivered across the plurality of sections at the pre-marked surface.

In some implementations, the embodiments described herein can optionally include one or more of the following features. The plurality of instruction instruments include a plurality of cards providing instructions configured to initiate the plurality of users to perform actions at the plurality of sections. The plurality of instruction instruments include a die. The plurality of users include first, second, third, fourth, and fifth users, and the plurality of sections includes first, second, third, fourth, and fifth sections that are assigned to the first, second, third, fourth, and fifth users respectively. The plurality of users include a sixth user, and the interlocked modular pieces are assigned to the sixth user and delivered, by the sixth user, to each of the first, second, third, fourth, and fifth sections. The first section corresponds to an inbound department at the distribution center, the second section corresponds to a storing department at the distribution center, the third section corresponds to a picking department at the distribution center, the fourth section corresponds to a packing department at the distribution center, and the fifth section corresponds to an outbound department at the distribution center. The first section includes visual elements that depict: (i) at least one store, (ii) an automated conveyor belt configured to receive the plurality of modular pieces and extend across at least the first section and the second section, (iii) a manual dock, and (iv) a manual dock pallet staging area. The plurality of instruction instruments include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the manual dock depicted on the pre-marked surface. The plurality of instruction instruments include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the automated conveyor belt depicted on the pre-marked surface. The second section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the first section of the pre-marked surface and move the plurality of modular pieces from the second section to the third section of the pre-marked surface, (ii) non-conveyable aisles, and (iii) conveyable aisles. The plurality of instruction instruments include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the non-conveyable aisles depicted on the pre-marked surface. The plurality of instruction instruments include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the conveyable aisles depicted on the pre-marked surface. The third section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the second section of the pre-marked surface and move the plurality of modular pieces from the third section to the fourth section of the pre-marked surface, (ii) a full pallet staging area, (iii) a carton air staging area, and (iv) a re-palletization line. The plurality of instruction instruments includes a die configured to be rolled, by the third user at the third section, to determine a zone amongst a plurality of zones at the re-palletization line depicted on the pre-marked surface, the zone being configured to allow the third user to perform at least one repalletization action with the plurality of modular pieces. The fourth section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the third section of the pre-marked surface and move the plurality of modular pieces from the fourth section to a packing area depicted in the fourth section of the pre-marked surface, (ii) break pack aisles, and (iii) the packing area. The packing area is configured to receive the plurality of modular pieces that are ready to be transported to a designated store of a plurality of stores for receiving inventory, the inventory being represented by the plurality of modular pieces. The packing area includes a plurality of mods. Each of the plurality of mods is assigned to a store amongst the plurality of stores. The plurality of instruction instruments include: a first subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces, the actions including breakpacking actions; and a second subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces that include packing actions. The plurality of instruction instruments further includes a die configured to be rolled, by the fourth user at the fourth section, to determine a zone depicted in the fourth section of the pre-marked surface, the zone being configured to allow the fourth user to perform the actions with the plurality of modular pieces. The plurality of modular pieces are stackable bricks, and the action performed by the one of the plurality of users includes stacking the bricks according to instructions provided by an instruction instrument amongst the plurality of instruction instruments that is randomly selected by the one of the plurality of users. The plurality of modular pieces are different colors and different sizes. The different colors and the different sizes indicate at least one of units of inventory at the distribution center, quantity of the inventory at the distribution center, size of the inventory at the distribution center, a store, type of supplies used at the distribution center as part of the workflow, or type of the inventory at the distribution center. The components at the distribution center represented by the plurality of modular pieces include at least one of inventory, pallets, or warehouse equipment.

The devices, system, and techniques described herein may provide one or more of the following advantages. For example, the disclosed techniques provide real-time simulation of real-world workflows and operations in distribution centers, which allows users to identify issues such as waste in every stage of the workflows and operations without actually having to experience such issues in an actual, real-world distribution center. The waste can include defects, over production, waiting, not utilizing talent, transportation, inventory, motion, and/or excess processing. The disclosed techniques gamify the distribution center workflow and operations to help users decide how to best execute actions, solve problems, and remove constraints in a team environment in the distribution center and at various stages at the distribution center. The disclosed techniques therefore recreate realistic scenarios that may arise in the distribution center and allow for the users to act in these scenarios in a game-like environment. Using the disclosed system, for example, users can identify, recognize, and learn appropriate corrections throughout the workflow and operations of the distribution center. The users can then apply these corrections to the real-world workflows and operations in the real-world distribution center to resolve or reduce issues/bottlenecks, reduce waste, and optimize overall operations. Furthermore, the disclosed system allows real-world workflows to be mapped to a pre-marked surface, such as a game board, so that any organization or entity that engages in distribution operations can use the pre-marked surface to identify issues in their operations and ways to resolve those issues.

As another example, the disclosed techniques can be implemented in a computer-based system such that the pre-marked surface, instruction instruments, and modular pieces can be provided in electronic format to users that are physically remote from each other. The disclosed system can be presented in graphical user interface (GUI) displays at computing devices of the users and can allow for the users to engage in simulating and testing workflows and processes as described herein. The users can work together to identify and resolve issues that may arise in distribution centers across the world using the computer-implemented version of the disclosed techniques.

Further, the use of bricks and cards provides a tangible and manual interface, allowing users to see physical and system barriers that impede performance, create safety risks, and increase labor utilization.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a conceptual diagram of a system for demonstrating distribution operations at a distribution center.

FIG. 2 is a first example section of a pre-marked surface for demonstrating distribution operations at a distribution center.

FIG. 3 is a second example section of the pre-marked surface for demonstrating distribution operations at the distribution center.

FIG. 4 is a third example section of the pre-marked surface for demonstrating distribution operations at the distribution center.

FIG. 5 is a fourth example section of the pre-marked surface for demonstrating distribution operations at the distribution center.

FIG. 6 is a fifth example section of the pre-marked surface for demonstrating distribution operations at the distribution center.

FIG. 7 is another example system for demonstrating distribution operations at a distribution center.

FIGS. 8A-8B illustrate example instruction instruments used with the disclosed techniques for demonstrating distribution operations at a distribution center.

FIG. 9 is an example score card for assessing distribution operations at the distribution center using the disclosed techniques.

FIG. 10 illustrate example downtime charts for assessing distribution operations at a distribution center.

FIG. 11 illustrates another example system for demonstrating distribution operations at a distribution center.

FIGS. 12A-12B is a flowchart of a process for demonstrating distribution operations at a distribution center using the disclosed techniques.

FIG. 13 is a schematic diagram that shows an example of a computing device and a mobile computing device.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

This document generally relates to systems, methods, and techniques for demonstrating operations in a distribution center. The disclosed techniques gamify the operations in the distribution center to help users, such as workers associated with the distribution center, identify issues, such as inefficiencies, bottlenecks, and waste, in distribution operations, determine solutions, and implement those solutions in real life in the distribution center. In other words, the disclosed techniques can be used to teach users, whether working alone or in teams, how to recognize issues that may disrupt continuous flow of workflows and/or processes through the distribution center. The users can learn to problem solve, thereby improving performance and overall operations in the distribution center. The disclosed techniques may also combine various schools of thought, including Heijunka (which can be used to teach and improve level scheduling for operations planning), Bullwhip Effect (which can be used to teach working in silos during execution of the operations), and Theory of Constraints (which can be used for problem solving to optimize efficiency in performing the operations).

Referring to the figures, FIG. 1 is a conceptual diagram of a system 100 for demonstrating distribution operations at a distribution center 101. The distribution center 101 can be represented or otherwise depicted by a pre-marked surface 102. The pre-marked surface 102 can be a board, such as a game board. In some implementations, the pre-marked surface 102 can represent or depict a particular type of distribution center. For example, refer to FIG. 11, in which a pre-marked surface represents an automated distribution center. The pre-marked surface 102 can represent or depict a generic distribution center. The pre-marked surface 102 can additionally or alternatively represent or depict the particular distribution center 101.

The distribution center 101 can be any type of distribution center, warehouse, or storage facility. The distribution center 101 can be part of a network of distribution centers, fulfillment systems, and/or stores.

The pre-marked surface 102 can be configured to represent a workflow for the distribution center 101 (e.g., an entire lifecycle of a distribution center, from inbound to outbound), and can be used by a plurality of users 106A-N to demonstrate distribution operations in the distribution center 101 and train the plurality of users 106A-N about how to optimize operations in the distribution center 101 to reduce waste or other issues that may arise in real-world scenarios at the distribution center 101. As a result, the pre-marked surface 102 can be used to gamify real-world operations at the distribution center 101 as a learning tool for the users 106A-N. The users 106A-N can be employees and/or human workers (e.g., field workers) who work in and out of the distribution center 101. For example, one or more of the users 106A-N can include Mezzanine Operators, Production Controllers (PCs), Operations Managers (OMs), Senior Operations Managers (SOMs), and/or Operations Directors (ODs). A Mezzanine Operator is a person that works on an elevated platform aside moving conveyance and trouble shoots blockages, jams, and communicate said information to their leaders. A Production Controller is a leader assigned to create the final plans that maximize volume process for a shift. An Operations Manager is a department level leader that is responsible for Team Member performance. A Senior Operations Manager is a leader responsible for a shift's performance throughout a building. An Operations Director is a leader that provides strategic direction and is accountable for total performance for a shift (days/nights), for a building.

The system 100 can also include instruction instruments 114A-N. The instruction instruments 114A-N can be selected (e.g., randomly selected) by one or more of the users 106A-N while playing a game at the pre-marked surface 102 for demonstrating the distribution operations of the distribution center 101. The instruction instruments 114A-N can include one or more sets of cards 108A-N. The instruction instruments 114A-N can additionally or alternatively include one or more die 110A-N. The die 110A, for example, can be a four-sided die. In some implementations, other types of die may also be used.

The cards 108A-N can each include instructions for performing, by at least one of the users 106A-N, actions during the game. Each of the actions performed by the users 106A-N can impact the workflow for the distribution center 101 that is represented by the pre-marked surface 102. The actions performed by the users 106A-N can also impact actions and decisions made by at least one other user amongst the users 106A-N during the game. The cards 108A-N can be used to inject randomness into the workflow represented by the pre-marked surface 102, which can mimic real-world scenarios that may arise or have arisen in the distribution center 101 or other distribution centers. Therefore, the users 106A-N can learn how to address those real-world scenarios using the system 100.

The system 100 can also include a plurality of modular pieces 112A-N that represent different components in the distribution center 101. For example, the modular pieces 112A-N can represent items, other types of inventory or goods, pallets, cages, cases, or other warehouse/distribution center equipment. The modular pieces 112A-N can have different sizes, colors, shapes, or other visual indicia. The different sizes, colors, shapes, or other visual indicia can be used to differentiate what inventory or other objects in the distribution center 101 that the modular pieces 112A-N are intended to represent. The different sizes, colors, shapes, or other visual indicia may also be used to indicate different units, quantities, etc. associated with different type of inventory or objects in the distribution center 101.

The modular pieces 112A-N can, in some implementations, be bricks or other objects that can be stacked on top of each other to create a group of items or other type of inventory that moves throughout the workflow of the distribution center 101 that is represented and depicted by the pre-marked surface 102. For example, at least one of the modular pieces 112A-N can be moved, by one or more of the users 106A-N, across the pre-marked surface 102 in the workflow for the distribution center 101 based at least in part on the actions performed by the users 106A-N responsive to selecting at least one of the instruction instruments 108A-N during the gameplay.

Referring back to the pre-marked surface 102, the pre-marked surface 102 can be segmented into zones 104A-N, where each zone represents a zone in the distribution center 101 at which certain sub-processes and/or sub-workflows are performed in the workflow of the distribution center 101. In some implementations, each of the zones 104A-N can represent sub-processes and/or sub-workflows that are performed in the distribution center 101. Although 5 zones 104A-N are represented at the pre-marked surface 102, additional or fewer zones can also be represented at the pre-marked surface 102, which can further be based on the type of distribution center 101.

As an illustrative example of the pre-marked surface 102, the zone 104A can represent an inbound zone in the distribution center 101, in which sub-processes are performed to unload items, pallets, or other goods from delivery trucks and prepare those items to be routed into the distribution center 101 for storage. Refer to FIG. 2 for further discussion about the zone 104A. The zone 104B can represent a storing zone in the distribution center 101, in which sub-processes are performed for storing, warehousing, or otherwise moving the inbound items, pallets, or other goods around the distribution center 101. Refer to FIG. 3 for further discussion about the zone 104B. The zone 104C can represent a picking zone in the distribution center 101, in which sub-processes are performed for depalletization, repalletization, and/or picking of items to be shipped/delivered to customers (e.g., stores). Refer to FIG. 4 for further discussion about the zone 104C. The zone 104D can represent a packing zone in the distribution center 101, in which sub-processes are performed for packing the picked items to be shipped/delivered to customers. Refer to FIG. 5 for further discussion about the zone 104D. The zone 104E can represent an outbound zone in the distribution center 101, in which sub-processes are performed to prepare and ship the packed items to customers. Refer to FIG. 6 for further discussion about the zone 104E.

In some implementations, the pre-marked surface can be approximately 17 feet long. Depending on a size of the distribution center 101, a type of the distribution center 101, or other distribution center characteristics, 8-11 users can engage in gameplay using the system 100. The users 106A-N can engage in gameplay over 4 rounds that build on learnings and actions in the previous round or rounds. In some illustrative examples, each round can be approximately 15 minutes long. Any mistakes made by one of the users 106A-N and/or defects injected into the workflow out of randomness (e.g., by the user 106A selecting a card amongst the cards 108A-N that instructs the user 106A to add a defect to the workflow) can be passed on to a next user amongst the users 106A-N to deal with. For example, the next user may have a penalty (e.g., approximately a 30 second penalty) in which they cannot perform other tasks in their respective zone for a duration of the penalty. The next user may additionally or alternatively have to stop their current tasks to cure the defect that was passed to them. The next user may additionally or alternatively pass the defect on to another user. In so doing, the users 106A-N can experience unexpected scenarios in the workflow that mimic real-world scenarios at the distribution center 101. The users 106A-N can learn how to address these types of scenarios using the system 100 and without having to experience these scenarios in real-world practice at the distribution center 101.

The performance of the users 106A-N during each round can be captured in metrics such as scores and/or downtime charts. These metrics can then be assessed by the users 106A-N and/or a computing system to determine ways in which the users 106A-N can improve their actions in real-world implementation of the workflow of the distribution center 101. Refer to FIGS. 9-10 for further discussion.

Still referring to FIG. 1, to start gameplay (e.g., in any round of gameplay described herein), the user 106A can select at least one of the instruction instruments 114A-N at their assigned zone 104A (block A, 120). For example, the user 106A can randomly select one of the cards 108A-N, or select one of the cards 108A-N that are stacked in a randomized order. In some implementations, the user 106A may role at least one of the die 110A-N. At the assigned zone 104A, the user 106A can then perform at least one action with at least one of the modular pieces 112A-N based on the selected instruction instrument (block B, 122). Performing the at least one action can include moving the modular pieces 112A-N around the zone 104A to mimic unloading items off a delivery truck in the distribution center 101 and preparing the unloaded items for transport/storage inside the distribution center 101. Part of performing the at least one action can include moving the at least one of the modular pieces 112A-N to the next zone represented at the pre-marked surface 102, such as the zone 104B. The user 106A can then continue to perform blocks A-B, 120-122, until a current round of gameplay ends (e.g., a timer for the current round ends, a predetermined amount of time for the current round expires, the user 106A runs out of instruction instruments 114A-N to select from, etc.).

The user 106B can receive, from the zone 104A, the at least one of the modular pieces 112A-N at their assigned zone, zone 104B. The user 106B can then select at least one of the instruction instruments 114A-N at their assigned zone 104B (block A, 120) and then perform at least one action with at least one of the modular pieces 112A-N based on the selected instruction instrument (block B, 122). Performing the at least one action can include moving the modular pieces 112A-N to storage locations represented at the zone 104B to mimic storing the items in the distribution center 101. Part of performing the at least one action can include moving the at least one of the modular pieces 112A-N to the next zone represented at the pre-marked surface 102, such as the zone 104C. The user 106B can then continue to perform blocks A-B, 120-122, with any other modular pieces 112A-N that are moved to the user 106B's zone 104B as a result of actions performed by the user 106A at their zone 104A. Similarly to the user 106A, the user 106B continues to perform blocks A-B, 120-122, until the current round of gameplay ends.

The user 106C can receive, from the zone 104B, the at least one of the modular pieces 112A-N at their assigned zone, zone 104C. The user 106C can then select at least one of the instruction instruments 114A-N at their assigned zone 104C (block A, 120) and then perform at least one action with at least one of the modular pieces 112A-N based on the selected instruction instrument (block B, 122). Performing the at least one action can include moving one or more of the modular pieces 112A-N to designated locations in the zone 104C to mimic picking items for delivery to particular customers (e.g., stores). Part of performing the at least one action can include moving the at least one of the modular pieces 112A-N to the next zone represented at the pre-marked surface 102, such as the zone 104D. The user 106C can then continue to perform blocks A-B, 120-122, with any other modular pieces 112A-N that are moved to the user 106C's zone 106C as a result of actions performed by the user 106B at their zone 104B. Similarly to the users 106A-B, the user 106C continues to perform blocks A-B, 120-122, until the current round of gameplay ends.

The user 106D can receive, from the zone 104C, the at least one of the modular pieces 112A-N at their assigned zone, zone 104D. The user 106D can then select at least one of the instruction instruments 114A-N at their assigned zone 104D (block A, 120) and then perform at least one action with at least one of the modular pieces 112A-N based on the selected instruction instrument (block B, 122). The at least one action can include preparing the modular pieces 112A-N in one or more locations represented in the zone 104D, such as stacking one or more of the modular pieces 112A-N, to mimic packing the items for shipment to respective customers (e.g., stores). Part of performing the at least one action can include moving the at least one of the modular pieces 112A-N to the next zone represented at the pre-marked surface 102, such as the zone 104E. The user 106D can then continue to perform blocks A-B, 120-122, with any other modular pieces 112A-N that are moved to the user 106D's zone 106D as a result of actions performed by the user 106C at their zone 104C. Similarly to the users 106A-C, the user 106D continues to perform blocks A-B, 120-122, until the current round of gameplay ends.

The user 106N can receive, from an adjacent previous zone or any of the previous zones, the at least one of the modular pieces 112A-N at their assigned zone, zone 104E. The user 106N can then select at least one of the instruction instruments 114A-N at their assigned zone 104E (block A, 120) and then perform at least one action with at least one of the modular pieces 112A-N based on the selected instruction instrument (block B, 122). The at least one action can include moving the modular pieces 112A-N to one or more locations in the zone 104E that correspond to the respective customers to mimic preparing the items for outbound shipment to the respective customers. The user 106N can continue to perform blocks A-B, 120-122, with any other modular pieces 112A-N that are moved to the user 106N's zone 106E as a result of actions performed by the user 106D at their zone 104D. Similarly to the other users, the user 106N continues to perform blocks A-B, 120-122, until the current round of gameplay ends.

In some implementations, the users 106A-N at one or more of the zones 104A-E can receive random instructions (e.g., from other users, from selection of one or more of the instruction instruments 114A-N). One or more of the users 106A-N can additionally or alternatively perform actions based on their own judgement and based on actions performed by other users, rather than from selecting one or more of the instruction instruments 114A-N described herein.

FIG. 2 is a first example section 200 of a pre-marked surface for demonstrating distribution operations at a distribution center. The section 200 can be the same as or similar to the zone 104A of the pre-marked surface 102 described in FIG. 1. The section 200 can represent a zone in the distribution center where inbound tasks are performed. Such inbound tasks can include, for example, unloading items or other goods from delivery trucks, preparing the unloaded items for transport and/or storage in the distribution center, and/or moving the unloaded items onto conveyor belts to then be transported and stored in the distribution center.

The section 200 can include visual representations of various distribution center components that may be used to perform inbound tasks. The illustrative example section 200 includes components such as stores 210A-N, a conveyor belt 212, an automated receiving technology (ART) system 214, a breakpack section 216, a full case section 218, a process board 220, empty pallets 224, a key 228, a manual dock area 226 for receiving full case non-conveyable items 234A, full case conveyable items 234B, and full case breakpack items 234N, a manual dock full pallet staging area 236 including a full case non conveyable staging area 238A, a full case conveyable staging area 238B, and a full case breakpack staging area 238N, and a manual conveyor belt 240 (or any other type of conveyor belt that can be used in the distribution center). Breakpack is the process of picking units in a lower quantity than a full case. The breakpack can be also referred to as loose pick, unit pick, each pick, or inner pack pick.

The section 200 is merely intended to be illustrative. The section 200 can include additional or fewer distribution center components. The section 200 can also include components that are unique to a particular distribution center and/or a particular type of distribution center.

Referring to the components represented at the section 200, the stores 210A-N can represent any quantity of customers, such as retail environments, that store items at the distribution center. Each store 210A-N can, for example, request or purchase inventory from a manufacturer. The manufacturer can deliver or ship that inventory to the distribution center, which can be ingested into the distribution center at the inbound section 200 of the pre-marked surface. Users at the inbound section 200 can perform tasks with that inventory, such as preparing the inventory for storage in the distribution center, unpacking the inventory, packing the inventory, etc., and load that inventory onto conveyor belts to be routed into the distribution center for storage. At a later time, any of the stores 210A-N can request their respective inventory to be pulled/picked from storage in the distribution center and shipped/delivered to their location. During gameplay, the user or users assigned to the section 200 can perform tasks/actions with modular pieces representing items or inventory for any one or more of the stores 210A-N. The user(s) can learn how to manage and perform many tasks for many customers.

The conveyor belt 212 can be any type of conveyor belt 212 used for moving items around the distribution center (e.g., moving items from one section to a next section on the pre-marked surface, as described and shown in FIG. 1). The conveyor belt 212 can be an automated conveyor belt. For example, the conveyor belt 212 can be used in performing automated distribution center tasks that may include using the ART 214. Moreover, the section 200 can include visual representations of modular piece locations 213A-N at one or more positions along a length of the conveyor belt 212. The modular piece locations 213A-N can be locations at which the user assigned to the section 200 or other users can place any one or more of the modular pieces that the user(s) has performed actions with. For example, once the user prepares a modular piece representing an item to be put into storage in the distribution center for a particular store, the user can place the modular piece at a first modular piece location 213A-N represented on the conveyor belt 212. The user or another user can then move the modular piece along the remaining modular piece locations 213A-N of the conveyor belt 212 until the modular piece is moved onto a next section of the pre-marked surface (e.g., refer to FIG. 3). In some implementations, one or more modular pieces can be placed at one or more of the modular piece locations 213A-N to represent bottlenecks or buffer inventory. Buffer inventory represents an inventory that is in queue, awaiting processing. In some cases, a minimal amount (Lower Control Limit) of inventory needs to be in queue to prevent users (Team Members) from running out of work. Too much buffer would exacerbate the bullwhip effect and may also cause work stoppages. Such modular pieces may not be moved from their locations for at least a threshold amount of time (e.g., 30 seconds, 1 minute, an entire round of gameplay) and therefore can represent real-world scenarios of bottlenecks, obstacles, and/or issues that may arise during inbound tasks/operations in the distribution center. The user(s) at the section 200 must then use their judgement to determine how to efficiently perform other inbound actions with other modular pieces while dealing with these bottlenecks, obstacles, and/or issues.

The ART 214 is a system that combines physical hardware (e.g., conveyors, sorters, scanners, print-and-apply label applicators, etc.), and software that sort newly unloaded goods by SKU and physical dimension, allowing optimal storage and reduced labor costs.

The breakpack section 216 can include modular pieces representing breakpack items (e.g., items picked and shipped in less-than-full case) to be routed to storage in the distribution center using automated techniques (e.g., using the ART 214 and the conveyor belt 212). Breakpack actions can be performed with the modular pieces at the breakpack section 216, such as breaking down or otherwise separating modular pieces that are stacked together. Separating the modular pieces into individual modular pieces can represent breaking down inbound pallets or cases into individual items (or multiple groups of items). The individual items may, further down a workflow for the distribution center for example, then be combined into pallets or cases having mixed items (e.g., another user can stack one or more of the individual modular pieces with other modular pieces).

The full case section 218 can include modular pieces representing full cases or pallets of items to be routed to storage in the distribution center using automated techniques (e.g., using the ART 214 and the conveyor belt 212). Full case actions can be performed with the modular pieces at the full case section 218, such as simply moving stacked modular pieces that represent a full case or pallet onto the conveyor belt 212. In some implementations, the user may first build a stack of modular pieces to represent an inbound full case of items, then add the stack of modular pieces to the ART 214 and/or the conveyor belt 212.

The process board 220 can be a physical board where near-time metrics are tracked during a shift, such as volume attainment, observed disruptions to business plans, and countermeasures to reduce or remedy disruptions to performance. During the game, the process boards are sticky notes of a certain size (e.g., 3″×3″) that capture: Count of Safety Incidents, Count of Quality Defects, Count of Units deemed as Excess Inventory not Processed, and Count of Work Stoppages.

The empty pallets 224 can include one or more modular pieces that represent empty pallets in the distribution center. Sometimes, the user can perform actions that include stacking modular pieces on one or more modular pieces that represent the empty pallets 224, then move the stacked modular pieces along either of the conveyor belts 212 or 240. Sometimes, the user can perform actions that include unstacking modular pieces, placing the modular pieces that represent the empty pallets 224 at the empty pallets 224 represented at the section 200, and then move the individual modular pieces along the conveyor belt 212 and/or 240.

The key 228 can visually indicate what each of the different types of modular pieces represent at the section 200 and/or across multiple sections of the pre-marked surface described herein. For example, the same key 228 can be used and represented at each section of the pre-marked surface to provide guidance to user(s) at the section about what the modular pieces represent. The key 228 can indicate which modular pieces (e.g., size, shape, and/or color) represent each of the stores 210A-N, different types of supplies that may be used in the distribution center, such as pallets, cases, or other distribution center equipment, and different types of items (e.g., inventory, freight). As a merely illustrative example, white square modular pieces can represent the store 210A, black square modular pieces can represent the store 210B, yellow square modular pieces can represent the store 210C, and blue square modular pieces can represent the store 210N. As another merely illustrative example, yellow rectangular modular pieces can represent supplies such as the empty pallets 224, red square modular pieces can represent the full case conveyable items 234B, black rectangular modular pieces can represent the full case non-conveyable items 234A, and green square modular pieces can represent the full case breakpack items 234N.

The manual dock area 226 for receiving full case non-conveyable items 234A, full case conveyable items 234B, and full case breakpack items 234N can visually represent a manual dock area of the distribution center where tasks/actions are manually performed by workers (rather than automated tasks/actions, such as those tasks performed wit the ART 214). The manual dock full pallet staging area 236 including a full case non conveyable staging area 238A, a full case conveyable staging area 238B, and a full case breakpack staging area 238N can visually represent locations in the distribution center where workers may manually stage/prepare the full case non-conveyable items 234A, the full case conveyable items 234B, and/or the full case breakpack items 234N to then be transported to other sections/zones in the distribution center. Dependent on the data from the cards 202A-N and 204A-N, a user can move one modular piece from sections 234A, 234B, or 234N and placed in on a modular piece on sections 238A, 238B, or 238N.

Once the user assigned to the section 200 performs on or more actions with modular pieces in the manual dock full pallet staging area 236, the user can move the modular pieces onto the conveyor belt 240. The user or other users can then move the modular pieces along the conveyor belt 240 to one or more other sections represented at the pre-marked surface (e.g., refer to FIG. 3). The conveyor belt 240 can be a manual conveyor belt. The conveyor belt 240 can also be any other type of conveyor belt, such as the conveyor belt 212, that can be used to convey or move the modular pieces representing items (e.g., inventory) to different sections of the distribution center, as represented on the pre-marked surface.

The section 200 also can include 4 sets of cards 202A-N, 204A-N, 206A-N, and 208A-N, which can be randomly selected by a user at the section 200 during a round of gameplay described herein. Each of the sets of cards 202A-N, 204A-N, 206A-N, and 208A-N can provide different instructions to the user that prompt the user to perform different types of actions with different inbound scenarios. The cards 202A-N, 204A-N, 206A-N, and 208A-N can inject real-world scenarios into the gameplay to which the user and other downstream users must respond.

The cards 202A-N can include instructions for performing inbound tasks with a low flow dock. Tasks (cards) are assigning the movement of modular pieces from sections 234A, 234B, or 234N, to sections 238A, 238B, or 238N. The low flow dock is newly receipted freight that is received on the manual dock (no automation) and does not have immediate outbound demand and will be stored in the warehouse.

The cards 204A-N can include instructions for performing inbound tasks with a high flow dock. Tasks (cards) are assigning the movement of modular pieces from sections 234A, 234B, or 234N, to sections 238A, 238B, or 238N. The high flow dock is newly receipted freight that is received on the manual dock (no automation) and has immediate outbound demand and is immediately placed on a conveyor and transported to an outbound trailer and is consigned to a specific customer or store.

The cards 206A-N can include instructions for performing inbound tasks with a low flow ART. Tasks (cards) are assigning the movement of modular pieces from sections 216 or 218 to section 212. The low flow ART is newly receipted freight that is received through the Automated Receiving Technology and does not have immediate outbound demand and will be stored in the warehouse.

The cards 208A-N can include instructions for performing inbound tasks with a high flow ART. Tasks (cards) are assigning the movement of modular pieces from sections 216 or 218 to section 212. The high flow ART is newly receipted freight that is received through the Automated Receiving Technology and has immediate outbound demand and is immediately placed on a conveyor and transported to an outbound trailer and is consigned to a specific customer or store.

The cards 202A-N, 204A-N, 206A-N, and 208A-N are merely illustrative examples of instruction instruments that can be used during the rounds of gameplay described herein. The cards 202A-N, 204A-N, 206A-N, and 208A-N can include different instructions and/or fewer/additional sets of cards can be used in different implementations of the disclosed techniques.

During gameplay using the illustrative section 200, the user assigned to the section 200 can select one of the cards from the sets of cards 202A-N, 204A-N, 206A-N, and 208A-N to perform an action for items (e.g., inventory) associated with one of the stores 210A-N. The user can use their judgement to decide which of the stores 210A-N they would like to select a card for. The user can also be instructed (e.g., by a prompt or another user) to select a card for a particular store amongst the stores 210A-N. The user can use their judgement to decide which of the sets of cards 202A-N, 204A-N, 206A-N, and 208A-N they would like to select a card from. The user can also be instructed to select a card from a particular set of cards amongst the sets of cards 202A-N, 204A-N, 206A-N, and 208A-N.

The cards 202A-N, 204A-N, 206A-N, and 208A-N can include instructions such as prompting the user to select a certain quantity of modular pieces (e.g., items) to bring into the section 200 for the particular store. The instructions can include prompting the user to add the modular pieces to the conveyor belt 212 using the ART 214. These instructions, for example, can be included in the cards 206A-N and/or 208A-N and can therefore require the use of automation and automated techniques to prepare modular pieces in the inbound section 200 for ingestion and storage in other sections in the distribution center. The instructions can include prompting the user to unload, pack, and/or stage items using the modular pieces in the manual dock area 226 and/or the manual dock full pallet staging area 236, then load those modular pieces onto the conveyor belt 240. These instructions can be included in the cards 202A-N and/or 204A-N. One or more other instructions are also possible, as described herein.

As illustrative examples, the cards 202A-N and/or 204A-N can include a card that instructs the use to draw/select/flip another card (from the same set of cards or from another set of cards). Additionally or alternatively, the card can instruct the user to stack a predetermined quantity of a predetermined type of modular piece on top of another predetermined quantity of another predetermined type of modular piece, then move the stacked modular pieces onto the conveyor belt 240. Such instructions can present a high flow manual dock breakpack action, which can be performed by the user in the manual dock full pallet staging area 236 of the section 200. For example, the card can instruct the user to stack one green square modular piece representing the full case breakpack items 234N on top of one yellow rectangle modular piece representing the empty pallets 224, then move the stacked modular pieces to the conveyor belt 240. These stacked modular pieces can represent a pallet that is not fully packed but can receive mixed items during one or more other sub-processes in the workflow for the distribution center. Another example card can represent a high flow manual dock conveyable action for a particular store and thus can instruct the user to stack one red square modular piece representing the full case conveyable items 234B on top of one blue square modular piece representing the store 210N on top of one yellow rectangular modular piece representing the empty pallets 224, then move the stacked modular pieces to the conveyor belt 240. Another example card can represent a high flow manual dock non-conveyable action and thus can instruct the user to stack one black rectangular modular piece representing the full case non-conveyable items 234A on top of one yellow rectangular modular piece representing the empty pallets 224, then move the stacked modular pieces onto the conveyor belt 240.

As illustrative examples, the cards 206A-N and/or 208A-N can include a card that instructs the user to draw/select/flip another card (from the same set of cards or from another set of cards). Additionally or alternatively, the cards 206A-N and/or 208A-N can include a card that instructs the user to move a predetermined quantity of a particular type of modular piece onto the ART 214, the conveyor belt 212, and/or one or more of the modular piece locations 213A-N at the conveyor belt 212. For example, the card can represent a breakpack action in high flow ART tasks that requires the user to identify one green square modular piece and place that modular piece on the ART 214 and/or the conveyor belt 212. Additionally or alternatively, the cards 206A-N and/or 208A-N can include a card that instructs the user to build a predetermined quantity of one or more particular types of modular pieces in a particular order/design/arrangement and then move the built modular pieces onto the ART 214, the conveyor belt 212, and/or one or more of the modular piece locations 213A-N. For example, the card can represent an ART conveyable flow action for the store 210N in high flow ART tasks that requires the user to stack one red square modular piece representing the full case conveyable items 234B on top of one blue square modular piece representing the store 210N, then moving these stacked modular pieces onto the ART 214 and/or the conveyor belt 212.

In some implementations, the user may be instructed to keep a stack of modular pieces including the modular piece that represents a pallet in the manual dock full pallet staging area 236 until the modular piece representing the pallet is full. At this point, the user can be instructed (e.g., by a prompt, another user, one or more cards) to stack another modular piece representing another pallet on top of the modular piece representing the full pallet. The user can be instructed to stack any quantity of modular pieces representing additional pallets (e.g., 3 yellow rectangular modular pieces) on top of the modular piece representing the full pallet before moving these modular pieces to the conveyor belt 240. This process simulates the utilization of the triple pallet jack (can move a maximum of three pallets at once.

The section 200 can include a machine-readable optical label, such as a barcode (e.g., QR code), which a user can scan using a mobile device or other computing devices. The label can enable the user's device to access one or more instructions for the user specific to the section 200.

FIG. 3 is a second example section 300 of the pre-marked surface for demonstrating distribution operations at the distribution center. The section 300 can be the same as or similar to the zone 104B of the pre-marked surface 102 described in FIG. 1. The section 300 can represent a zone in the distribution center where warehousing or storing tasks are performed. Such tasks can include, for example, building pallets, cases, and/or cages of items for storage, moving items into storage locations, and/or removing items from storage locations to be sent to another section or zone in the distribution center (e.g., refer to FIG. 4).

The section 300 can include visual representations of various distribution center components that may be used to perform warehousing/storing tasks. The illustrative example section 300 includes components such as a first conveyor belt 302, a second conveyor belt 303, one or more modular piece locations 304A-N along the conveyor belts 302 and/or 304, the conveyor belt 240, non-conveyable aisles 306A-N, non-conveyable work in progress area 308, empty cages 310, empty pallets 312, stores 314A-N, a conveyable work in progress area 316, conveyable aisles 318A-N, and a process board 320. The section 300 is merely intended to be illustrative. The section 300 can include additional or fewer distribution center components. The section 300 can also include components that are unique to a particular distribution center and/or a particular type of distribution center.

Referring to the components represented at the section 300, the first conveyor belt 302 can be the same as or similar to the conveyor belt 212 described in reference to FIG. 2. The second conveyor belt 303 can be similar to or the same as the conveyor belt 212. The second conveyor belt 303 can be used for transporting breakpack full cases of items in the distribution center. The two sections 302 and 303 transition into different workstations. The section 302 transfers modular pieces to the section 402, and the section 303 transfers modular pieces to the section 403. In some implementations, the conveyor belt 303 can be used to transport modular pieces that do not go into storage in the section 300 but rather go straight to a picking/palletization zone, such as the section represented and described in FIG. 4. The modular piece locations 304A-N along the conveyor belts 302 and/or 303 are similar to or the same as the modular piece locations 213A-N described in reference to FIG. 2. The conveyor belt 240 continues from the section 200 of FIG. 2 and can continue across multiple and/or all of the sections represented at the pre-marked surface described herein.

The non-conveyable aisles 306A-N can represent aisles, racks, or other types of storage locations in the distribution center where non-conveyable items can be stored. A user assigned to the section 300 may, for example, perform actions such as moving modular pieces that represent non-conveyable items from either of the conveyor belts 302, 302, and/or 240 into the non-conveyable aisles 306A-N to represent moving non-conveyable items to non-conveyable item storage locations in the distribution center.

The non-conveyable work in progress area 308 can represent an area in the distribution center where one or more workers may prepare non-conveyable items to be transported to another location/section in the distribution center. For example, the user assigned to the section 300 may perform actions such as retrieving one or more modular pieces in the non-conveyable aisles 306A-N and stacking them on top of one or more empty cages 310 and/or empty pallets 312 in the non-conveyable work in progress area 308 for a particular store of the stores 314A-N. The user may then move the stacked modular pieces onto the conveyor belt 240 to be transported to the next section represented at the pre-marked surface (e.g., refer to FIG. 4).

The empty cages 310 can represent modular pieces that may be used by the user assigned to the section 300 when performing tasks with other modular pieces at this section. For example, the user can perform an action such as stacking multiple modular pieces representing items for storage on top of a modular piece representing an empty cage 310, then move the empty cage 310 with the stacked modular pieces to either of the non-conveyable aisles 306A-N or the conveyable aisles 318A-N for storage. The modular pieces representing the empty cages 310 can also be used by the user to perform actins such as picking items to be transported to the next section in the distribution center (e.g., refer to FIG. 4).

The conveyable work in progress area 316 can represent an area in the distribution center where one or more workers may prepare conveyable items to be transported to another location/section in the distribution center. For example, the user assigned to the section 300 may perform actions such as retrieving one or more modular pieces in the conveyable aisles 318A-N and stacking them on top of one or more empty cages 310 and/or empty pallets 312 in the conveyable work in progress area 316 for a particular store of the stores 314A-N. The user may then move the stacked modular pieces onto the conveyor belt 240 to be transported to the next section represented at the pre-marked surface (e.g., refer to FIG. 4).

The conveyable aisles 318A-N can represent aisles, racks, or other types of storage locations in the distribution center where conveyable items can be stored. The user assigned to the section 300 may, for example, perform actions such as moving modular pieces that represent conveyable items from either of the conveyor belts 302, 302, and/or 240 into the conveyable aisles 318A-N to represent moving conveyable items to conveyable item storage locations in the distribution center.

The empty pallets 312 can be the same as or similar to the empty pallets 224 described in reference to FIG. 2. The stores 314A-N can be the same as or similar to the stores 210A-N described in reference to FIG. 2. Moreover, the process board 320 can be the same as or similar to the process board 220 described in FIG. 2.

The user assigned to the section 300 can perform actions with the modular pieces that are received from the user at the section 200 of FIG. 2. The user assigned to the section 300 can perform actions that are described on one or more sets of cards 322A-N and 324A-N. A card can be randomly selected by the user during a round of gameplay described herein. Each of the sets of cards 322A-N and 324A-N can provide different instructions to the user that prompt the user to perform different types of actions with different warehousing/storing scenarios. The cards 322A-N and 324A-N can inject real-world scenarios into the gameplay to which the user and other downstream users must respond.

The cards 322A-N can include instructions for performing warehousing tasks with non-conveyable items. Task (cards) from section 322A-N provide instructions to move modular pieces from 306A-N to modular pieces in section 308.

The cards 324A-N can include instructions for performing warehousing tasks with conveyable items. Task (cards) from section 324A-N provide instructions to move modular pieces from 314A-N to modular pieces in section 316. In some cases, the way that the user knows whether to choose non-conveyable versus conveyable cards is a subjective decision, allowing the user to decide between short term departmental productivity gains while hindering total building performance. Short-sighted decisions will create the bullwhip effect to downstream partners.

The cards 322A-N and 324A-N are merely illustrative examples of instruction instruments that can be used during the rounds of gameplay described herein. The cards 322A-N and 324A-N can include different instructions and/or fewer/additional sets of cards can be used in different implementations of the disclosed techniques.

During gameplay using the illustrative section 300, the user assigned to the section 300 can select one of the cards from the sets of cards 322A-N and 324A-N when they receive modular pieces on either of the conveyor belts 302, 303, and/or 240, from the section 200 (refer to FIG. 2). The selected card can instruct the user about at least one action to perform with the received modular pieces representing items to be warehoused/stored in the section 300.

The cards 322A-N and 324A-N can include instructions such as prompting the user to select a predetermined quantity of a particular type of modular piece to stack on top of another particular type of modular piece. For example, the instructions on a card from the non-conveyable cards 322A-N can prompt the user to stack a black rectangular modular piece representing non-conveyable items on top of a yellow rectangular modular piece representing the empty pallets 312, then move the stacked modular pieces into the non-conveyable aisles 306A-N and/or onto the conveyor belt 240 to be routed to the next section. Another example card from the non-conveyable cards 322A-N can prompt the user to stack a black rectangular modular piece representing non-conveyable items on top of an orange rectangular modular piece representing the empty cages 310, then move the stacked modular pieces into the non-conveyable aisles 306A-N and/or onto the conveyor belt 240.

Illustrative examples of conveyable cards 324A-N can include a card instructing the user to build a full pallet for a particular store. For example, the card can prompt the user to stack one purple square modular piece representing a full case of conveyable items on top of one yellow square modular piece representing a particular store (e.g., the store 314C) on top of one yellow rectangular modular piece representing the empty pallets 312, then move the stacked modular pieces to the conveyable aisles 318A-N and/or the conveyor belt 240. Another example card can prompt the user to build a cage (e.g., case, carton air) for a particular store by instructing the user to stack one purple square modular piece representing a full case of conveyable items on top of a blue square modular piece representing a particular store (e.g., the store 314N) on top of one orange rectangular modular piece representing the empty cages 310, then move the stacked modular pieces to the conveyable aisles 318A-N and/or the conveyor belt 240.

In some implementations, the user may be instructed to keep a stack of modular pieces including the modular piece that represents a pallet and/or a cage (e.g., case, carton air) in the non-conveyable work in progress area 308 and/or the conveyable work in progress area 316 until the modular piece representing the pallet and/or the cage is full. At this point, the user can be instructed (e.g., by a prompt, another user, one or more cards) to stack another modular piece representing another pallet and/or cage on top of the modular piece representing the full pallet and/or the full cage. The user can be instructed to stack any quantity of modular pieces representing additional pallets and/or cages (e.g., 3 yellow rectangular modular pieces representing 3 full pallets, 5 orange rectangular modular pieces representing 5 full cages) on top of the modular piece representing the full pallet and/or the full cage before moving these modular pieces to the conveyor belt 240. This process simulates the utilization of the triple pallet jack (can move a maximum of three pallets at once). Similarly, where cage carts are used, it is best practice to move a maximum of five cage carts at one time.

The section 300 can include a machine-readable optical label, such as a barcode (e.g., QR code), which a user can scan using a mobile device or other computing devices. The label can enable the user's device to access one or more instructions for the user specific to the section 300.

FIG. 4 is a third example section 400 of the pre-marked surface for demonstrating distribution operations at the distribution center. The section 400 can be the same as or similar to the zone 104C of the pre-marked surface 102 described in FIG. 1. The section 400 can represent a zone in the distribution center where depalletization and/or repalletization tasks can be performed. Depalletization involves removing individual cartons from a pallet and moving the individual cartons onto a conveyor. Repalletization involves removing cartons from a conveyor and palletizing them for a consolidated movement. Once actions/tasks are performed with items in the section 400, the items can be sent to another section or zone in the distribution center (e.g., refer to FIG. 5).

The section 400 can include visual representations of various distribution center components that may be used to perform depalletization and/or repalletization tasks. The illustrative example section 400 includes components such as a first conveyor belt 402, a second conveyor belt 403, one or more modular piece locations 404A-N along the conveyor belts 402 and/or 403, the conveyor belt 240, an ergo loading area 406, empty pallets 408, a full pallet staging area 410, a manual loading area 412, a process board 414, a carton air (e.g., cage, case) staging area 416, a carton air loading area 418, empty cages 420, a re-palletization zones 422A-N, and a re-palletization staging area 424. The section 400 is merely intended to be illustrative. The section 400 can include additional or fewer distribution center components. The section 400 can also include components that are unique to a particular distribution center and/or a particular type of distribution center. The term “ergo” in the ergo loading area 406 represents an ergonomic depalletizer process where the user is at a consistent waist height to the freight being handled. The section 406 can be used an induction point for the section 402. The term “carton air” in the carton air staging area 416 represents that a team member is picking freight via an order picker while off the ground on a powered industrial truck, such as an order picker. The “carton “air” can also be referred to as carton picking or full case picking.

Referring to the components represented at the section 400, the first conveyor belt 402 can be the same as or similar to the conveyor belt 302 described in reference to FIG. 3. The second conveyor belt 403 can be similar to or the same as the conveyor belt 303 in FIG. 3. For example, in some implementations, full case breakpack items 234N that are added to the conveyor belt 212 at the section 200 in FIG. 2 can be transported along the conveyor belt 212, along the conveyor belt 303 at the section 300 in FIG. 3, and then be directed along the conveyor belt 403 at the section 400 in FIG. 4 to be re-palletized at one of the zones 422A-N in the re-palletization staging area 424. Users at the section 300 in FIG. 3 may not perform actions with the items 234N and instead, actions can be performed with the items 234N by users at the section 200 and the section 400.

The modular piece locations 404A-N along the conveyor belts 402 and/or 402 are similar to or the same as the modular piece locations 213A-N described in reference to FIG. 2. The conveyor belt 240 continues from the sections 200 of FIG. 2 and 300 of FIG. 3, and can continue across multiple and/or all of the sections represented at the pre-marked surface described herein.

The ergo loading area 406 is an induction point for modular pieces to be conveyed to section 402.

The full pallet staging area 410 can represent an area in the distribution center where workers may prepare full pallets of items to be shipped from the distribution center. A user assigned to the section 400 may, for example, perform actions such as stacking modular pieces that represent items to be shipped out on top of one or more modular pieces that represent pallets. The user can receive modular pieces via the conveyor belt 240 that represent conveyable full case. The user can move these modular pieces to the full pallet staging area 410 and stack those modular pieces on one or more of the pallets 408 in the full pallet staging area 410. As another example, the user can perform actions such as moving the stacked modular pieces in the ergo loading area 406 so that the stacked modular pieces can be routed to the conveyor belt 402 and moved along to a next section represented at the pre-marked surface (e.g., refer to FIG. 5).

The manual loading area 412 can represent an area in the distribution center where workers may load one or more full pallets and/or carton airs of items onto the conveyor belt 402 and/or 403.

The carton air (e.g., cage, case) staging area 416 can represent an area in the distribution center where workers prepare carton airs of items to be shipped from the distribution center. The worker assigned to the section 400 may, for example, perform actions such as stacking modular pieces that represent items to be shipped on top of one or more modular pieces that represent carton airs. As another example, the user can perform actions such as moving the stacked modular pieces in the carton air loading area 418 and/or the manual loading area 412 so that the stacked modular pieces can be routed to the next section represented at the pre-marked surface.

Accordingly, the carton air loading area 418 can represent an area in the distribution center where workers may load one or more packed carton airs of items ono the conveyor belt 402 and/or 403.

The re-palletization zones 422A-N can represent one or more zones where full case breakpack items may be routed from the conveyor belt 403. The received items can be repalletized in the sections 422A-Z and then moved to the section 424 for staging until cage carts are built before being moved to the conveyor belt 240. Cage can refer to the physical cart while Carton Air can refer to the process of picking while using a Cage attached to an Order Picker and lifted off the ground. The user can, for example, receive modular pieces representing full case breakpack items via the conveyor belt 403. The user can move those modular pieces to at least one of the zones represented by the re-palletization zones 422A-N. The user can be instructed to stack one or more of those modular pieces with one or more modular pieces representing the cages 420 in the re-palletization staging area 424. Once the modular pieces are stacked according to the instructions, the user can move the stacked modular pieces to the conveyor belt 240 to be routed to the next section represented at the pre-marked surface.

The empty pallets 408 can be the same as or similar to the empty pallets 224 described in reference to FIG. 2. The process board 414 can be the same as or similar to the process board 220 described in FIG. 2. The empty cages 420 can be the same as or similar to the empty cages 310 described in reference to FIG. 3.

The user assigned to the section 400 can perform actions with the modular pieces that are received from the user at the section 300 of FIG. 3. The user assigned to the section 400 can perform actions that correspond to one or more sides of the die 110A, which the user rolls during a round of gameplay. The user can roll the die 110A to determine in which of the re-palletization zones 422A-N the user should re-palletize the modular pieces representing the full case breakpack items.

Here, when freight is staged from the section 240, the user can induct the freight to the section 406.

During gameplay using the illustrative section 400, the user assigned to the section 400 can roll the die 110A once they receive modular pieces on the conveyor belt 403. The rolled die 110A value(s) can indicate to the user where to stack the received modular pieces in the re-palletization zones 422A-N. For example, the die 110A can be 4-sided. Each side represents one of the zones 422A-N. The user may roll a 3, which indicates that the user should stack the modular piece representing the full case breakpack items (e.g., a green square modular piece) on a modular piece representing a cage 420 (e.g., an orange rectangular modular piece) in a third zone of the re-palletization zones 422A-N represented at the section 400.

In some implementations, the user may be instructed to keep a stack of modular pieces including the modular piece that represents the cage 420 in the re-palletization staging area 424 until the modular piece representing the cage 420 is full. At this point, the user can be instructed (e.g., by a prompt, another user, using their judgement) to stack another modular piece representing another cage 420 on top of the modular piece representing the full cage. The user can be instructed to stack any quantity of modular pieces representing additional pallets and/or items on top of the modular piece representing the full cage before moving these modular pieces to the conveyor belt 240. As an illustrative example, once the modular piece representing the cage 420 is full (e.g., 2 green modular pieces representing full case breakpack items are stacked thereon), the user can continue stacking full cages until 5 full cages are stacked together. The user can then move the stack of 5 full cages with their respective items onto the conveyor belt 240 to be routed to the next section described in FIG. 5.

The section 400 can include a machine-readable optical label, such as a barcode (e.g., QR code), which a user can scan using a mobile device or other computing devices. The label can enable the user's device to access one or more instructions for the user specific to the section 400.

FIG. 5 is a fourth example section 500 of the pre-marked surface for demonstrating distribution operations at the distribution center. The section 500 can be the same as or similar to the zone 104D of the pre-marked surface 102 described in FIG. 1. The section 500 can represent a zone in the distribution center where packing and breakpacking tasks can be performed. Once the actions/tasks are performed with items in the section 500, the items can be sent to another section or zone in the distribution center (e.g., refer to FIG. 6).

The section 500 can include visual representations of various distribution center components that may be used to perform packing and breakpacking tasks. The illustrative example section 500 includes components such as a conveyor belt 502, one or more modular piece locations 504A-N along the conveyor belt 502, breakpack aisles 506A-N, store ship racks (SSPs) 508, a breakpack work in progress area 510, empty pallets 512, empty cages 514, a process board 520, a packing mods staging area 522, store packing mods 524A-N, stores 530A-N, and the conveyor belt 240. The SSPs 508 are the lowest unit of measure that a store can receive of a SKU. For example, a carton of widgets contains 4 inner packs of 25, totaling 100 pieces per carton. The SSP value would be set at 25, and the store cannot receive less than one inner pack of 25. The section 500 is merely intended to be illustrative. The section 500 can include additional or fewer distribution center components. The section 500 can also include components that are unique to a particular distribution center and/or a particular type of distribution center.

Referring to the components represented at the section 500, the conveyor belt 502 can be the same as or similar to any one or more of the conveyor belts 212, 302, 303, 402, and/or 403 described in FIGS. 2-4. The conveyor belt 502 can be a continuation of the belt 402. The breakpack/packing can feed the belt 502 from the small conveyance that is fed by the sections 524A-N. For example, items can be moved from the section 400 along the conveyor belt 402 to the conveyor belt 502 of the section 500. A user assigned to the section 500 can then perform one or more packing and/or breakpacking actions with the items that are moved to the section 500.

The one or more modular piece locations 504A-N along the conveyor belt 502 are similar to or the same as the modular piece locations 213A-N described in reference to FIG. 2. The conveyor belt 240 continues from the sections 200 of FIG. 2, 300 of FIG. 3, and 400 of FIG. 4, and can continue across multiple and/or all of the sections represented at the pre-marked surface described herein.

The breakpack aisles 506A-N can represent locations in the distribution center where breakpack items may be stored or otherwise placed. Breakpack items can include full case breakpack items as described above. Breakpack items can additionally or alternatively include SSP breakpack items. The user assigned to the section 500 may, for example, perform actions such as placing modular pieces that represent breakpack items in the breakpack aisles 506A-N. The user can also perform actions such as retrieving one or more modular pieces representing the breakpack items from the breakpack aisles 506A-N and unstack or stack them with other modular pieces (such as modular pieces representing the empty pallets 512, the empty cages 514, one or more of the stores 530A-N, and/or one or more other items) in the breakpack work in progress area 510 represented at the section 500.

The SSP 508 represents the physical warehouse section where breakpack items are stowed and pick. A user can flip cards in the section 516A-N and pick SSPs (Green 1×1 modular pieces) and move them to Zones 1-4 as depicted in the progress area 510.

The breakpack work in progress area 510 can represent an area in the distribution center where workers perform breakpacking actions with breakpack items. The user can, for example, perform actions. For example, a user can flip cards in the section 516A-N and pick SSPs (Green 1×1 modular pieces) and move them to Zones 1-4 in the progress area 510. Once a full pallet, represented by the yellow 2×4 brick or carton air, represented by the orange 2×4 brick is completed, it is moved to the section 522 awaiting packing in section 524A-N.

The actions can be performed with respect to particular zones in the breakpack work in progress area 510.

The packing mods staging area 522 can represent an area in the distribution center where pallets and/or cages of breakpack items that are prepared in the breakpack work in progress area 510 are maintained/held until ready to be packed for shipment to one or more of the stores 530A-N. The user can perform actions such as moving the modular pieces that are prepared in the breakpack work in progress area 510 to the packing mods staging area 522 once the user completes the breakpacking actions with the modular pieces.

The store packing mods 524A-N can represent areas in the distribution center where items can be packed for a particular store to then be shipped/delivered to the store. In FIG. 5, the designations of A, B, C, D represent packing zones, e.g., apparel, food, health and beauty, etc. The user can perform actions such as moving one or more of the modular pieces from the packing mods staging area 522 to one of the store packing mods 524A-N for which the modular pieces are to be delivered. The user can perform actions such as stacking one or more modular pieces in the respective store packing mods 524A-N as a packing operation. Once the packing operation is complete, the user can move the stacked modular pieces onto the conveyor belt 502 to be delivered to the next section represented at the pre-marked surface (e.g., refer to FIG. 6).

The empty pallets 512 can be the same as or similar to the empty pallets 224 described in reference to FIG. 2. The empty cages 514 can be the same as or similar to the empty cages 310 described in reference to FIG. 3. The process board 520 can be the same as or similar to the process board 220 described in FIG. 2. The stores 530A-N can be the same as or similar to the stores 210A-N described in FIG. 2.

The user assigned to the section 500 can perform actions with the modular pieces that are received from the user at the section 400 of FIG. 4. The user assigned to the section 500 can perform breakpack actions that correspond to a card that is randomly selected by the user amongst a set of breakpack cards 516A-N and one or more sides of a die 110B that the user rolls during a round of gameplay. The user can select a card amongst the breakpack cards 516A-N to determine what type of breakpack action to perform and the user can roll the die 110B to determine in which of the zone in the breakpack work in progress area 510 to perform the breakpack action. The user can also perform packing actions that correspond to a card that is randomly selected amongst a set of packing cards 526A-N and one or more sides of a die 110C that the user rolls during the round of gameplay. The user can select a card amongst the packing cards 526A-N to determine what type of packing action to perform and the user can roll the die 110C to determine in which of the store packing mods 524A-N to perform the packing action. The dice 110B and 110C can be the same as or similar to the dice 110A-N described throughout this disclosure.

The section 500 can include a machine-readable optical label, such as a barcode (e.g., QR code), which a user can scan using a mobile device or other computing devices. The label can enable the user's device to access one or more instructions for the user specific to the section 500.

FIG. 6 is a fifth example section 600 of the pre-marked surface for demonstrating distribution operations at the distribution center. The section 600 can be the same as or similar to the zone 104E of the pre-marked surface 102 described in FIG. 1. The section 600 can represent a zone in the distribution center where shipping tasks can be performed. Once the actions/tasks are performed with items in the section 600, the items are ready to be shipped or delivered to customers, such as the stores described above.

The section 600 can include visual representations of various distribution center components that may be used to perform shipping tasks. The illustrative example section 600 includes components such as a conveyor belt 602, one or more modular piece locations 604A-N along the conveyor belt 602, a non-conveyable staging area 606, empty pallets 608, empty cages 610, store outbound zones 616A-N, a process board 618, and the conveyor belt 240. The section 600 is merely intended to be illustrative. The section 600 can include additional or fewer distribution center components. The section 600 can also include components that are unique to a particular distribution center and/or a particular type of distribution center.

Referring to the components represented at the section 600, the conveyor belt 602 can be the same as or similar to any one or more of the conveyor belts 212, 302, 303, 402, 403, and/or 502 described in FIGS. 2-5. For example, items that are packed for any of the stores described herein can be moved from the section 500 along the conveyor belt 502 to the conveyor belt 602 of the section 600, then routed to the respective store outbound zones 616A-N. A user assigned to the section 600 can accordingly perform one or more shipping actions with the items that are moved to the section 600.

The one or more modular piece locations 604A-N along the conveyor belt 602 are similar to or the same as the modular piece locations 213A-N described in reference to FIG. 2. The conveyor belt 240 continues from the sections 200 of FIG. 2, 300 of FIG. 3, 400 of FIG. 4, and 500 of FIG. 5. As shown in FIG. 6, the conveyor belt 240 ends at the section 600. The user assigned to the section 600 can perform actions such as moving modular pieces from the conveyor belt 240 to the non-conveyable staging area 606.

The non-conveyable staging area 606 can represent an area in the distribution center where workers may prepare one or more non-conveyable items for shipment. The user assigned to the section 600 can, for example, perform actions such as moving one or more modular pieces representing non-conveyable items to the non-conveyable staging area 606 and stacking the modular pieces with other modular pieces (such as modular pieces representing the empty pallets 608 and/or the empty cages 610). Once the user stacks the modular pieces to create a full pallet and/or a full cage of modular pieces representing non-conveyable items, the user can move the stacked modular pieces to the conveyor belt 602. The stacked modular pieces can then be routed, by the user or any other users at the section 600, from the conveyor belt 602 to the store outbound zone 616A-N representing a store that is intended to receive the items represented by the stacked modular pieces.

The store outbound zones 616A-N can represent aisles, locations, areas, zones, conveyor belts, and/or trailers in the distribution center where items for a particular store are sent after all other tasks/actions/operations are performed with those items in the distribution center. The store outbound zones 616A-N can be connected to the conveyor belt 602 so that items that are ready to be shipped to their respective stores can be routed automatically to the designated store outbound zones 616A-N, then loaded into a truck, trailer, or other equipment to be delivered/shipped to the respective stores. Any one or more of these actions can be performed by workers in the distribution center and/or automated warehouse vehicles in the distribution center, including but not limited to forklifts and/or robots. In the illustrative example of FIG. 6, the store outbound zones 616A-N can correspond to each of the stores described herein, such as the stores 210A-N in FIG. 2. The section 600 can include additional or fewer store outbound zones 616A-N, where each store outbound zone may correspond to one or multiple customers.

The empty pallets 608 can be the same as or similar to the empty pallets 224 described in reference to FIG. 2. The empty cages 610 can be the same as or similar to the empty cages 310 described in reference to FIG. 3. The process board 618 can be the same as or similar to the process board 220 described in FIG. 2.

The user assigned to the section 600 can perform actions with the modular pieces that are received from the user at the section 500 of FIG. 5. The user assigned to the section 600 can perform shipping actions that correspond to cards that are randomly selected by the user amongst a set of outbound cards 612A-N and/or a set of trailer cards 614A-N. The user can select a card amongst the outbound cards 612A-N to determine what type of shipping action to perform with modular pieces received at the conveyor belts 602 and/or 240 (e.g., actions to stack one or more modular pieces representing non-conveyable items in the non-conveyable staging area 606). The user can select a card amongst the trailer cards 614A-N to determine other types of shipping actions to perform with the modular pieces received at the conveyor belts 602 and/or 240 (e.g., actions to route one or more of the modular pieces to one or more of the store outbound zones 616A-N). Other actions are also possible.

The section 600 can include a machine-readable optical label, such as a barcode (e.g., QR code), which a user can scan using a mobile device or other computing devices. The label can enable the user's device to access one or more instructions for the user specific to the section 600.

FIG. 7 is another example system 700 for demonstrating distribution operations at a distribution center described herein. The system 700 can include a computer system 702 and user devices 704A-N that communicate (e.g., wired and/or wirelessly) via network(s) 716. The computer system 702 can be any type of computing device, network of computers, and/or cloud-based system. The user devices 704A-N can be any type of computing devices, mobile devices, mobile phones, smartphones, tablets, laptops, and/or computers.

The computer system 702 can be configured to provide an electronic version of the pre-marked surface 102, the instruction instruments 114A-N, and the modular pieces 112A-N described herein (e.g., refer to FIGS. 1-6) to users at the user devices 704A-N. As a result, the users can simulate distribution operations at the distribution center from their respective user devices 704A-N. The users can, for example, be remote from each other, and use the system 700 to work together to simulate the distribution operations at the distribution center as described herein. The users can be part of teams and/or associated with distribution centers all over a geographic region. These users can bring their diverse experience and skills to rounds of gameplay at their user devices 704A-N, thereby affecting simulation of the distribution operations and learning outcomes for all the users, regardless of whether the users work together in real-world teams at real-world distribution centers.

Referring to the system 700, the computer system 702 can generate and transmit instructions to one or more of the user devices 704A-N to present a pre-marked surface 706 (block A, 720). The pre-marked surface 706 can be a virtual or electronic version of the pre-marked surface 102 described in reference to FIG. 1. The instructions transmitted in block A (720) can also include instructions to present instruction instruments 708A-N and modular pieces 714A-N at the user device(s) 704A-N. The instruction instruments 708A-N can include cards 710A-N and/or dice 712A-N. The instruction instruments 708A-N, including the cards 710A-N and the dice 712A-N and the modular pieces 714A-N can be virtual or electronic versions of the instruction instruments 114A-N, the cards 108A-N, the dice 110A-N, and/or the modular pieces 112A-N described in reference to at least FIG. 1.

In some implementations, the instructions can also instruct the user device(s) 704A-N to present one or more tools or other interfaces at the user device(s) 704A-N. Such tools can include, for example, data fields that allow the user at the user device(s) 704A-N to provide, as input, workflows and/or work plans associated with one or more distribution centers. The user can also use such tools to provide, as input, one or more tasks that may be performed by various users at one or more distribution centers, as part of a workflow for the distribution center(s) and/or sub-workflows for the distribution center(s). As a result, during gameplay, the user inputted workflows, plans, and/or tasks can be simulated and the users at their respective user devices 704A-N can perform tasks that are unique to particular distribution centers.

The instructions, once executed by the user device(s) 704A-N cause the user device(s) 704A-N to present at least the pre-marked surface 706 in a graphical user interface (GUI) display at the user device(s) 704A-N (block B, 722). The instructions may also cause the user device(s) 704A-N to present any of the instruction instruments 708A-N described herein. In some implementations, the instructions can cause the user device(s) 704A-N to present one or more sections of the pre-marked surface 706. For example, the first instructions can be sent to a first user device to cause the first user device to present a first section of the pre-marked surface 706 (refer to FIG. 2). A user at the first user device can be assigned the first section of the pre-marked surface 706 and therefore can perform actions with regards to the first section of the pre-marked surface 706 during a round of gameplay. The computer system 702 can send other instructions to another user device that can cause the another user device to present another section of the pre-marked surface 706 that a user of the another user device is assigned for the round of gameplay. As a result, each user device can present different information during the round of gameplay, such as different sections, as described further in reference to FIGS. 2-6, of the pre-marked surface 706.

The user device(s) 704A-N can receive user input indicating actions performed by the respective user at the device during the round of gameplay (block C, 724). For example, the user device 704A can present the first section of the pre-marked surface 706, as described further in reference to FIG. 2. As part of presenting the first section of the pre-marked surface 706 in the GUI display, the user device 704A can also present selectable graphical icons indicating at least one set of the cards 710A-N. During the round of gameplay, the user can provide user input at the user device 704A, such as clicking or selecting one or more of the cards 710A-N, which can cause the user device 704A to present instructions associated with the selected card 710A (e.g., as a visual overlay, a pop-out window, etc.) to the user. The card instructions can instruct the user to stack 2 modular pieces 714A-N on top of each other then put the stacked modular pieces 713A-N on a conveyor belt presented at the first section of the pre-marked surface 706 at the user device 104A. The user can provide user input indicating selection of the 2 modular pieces 714A-N from visual elements presented at the GUI display of the user device 704A and dragging of the 2 modular pieces 714A-N into a formation on the GUI display that represents a stacking action. Once stacked, the user can provide user input at the user device 704A to drag the stacked modular pieces 714A-N to the conveyor belt. The user may provide additionally user input to move the stacked modular pieces 714A-N across the conveyor belt until the stacked modular pieces 714A-N are positioned at an end of the conveyor belt presented at the user device 704A. At this point, the computer system 702 can generate additional instructions that cause the user device 704A to stop presenting the stacked modular pieces 714A-N at the user device 704A and cause another user device 704B presenting a next section of the pre-marked surface 706 (e.g., refer to the section described in FIG. 3) to present the stacked modular pieces 714A-N on a conveyor belt at the next section of the pre-marked surface 706.

In some implementations, once the user provides user input at the user device 704A to put the stacked modular pieces 714A-N on the conveyor belt, the computer system 702 can provide updated instructions to the user device 704A that causes the user device 704A to present a visual display of the stacked modular pieces 714A-N automatically moving (e.g., at a predetermined rate or speed) along the conveyor belt until the stacked modular pieces 714A-N disappear from presentation at the user device 704A. The computer system 702 can then provide instructions to the another user device 704B that is presenting the next section of the pre-marked surface 706 to cause the another user device 704B to present a visual display of the stacked modular pieces 714A-N moving along the conveyor belt presented with the next section of the pre-marked surface 706. The user at the another user device 704B can then provide user input indicating actions performed with those stacked modular pieces 714A-N, as described herein.

Once user input is received at the user device(s) 704A-N (block C, 724), the user device(s) 704A-N can transmit the user input to the computer system 702 (block D, 726).

The computer system 702 can determine outcomes based on the received user input in block E (728). Based on the determined outcomes, the computer system 702 can generate and transmit additional instructions to the user device(s) 704A-N (block A, 720), and repeat blocks B-E (722-728) until the round of gameplay is complete/ends.

Determining the outcomes in block E (728) can include generating instructions for the user device(s) 704A-N based on the user actions provided by the user input. For example, if the user provides user input indicating placement of the stacked modular pieces 714A-N on the conveyor belt, the computer system 702 can use this input to generate instructions that cause the user device 704A to show a visual representation of the stacked modular pieces 714A-N moving automatically across the conveyor belt presented at the GUI display of the user device 704A.

Determining the outcomes in block E (728) can also include scoring each of the users and/or groups of users at the end of each round of gameplay, based on the actions they performed during the round of gameplay. Refer to FIG. 9 for further discussion about scoring the round of gameplay. As another example, determining the outcomes in block E (728) can include generating at least one recommendation, based at least in part on the actions performed by the user or a group of users during the round of gameplay, about how the user or group of users can improve their actions for implementation in the real-world distribution center(s). One or more other operations described herein can be performed by the computer system 702 as part of determining the outcomes in block E (728).

FIGS. 8A-B illustrate example instruction instruments used with the disclosed techniques for demonstrating distribution operations at a distribution center. The instruction instruments in FIGS. 8A-B are merely illustrative and non-limiting. Additional, fewer, or other types of instructions can be provided by the instruction instruments described herein.

Referring to both FIGS. 8A-B, a set of cards 800A-N can include instructions for performing inbound actions at a high flow manual dock. The set of cards 800A-N can be used by a user assigned to the first section 200 of the pre-marked surface 102, as described further in reference to FIG. 2. As illustrative examples, the cards 800A-N can include a card with instructions for a user to stack one or more modular pieces that represent non-conveyable items with at least one modular piece representing a pallet then move the stacked modular pieces onto a particular conveyor belt presented at the first section 200 of the pre-marked surface 102. Another example card can include instructions for the user to stack a particular modular piece (or multiple modular pieces) representing conveyable items on a modular piece associated with a particular store and/or a modular piece representing a pallet, then move the stacked pieces to a particular conveyor belt. Another example card can include instructions for the user to stack one or more modular pieces representing breakpack item(s) and supplies in the distribution center, such as pallets, then move the stacked modular pieces to a particular conveyor belt. Another example card can include instructions for the user to select another card amongst the cards 800A-N.

A set of cards 802A-N can include instructions for performing inbound actions at a high flow ART. The set of cards 802A-N can be used by a user assigned to the first section 200 of the pre-marked surface 102, as described further in reference to FIG. 2. As illustrative examples, the cards 802A-N can include a card with instructions for a user to stack one or more modular pieces that represent conveyable items with at least one modular piece representing a pallet then move the stacked modular pieces to the ART presented at the first section 200 of the pre-marked surface 102. Another example card can include instructions for the user to stack a particular modular piece (or multiple modular pieces) representing conveyable items on a modular piece associated with a particular store and/or a modular piece representing a pallet, then move the stacked pieces to the ART. Another example card can include instructions for the user to stack one or more modular pieces representing breakpack item(s) and supplies in the distribution center, such as pallets, then move the stacked modular pieces to the ART. Another example card can include instructions for the user to select another card amongst the cards 800A-N.

A set of cards 804A-N can include instructions for performing warehousing/storing actions with non-conveyable items in the distribution center. The set of cards 804A-N can be used by a user assigned to the second section 300 of the pre-marked surface 102, as described further in reference to FIG. 3. As illustrative examples, the cards 804A-N can include a card with instructions for a user to stack one or more modular pieces that represent non-conveyable items (such as the modular pieces that represent non-conveyable items that are received from the user at the first section 200 of the pre-marked surface 102) with at least one modular piece representing a pallet then move the stacked modular pieces to a designated location presented at the section 300 of the pre-marked surface 102. Another example card can include instructions for the user to stack one or more modular pieces that represent non-conveyable items (such as the modular pieces that represent non-conveyable items that are received from the user at the first section 200 of the pre-marked surface 102) with at least one modular piece representing a case, cage, or carton air, then move the stacked modular pieces to a designated location presented at the section 300 of the pre-marked surface 102.

A set of cards 806A-N can include instructions for performing warehousing/storing actions with conveyable items in the distribution center. The set of cards 806A-N can be used by the user assigned to the second section 300 of the pre-marked surface 102, as described further in reference to FIG. 3. As illustrative examples, the cards 806A-N can include a card with instructions for the user to stack one or more modular pieces that represent conveyable items (such as the modular pieces that represent conveyable items that are received from the user at the first section 200 of the pre-marked surface 102) with a modular piece representing a particular store and/or at least one modular piece representing a pallet, then move the stacked modular pieces to a designated location presented at the section 300 of the pre-marked surface 102. Another example card can include instructions for the user to stack one or more modular pieces that represent conveyable items (such as the modular pieces that represent conveyable items that are received from the user at the first section 200 of the pre-marked surface 102) with a modular piece representing a particular store and/or at least one modular piece representing a case, cage, or carton air, then move the stacked modular pieces to a designated location presented at the section 300 of the pre-marked surface 102.

A set of cards 808A-N can include instructions for performing packing actions with items in the distribution center. The set of cards 808A-N can be used by a user assigned to the fourth section 500 of the pre-marked surface 102, as described further in reference to FIG. 5. As illustrative examples, the cards 808A-N can include cards indicating in which store packing mod(s) the user should stack modular pieces to represent packing items for shipment to a particular store.

A set of cards 810A-N can include instructions for performing breakpacking actions with items in the distribution center. The set of cards 810A-N can be used by the user assigned to the fourth section 500 of the pre-marked surface 102, as described further in reference to FIG. 5. As illustrative examples, the cards 810A-N can include cards indicating whether the user should perform breakpacking actions with modular pieces representing full pallets or modular pieces representing cases, cages, or carton airs.

A set of cards 812A-N can include instructions for performing outbound actions with items in the distribution center. The set of cards 812A-N can be used by a user assigned to the fifth section 600 of the pre-marked surface 102, as described further in reference to FIG. 6. As illustrative examples, the cards 812A-N can include cards indicating whether the user should be performing loading actions for outbound shipment with modular pieces representing non-conveyable items or modular pieces representing conveyable items.

A set of cards 814A-N can include instructions for performing outbound trailer-packing actions with items in the distribution center. The set of cards 814A-N can be used by the user assigned to the fifth section 600 of the pre-marked surface 102, as described further in reference to FIG. 6. As illustrative examples, the cards 814A-N can instruct the user to build various different shapes and/or structures using modular pieces representing items to be shipped to particular stores/customers.

FIG. 9 is an example score card 900 for assessing distribution operations at the distribution center using the disclosed techniques. One or more scores can be determined for each round of gameplay using techniques described throughout this disclosure. The scores can be determined per user in the round of gameplay. The scores can additionally or alternatively be determined per group or team of users in the round of gameplay. The scores can be determined automatically by a computer system, such as the computer system 702 described in reference to FIG. 7. The scores can also be determined by a user, such as one of the users engaging in the round of gameplay or another user overseeing the users as they engage in the round of gameplay.

For each round 902 (e.g., period), the user(s) can be scored based on factors including but not limited to safety 904A, quality 904B, delivery 904C, productivity 904D, and units per hour 904N (UPH). The safety relates to the risk identified where a user (Team Member) could be injured by falling products, or mishandling products. The quality relates to the count of defects that were passed from one work cell to another. The delivery relates to the count of inventoried units (Cartons) which were not processed with a period. The productivity relates to the count of cartons shipped divided by the count of labor hours used during a period.

Safety 904A can indicate whether and how many modular pieces fall off the pre-marked surface during gameplay, which further can represent safety of operations being performed in a real-world distribution center. Quality 904B can indicate a number of times (or quantity) of a defect being passed downstream to other users at other sections of the pre-marked surface. Delivery 904C can indicate a count of items (e.g., modular pieces) still in play during the round of gameplay. Productivity 904D can indicate how many pallets or cases (e.g., cages, carton airs) of items (e.g., stacked modular pieces) are made during a round of gameplay. UPH 904N can, for example, be determined based on dividing total units of items (e.g., stacked modular pieces) shipped by total labor hours used to process the units of items for shipment. UPH 904N can, as another example, be determined based on dividing units of items (e.g., stacked modular pieces) produced by a total number of users during the round, multiplied by an amount of time to generate the units of items by the user or users. UPH 904N can be a similar metric to productivity 904D, except that UPH 904N can represent outcomes from changing an amount of labor used to produce the units of items.

The score card 900 is merely meant to be illustrative. The users can be scored using other metrics. The scoring metrics can vary based on gaming implementation, such as a type of distribution center and/or operations in a particular distribution center that the users are associated with. The users may also be scored using metrics for which user/team productivity is to be assessed.

The users can undergo 4 rounds of gameplay. In some implementations, the users can partake in additional or fewer rounds of gameplay. Gameplay rules may not change during each round of gameplay. In some implementations, one or more of the rules may change. During each round of gameplay, the same instruction instruments may be used, although the instruction instruments may be randomized (e.g., sets of cards may be shuffled and/or re-shuffled, cards that were drawn in previous rounds of gameplay may be removed from the sets and/or placed at a bottom of the sets, etc.). In some implementations, one or more gameplay factors may change, such as a quantity of users engaging in the round of gameplay, whether and how many modular pieces are added to conveyor belts to represent bottlenecks or buffer inventory, etc.

Each round of gameplay 902 can serve a different purpose for the users to learn and improve their operations in a real-world distribution center. For example, a first round can have a purpose of teaching the users how to work in silos (e.g., alone). During the first round, the users may not communicate with each other. Each user can perform actions with the modular pieces in an effort to achieve a highest throughput and clear their queue of actions to be performed before the round ends. They can perform these actions without seeking guidance or assistance from the other users. After the first round, the users can identify silos, such as which users had the highest throughput when working alone. The users can then identify ways in which efficiency in silos can be translated into entire department and/or team efficiency. In some implementations, assessment of the first round of gameplay can be performed/determined automatically, such as by the computer system 702 described in FIG. 7.

A second round can be associated with learning lessons via a Heijunka school of thought to reduce waste and increase volume. During the second round, output can be constrained while still requiring the users to efficiently clear their queues of actions to be performed without communicating with each other. Constrains can be placed on the users by, for example, requiring a user first at the first section of the pre-marked surface to only use their non-dominant hand to perform actions, such as picking cards, picking modular pieces, stacking modular pieces, and moving the modular pieces around the first section of the pre-marked surface. In some implementations, a winner of the first round can be required to throttle down their inbound team, thereby reducing their throughput during the second round of gameplay. After the second round, the users can identify ways in which level setting batches, waves, and/or queues can smooth workflow and improve overall output.

A third round can be associated with learning lessons by managing work in progress (WIPs), increasing communication amongst users, introducing Andons, and sharing demand signals. Users can learn values in upper and lower control limits. The users can identify queues of actions to be performed on the pre-marked surface and discuss amongst each other how to reduce those queues efficiently. An Andon is an alert sent by a user (team member) that there is a process or systemic defect that is causing safety, quality or throughput disruptions. It can be used as a trigger to stop work until the issue is resolved. Standard Work In Progress (SWIP) can be introduced in the third round of gameplay, which may reduce idle time (e.g., downtime described in FIG. 10) across one or more sections (e.g., departments) represented at the pre-marked surface. The Standard Work In Process (SWIP) is the minimal amount of work required to keep a work cell operational. SWIP has a lower and upper control limit. Inventory in excess of the upper control limit is considered excessive and adds to the total Work In Process. WIP is the total of all inventory that is actively moving through a distribution center, and is inclusive of SWIP.

For example, during the third round of gameplay, modular pieces representing buffer inventory can be placed at one or more locations along conveyor belts on the pre-marked surface to represent bottlenecks and increased volume in a supply chain. After the third round of gameplay, the users can efficiently identify bottlenecks and call those issues out to other users to strategically manage different levels of volume that may exist in the real-world distribution center.

A fourth round of gameplay can allow the users to identify constraints and solve those constraints as a team to maximize throughput and output. The users can take lessons learned from the prior rounds and communicate and work together during the fourth round to identify planning gaps, bottlenecks, resource constraints, and execute simple yet efficient problem-solving techniques. For example, the users can, as a team, pull Andons, pause labor, and/or move labor. An operations director (OD, a leader that provides the strategy for a shift and is accountable for the total performance of a shift) can be introduced in the fourth round to assist in making real-time operational changes to balance and optimize workflow. The OD can introduce changes such as instructing the first user at the first section of the pre-marked surface to use both their hands to perform actions at the first section of the pre-marked surface. As another example, the OD can introduce changes such as instructing one or more other users to perform actions at a slower temp/speed and/or reduce WIP.

The score card 900 and lessons learned in each of the rounds 902 can help the users learn what changes they can make to their actions in the real-world distribution center to improve productivity, perform actions better, reduce costs, and/or lower waste of inventory/labor/other resources. For example, the users can identify and learn ways in which to reduce one or more of the following forms of waste: defects, over production, waiting/downtime, not utilizing labor, transportation, inventory/items, motion/movement, and/or excess processing. Sometimes, actions performed during each round of gameplay can also be compared (e.g., by the users and/or by the computer system 702) to actual, real-world execution of similar actions in real-world distribution centers to identify improvements and/or adjustments that can be made to the real-world distribution center to widen a workflow and draw more inventory through the distribution center without adding more workers or other resources to that distribution center.

FIG. 10 illustrate example downtime charts 1000A-N for assessing distribution operations at a distribution center. More particularly, the downtime charts 1000A-N can represent downtime of users during each round of gameplay using the disclosed techniques. Downtime can indicate when a user(s) did not have actions to perform during the round of gameplay. As a result, the user(s) is idle, may be inefficient, and/or may be over-productive (e.g., by working too quickly on performing some actions). The charts 1000A-N can be used to visually identify when users experience overproduction and/or downtime. The charts 1000A-N can be used to visually identify which sections (e.g., departments) of the pre-marked surface described herein experience the most overproduction and/or downtime. Moreover, the charts 1000A-N can be used to visually identify how downtime may change per round, such as the downtime being passed along to other sections (e.g., departments) of the pre-marked surface as the rounds progress. Sometimes, when downtime passes from one section to the next as the rounds progress, this can indicate improved productivity and/or improvements in overall workflow.

As an illustrative example, the downtime charts 1000A-N can include a midpoint line 1004, which can indicate where productivity is expected to be for the users during a round of gameplay. Line section 1002 in the downtime charts 1000A-N represents downtime and thus reduced productivity. Portions of the line section 1002 that are above the midpoint line 1004 can indicate overproduction while portions of the line section 1002 that are below the midpoint line 1004 can indicate downtime. As shown between the charts 1000A and 1000B, 1000B and 1000C, and 1000C and 1000N, the line section 1002 both gets smaller and moves along the respective chart. This indicates that as the rounds progress, the users are learning how to efficiently deal with workflow issues, such as bottlenecks, thereby reducing overall downtime/overproduction and improving efficiency by opening up the workflow pipeline.

The charts 1000A-N can be generated by tallying or counting how many times a user experiences a work/task/action stoppage in their assigned section of the pre-marked surface. This tally or count can be captured in a user's score card, such as the score card 900 depicted and described in reference to FIG. 9. Another user can transfer the tallies and/or counts for all the users in the round of gameplay to a graph, such as the charts 1000A-N. In some implementations, a computer system, such as the computer system 702 can automatically determine the tally or count and/or generate the charts 1000A-N.

FIG. 11 illustrates another example system 1100 for demonstrating distribution operations at a distribution center. The system 1100 can be similar to the system 100 described in at least FIG. 1. The systems 100 and 1100 can, however, be used to demonstrate distribution operations in different types of distribution centers. For example, the system 100 can be used to demonstrate distribution operations in a distribution center that includes manual operations and/or equipment that is manually operated by users/workers. The system 1100, on the other hand, can be used to demonstrate distribution operations in distribution centers that are set up/arranged to include more automation techniques and/or automated equipment, such as automated item-packing systems. Although the systems 100 and 1100 may be used to demonstrate distribution operations in different types/implementations of distribution centers, users can engage in similar or same rounds of gameplay using the disclosed techniques in order to learn and improve workflows and optimize efficiency in their respective real-world distribution centers.

Referring to the system 1100 in FIG. 11, the system 1100 can include a pre-marked surface 1102, the instruction instruments 114A-N, and the modular pieces 112A-N. The instruction instruments 114A-N can include the cards 108A-N and/or the dice 110A-N described at least in reference to FIG. 1. The modular pieces 112A-N can be the same as or similar to any of the modular pieces described throughout this disclosure.

The pre-marked surface 1102 can include multiple sections 1104A-D. Each of the sections 1104A-N can represent a different zone, department, sub-process, and/or sub-workflow in the distribution center that is represented by the pre-marked surface 1102. The pre-marked surface 1102 can include additional, different, or fewer sections, depending on a particular setup of the distribution center.

The example pre-marked surface 1102 includes 4 sections. The first section 1104A represents a breakpacking area of the distribution center. The second section 1104B represents a breakpack staging and/or conveyance area in the distribution center. The third section 1104C represents an induction area in the distribution center. The fourth section 1104D represents an outbound area in the distribution center. The section 1104A is breakpack, operated the same as the section 500. The sections 1104B and 1104C are a process named Auto Rebin, which is packing system that can be automated or manual. The sections 1104B and 1104C are limited to a number (e.g., 8) of distribution centers that have this system. The section 1104D is the same as section 600 identified earlier as outbound.

One or more of the sections 1104A-D can include similar or same warehouse/distribution center components and/or equipment, as depicted on the pre-marked surface 102 and described throughout this disclosure. For example, at least one conveyor belt can be visually represented as extending across at least a portion of the sections 1104A-D of the pre-marked surface 102. One or more of the sections 1104A-D may also include staging or work in progress areas (e.g., breakpack work in progress area in the section 1104A, breakpack staging area in the section 1104B), empty cages and/or empty pallets, process boards, presort decant areas (see section 1104B), tote or other conveyance systems (see section 1104B), manual and automated induction systems (see section 1104C), manual and automated induction mods (see section 1104C, and/or shipment areas, trucks, and/or trailers (see section 1104D).

In some implementations, users can engage in 4 rounds of gameplay using the system 1100. Refer to FIG. 9 for further discussion about the rounds of gameplay. In some implementations, the users can perform actions with modular pieces that represent cages (e.g., cases, carton airs), totes, work in progress (WIP) totes or cages, and/or manual and/or automated packing mods (whereas with the system 100, the users may perform actions with modular pieces that represent cages and pallets).

FIGS. 12A-B is a flowchart of a process 1200 for demonstrating distribution operations at a distribution center using the disclosed techniques. The process 1200 can be performed by one or more users engaging in rounds of gameplay to simulate and learn distribution operations at the real-world distribution center. In some implementations, the process 1200 can be performed by the computer system 702 described herein. The process 1200 can also be performed by one or more other computing systems, devices, computers, networks, cloud-based systems, and/or cloud-based services. For illustrative purposes, the process 1200 is described agnostically so as not to be tied to a particular user and/or computer system.

Referring to the process 1200 in both FIGS. 12A-B, a pre-marked surface having a plurality of sections is provided in block 1202. The pre-marked surface can be the pre-marked surface 102 of FIG. 1 and/or the pre-marked surface 1102 of FIG. 11. The pre-marked surface can be any other type of pre-marked surface that represents a workflow in a distribution center. The plurality of sections can represent various distribution operations at the distribution center and can be configured to be assigned to a plurality of users who demonstrate the distribution operations (e.g., users who engage in the distribution operations in a real-world distribution center). For example, the first section may correspond to an inbound department at the distribution center, the second section may correspond to a storing department at the distribution center, the third section may correspond to a picking department at the distribution center, the fourth section may correspond to a packing department at the distribution center, and the fifth section may correspond to an outbound department at the distribution center. The plurality of users may include first, second, third, fourth, and fifth users, and the plurality of sections can include first, second, third, fourth, and fifth sections that are assigned to the first, second, third, fourth, and fifth users respectively. Refer to FIGS. 2-6 for further discussion about the plurality of sections at the pre-marked surface.

In block 1204, a plurality of instruction instruments can be provided (e.g., to users) that are configured to be selected by a first user of the plurality of users. The instruction instruments can be randomly selected by the users. Each instruction instrument can be configured to initiate one of the plurality of users to perform an action at one of the plurality of sections that is assigned to the one of the plurality of users. The action can be configured to cause another of the plurality of users to take an action at another of the plurality of sections, where the action of the another of the plurality of users can be based on the action performed by the one of the plurality of users. The plurality of instruction instruments can include a plurality of cards providing instructions that can be configured to initiate the plurality of users to perform actions at the plurality of sections. The plurality of instruction instruments can additionally or alternatively include one or more die. In some implementations, the plurality of instruction instruments can include instructions configured to initiate the plurality of users to perform actions that correspond to real-life scenarios of inbound components for the distribution center.

A plurality of modular pieces can also be provided that are configured to be interlocked with each other and delivered across the pre-marked surface by the plurality of users (block 1206). The plurality of modular pieces can represent components at the distribution center. The components at the distribution center represented by the plurality of modular pieces can include at least one of inventory, pallets, and/or warehouse equipment. The modular pieces can be interlocked with each other at the plurality of sections and delivered across the plurality of sections based at least in part on selection of the plurality of instruction instruments that are associated with each of the plurality of sections at the pre-marked surface. The plurality of modular pieces can be stackable bricks. Actions performed by at least one of the plurality of users can include stacking the bricks according to instructions provided by an instruction instrument amongst the plurality of instruction instruments that is randomly selected by the at least one of the plurality of users. Moreover, the plurality of modular pieces can be different colors and different sizes. The different colors and the different sizes can each indicate at least one of units of inventory at the distribution center, quantity of the inventory at the distribution center, size of the inventory at the distribution center, a store, type of supplies used at the distribution center as part of the workflow, and/or type of the inventory at the distribution center.

The first user can be caused to select a first instruction instrument in block 1208. This action can begin a round of gameplay at the pre-marked surface for the plurality of users.

In block 1210, the first user can be caused to perform an action with at least one modular piece based on the selected first instruction instrument.

The first user can also be caused to deliver the modular piece(s) onto a conveyor belt represented at the pre-marked surface (block 1212). In some implementations, the plurality of users may include a sixth user, and the interlocked modular pieces can be assigned to the sixth user and delivered, by the sixth user, to each of the first, second, third, fourth, and fifth sections (e.g., once the first user delivers the modular piece(s), such as interlocked modular pieces, onto the conveyor belt). Therefore, the sixth user can be caused to deliver modular pieces and/or interlocked/stacked modular pieces on the conveyor belt across multiple sections of the pre-marked surface (instead of or in addition to causing the user assigned to the particular section to move the modular pieces across the conveyor belt represented at their section).

As an illustrative example of blocks 1208-1212, the first section at the pre-marked surface can include visual elements that depict: (i) at least one store, (ii) an automated conveyor belt that can be configured to receive the plurality of modular pieces and extend across at least the first section and the second section, (iii) a manual dock, and (iv) a manual dock pallet staging area. The plurality of instruction instruments at the first section can include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the manual dock depicted on the pre-marked surface. As another example, the plurality of instruction instruments at the first section can include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the automated conveyor belt depicted on the pre-marked surface.

As an illustrative example, providing the plurality of instruction instruments and the plurality of modular pieces can be configured to: cause the first user to select a threshold quantity of the plurality of modular pieces that satisfy one or more color and size criteria provided by the selected instruction instrument, and cause the first user to stack the selected threshold quantity of the plurality of modular pieces into a brick that is provided by the selected instruction instrument. The brick can represent inventory that is ingested into the distribution center and delivered across the plurality of sections at the pe-marked surface to represent movement of the inventory through the distribution center.

As yet another example, providing the plurality of instruction instruments and the plurality of modular pieces can cause the first user to move a modular piece having a first size and a first color onto an automated conveyor system defined at the section that is assigned to the first user at the pre-marked surface, the modular piece representing a breakpack flow in the workflow for the distribution center. As another example, the first user can be caused to interlock a first modular piece having a first color and a first size with a second modular piece having a second color and a second size and move the interlocked modular pieces onto an automated conveyor system defined at the section that is assigned to the first user at the pre-marked surface, the interlocked modular pieces representing a conveyable flow in the workflow for the distribution center.

As yet another example, the first user can be caused to interlock a first modular piece having a first color and a first size with a second modular piece having a second color and a second size and move the interlocked modular pieces onto a manual dock system defined at the section that is assigned to the first user at the pre-marked surface. The interlocked modular pieces can represent a breakpack flow in the workflow for the distribution center. The interlocked modular pieces can represent a non-conveyable flow in the workflow for the distribution center.

As another example, the first user can be caused to interlock a first modular piece having a first color and a first size with (i) a second modular piece having a second color and a second size and (ii) a third modular piece having a third color and a third size, and move the interlocked modular pieces onto a manual dock system defined at the section that is assigned to the first user at the pre-marked surface, the interlocked modular pieces representing a conveyable flow in the workflow for the distribution center.

The first user can be caused to select a next instruction instrument in block 1214.

In block 1216, the first user can be caused to perform a next action with another modular piece based on the selected next instruction instrument.

A next user that is assigned to a next section of the pre-marked surface can be caused to select an instruction instrument associated with the next section (block 1218). Block 1218 can be performed before, during, or after block 1216. The next user at the next section can be the second user assigned to the second section at the pre-marked surface.

In block 1220, the next user can be caused to perform an action with the modular piece(s) at the next section of the pre-marked surface based on the instruction instrument that the next user selected in block 1218.

As an illustrative example of at least blocks 1218-1220, the second section can include visual elements that depict (i) a conveyor belt that can be configured to receive the plurality of modular pieces from the first section of the pre-marked surface and move the plurality of modular pieces from the second section to the third section of the pre-marked surface, (ii) non-conveyable aisles, and (iii) conveyable aisles. The plurality of instruction instruments at the second section can include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the non-conveyable aisles depicted on the pre-marked surface. The plurality of instruction instruments at the second section can include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the conveyable aisles depicted on the pre-marked surface.

As an illustrative example, providing the plurality of instruction instruments and the plurality of modular pieces can further be configured to: cause the second user to select, from amongst a second plurality of instruction instruments, a first instruction instrument configured to cause the second user to perform an action at the section that is assigned to the second user, cause the second user to perform the action with the plurality of modular pieces based on the first instruction instrument, and responsive to performing the action, cause the second user to deliver the plurality of modular pieces onto the conveyor belt represented at the pre-marked surface to a section amongst the plurality of sections that is assigned to the third user (e.g., the third section).

As another example, the second user can be caused to interlock a first modular piece having a first color and a first size with a second modular piece having a second color and a second size. The interlocked modular pieces can represent a full pallet that is non-conveyable at the distribution center. The interlocked modular pieces can represent a carton air that is non-conveyable at the distribution center. As yet another example, the second user can be caused to interlock a first modular piece having a first color and a first size with (i) a second modular piece having a second color and a second size and (ii) a third modular piece having a third color and a third size.

It can be determined whether the round of gameplay has finished in block 1222. If the round of gameplay has not finished, the process 1200 can return to block 1208. The process 1200 can iterate through blocks 1208-1220 at each of the sections of the pre-marked surface until the round of gameplay ends (e.g., a predetermined amount of time for playing the round has ended, one or more of the plurality of users have completed all their queued actions at their assigned sections, at least one of the users such as the first user has run out of instruction instruments to choose from, etc.). Moreover, as described above, providing the plurality of instruction instruments and the plurality of modular pieces can further be configured to: cause the second user to select, from amongst the second plurality of instruction instruments, a next instruction instrument to perform a next action with the another of the plurality of modular pieces at the second section of the pre-marked surface.

The blocks 1208-1216 can be performed by each user at each of the sections of the pre-marked surface during the round of gameplay. As an illustrative example, the third section can include visual elements that depict (i) a conveyor belt that can be configured to receive the plurality of modular pieces from the second section of the pre-marked surface and move the plurality of modular pieces from the third section to the fourth section of the pre-marked surface, (ii) a full pallet staging area, (iii) a carton air staging area, and (iv) a re-palletization line. The plurality of instruction instruments at the third section can include a die that can be configured to be rolled, by the third user at the third section, to determine a zone amongst a plurality of zones at the re-palletization line depicted on the pre-marked surface, the zone being configured to allow the third user to perform at least one repalletization action with the plurality of modular pieces. Providing the plurality of instruction instruments and the plurality of modular pieces can further be configured to: cause the third user to roll the die to determine a zone represented at the section that is assigned to the third user at which to perform an action with the plurality of modular pieces, cause the third user to perform the action with the plurality of modular pieces in the zone that is determined based on rolling the die, and responsive to performing the action, cause the third user to deliver the plurality of modular pieces via the conveyor belt represented at the pre-marked surface to a section amongst the plurality of sections that is assigned to the fourth user (e.g., the fourth section). Providing the plurality of instruction instruments and the plurality of modular pieces may also cause, as described above, the third user to roll the die to determine a zone represented at the section that is assigned to the third user at which to perform a next action with the another of the plurality of modular pieces.

As another illustrative example, during the round of gameplay, the fourth section can include visual elements that depict (i) a conveyor belt that can be configured to receive the plurality of modular pieces from the third section of the pre-marked surface and move the plurality of modular pieces from the fourth section to a packing area depicted in the fourth section of the pre-marked surface, (ii) break pack aisles, and (iii) the packing area. The packing area can be configured to receive the plurality of modular pieces that are ready to be transported to a designated store of a plurality of stores for receiving inventory, the inventory being represented by the plurality of modular pieces. The packing area may include a plurality of mods, each of the plurality of mods being assigned to a store amongst the plurality of stores. The plurality of instruction instruments at the fourth section can include a first subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces, the actions including breakpacking actions. The plurality of instruction instruments at the fourth section can additionally or alternatively include a second subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces that include packing actions. Additionally or alternatively, the plurality of instruction instruments further can include a die that can be configured to be rolled, by the fourth user at the fourth section, to determine a zone depicted in the fourth section of the pre-marked surface, the zone being configured to allow the fourth user to perform the actions with the plurality of modular pieces.

Moreover, providing the plurality of instruction instruments and the plurality of modular pieces may also: cause the fourth user to select, from amongst a third plurality of instruction instruments, a first instruction instrument to cause the fourth user to perform an action at the section that is assigned to the fourth user, cause the fourth user to roll a die to determine a zone at the section that is assigned to the fourth user at which to perform the action with the plurality of modular pieces, cause the fourth user to perform the action with the plurality of modular pieces based on the first instruction instrument in the zone that is determined based on rolling the die, and responsive to performing the action, cause the fourth user to deliver the plurality of modular pieces to a packing mod depicted at the pre-marked surface, the packing mod corresponding to a store that is designated to receive inventory represented by the plurality of modular pieces.

As yet another illustrative example, the fifth section may include visual elements that depict (i) a conveyor belt that can be configured to receive the plurality of modular pieces from the fourth section of the pre-marked surface and move the plurality of modular pieces from the fourth section to the fifth section of the pre-marked surface, (ii) a non-conveyable staging area, and (iii) conveyor aisles that each correspond to a particular store for which the plurality of modular pieces are to be shipped in an outbound shipment from the distribution center. The plurality of instruction instruments at the fifth section can include a subset of cards providing instructions, to the fifth user at the fifth section, to perform actions with the plurality of modular pieces that include performing outbound shipment actions and trailer shipment actions.

Moreover, providing the plurality of instruction instruments and the plurality of modular pieces can: cause the fifth user to select, from amongst a fourth plurality of instruction instruments, a first instruction instrument to cause the fifth user to perform an action at the section that is assigned to the fifth user, cause the fifth user to perform the action with the plurality of modular pieces based on the first instruction instrument, and responsive to performing the action, cause the fifth user to deliver the plurality of modular pieces to a conveyor aisle depicted at the pre-marked surface that corresponds to a particular store for which the plurality of modular pieces are to be shipped in an outbound shipment from the distribution center.

Referring back to block 1222, if the round of gameplay has finished, then the plurality of users can be caused to score their performance for that round (block 1224). For example, the system described herein can include an evaluation system that can be configured to evaluate performance of the plurality of users. The performance can be calculated based on the plurality of modular pieces being delivered across the plurality of sections at the pre-marked surface, the performance representing at least one of safety, quality, delivery, and/or productivity. Sometimes, for example, performance can be calculated based on units per hours. Scoring the performance of the plurality of users can include generating a downtime chart based on identifying times during the round of gameplay at which a work stoppage occurs while delivering the plurality of modular pieces across the plurality of sections at the pre-marked surface. The times can represent times of overproduction and times of downtime amongst the plurality of users. A dip or spike in the downtime chart may represent at least one bottleneck experienced by the plurality of users while delivering the plurality of modular pieces across the plurality of sections at the pre-marked surface. Refer to FIGS. 9-10 for further discussion about scoring and assessing the performance of the plurality of users during each round of gameplay.

Optionally, the plurality of users can also be caused to begin another round of gameplay (block 1226). Beginning another round of gameplay can cause the process 1200 to be performed again from the start, at block 1202.

In a first round of four illustrative rounds of gameplay, a user amongst the plurality of users can win the first round based on performing actions with the plurality of modular pieces responsive to selecting instruction instruments amongst the plurality of instruction instruments more efficiently than other users amongst the plurality of users performing other actions with the plurality of modular pieces. In a second round of the four rounds, the user who won the first round can be instructed to remove a threshold quantity of users from the sections depicted on the pre-marked surface to remove waste and increase throughput in the workflow at the distribution center. In a third round of the four rounds, at least one of the plurality of modular pieces can be used as buffer inventory and placed along the workflow at the distribution center in at least one of the plurality of sections depicted on the pre-marked surface. In a fourth round of the four rounds, the plurality of users can be instructed to perform actions with the plurality of modular pieces that optimize operations in the workflow at the distribution center based on outcomes of the first, second, and third rounds.

In some implementations, as described in reference to FIG. 7, the system can include a computing system and a plurality of user devices in communication with the computing system over a network. The computing system can be configured to transmit, to at least one of the plurality of user devices, instructions that, when executed, cause the at least one of the plurality of user devices to present in a graphical user interface (GUI) display electronic versions of (i) the pre-marked surface, (ii) the plurality of instruction instruments, and (iii) the plurality of modular pieces (blocks 1202-1206). The at least one of the plurality of user devices can be configured to: receive first user input indicating selection of an instruction instrument amongst the plurality of instruction instruments (block 1208), receive second user input indicating an action performed with the plurality of modular pieces according to the selected instruction instrument (block 1210), and transmit, to the computing system, at least the second user input. The computing system can then be configured to deliver the plurality of modular pieces across a plurality of sections at the electronic version of the pre-marked surface based at least in part on the second user input (block 1212). Accordingly, the process 1200 can be performed in an implementation that includes the computing system, the plurality of user devices, and the electronic version of the pre-marked surface described herein.

FIG. 13 shows an example of a computing device 1300 and an example of a mobile computing device that can be used to implement the techniques described here. The computing device 1300 is intended to represent various forms of digital computers, such as laptops, desktops, workstations, personal digital assistants, servers, blade servers, mainframes, and other appropriate computers. The mobile computing device is intended to represent various forms of mobile devices, such as personal digital assistants, cellular telephones, smart-phones, and other similar computing devices. The components shown here, their connections and relationships, and their functions, are meant to be exemplary only, and are not meant to limit implementations of the inventions described and/or claimed in this document.

The computing device 1300 includes a processor 1302, a memory 1304, a storage device 1306, a high-speed interface 1308 connecting to the memory 1304 and multiple high-speed expansion ports 1310, and a low-speed interface 1312 connecting to a low-speed expansion port 1314 and the storage device 1306. Each of the processor 1302, the memory 1304, the storage device 1306, the high-speed interface 1308, the high-speed expansion ports 1310, and the low-speed interface 1312, are interconnected using various busses, and can be mounted on a common motherboard or in other manners as appropriate. The processor 1302 can process instructions for execution within the computing device 1300, including instructions stored in the memory 1304 or on the storage device 1306 to display graphical information for a GUI on an external input/output device, such as a display 1316 coupled to the high-speed interface 1308. In other implementations, multiple processors and/or multiple buses can be used, as appropriate, along with multiple memories and types of memory. Also, multiple computing devices can be connected, with each device providing portions of the necessary operations (e.g., as a server bank, a group of blade servers, or a multi-processor system).

The memory 1304 stores information within the computing device 1300. In some implementations, the memory 1304 is a volatile memory unit or units. In some implementations, the memory 1304 is a non-volatile memory unit or units. The memory 1304 can also be another form of computer-readable medium, such as a magnetic or optical disk.

The storage device 1306 is capable of providing mass storage for the computing device 1300. In some implementations, the storage device 1306 can be or contain a computer-readable medium, such as a floppy disk device, a hard disk device, an optical disk device, or a tape device, a flash memory or other similar solid state memory device, or an array of devices, including devices in a storage area network or other configurations. A computer program product can be tangibly embodied in an information carrier. The computer program product can also contain instructions that, when executed, perform one or more methods, such as those described above. The computer program product can also be tangibly embodied in a computer- or machine-readable medium, such as the memory 1304, the storage device 1306, or memory on the processor 1302.

The high-speed interface 1308 manages bandwidth-intensive operations for the computing device 1300, while the low-speed interface 1312 manages lower bandwidth-intensive operations. Such allocation of functions is exemplary only. In some implementations, the high-speed interface 1308 is coupled to the memory 1304, the display 1316 (e.g., through a graphics processor or accelerator), and to the high-speed expansion ports 1310, which can accept various expansion cards (not shown). In the implementation, the low-speed interface 1312 is coupled to the storage device 1306 and the low-speed expansion port 1314. The low-speed expansion port 1314, which can include various communication ports (e.g., USB, Bluetooth, Ethernet, wireless Ethernet) can be coupled to one or more input/output devices, such as a keyboard, a pointing device, a scanner, or a networking device such as a switch or router, e.g., through a network adapter.

The computing device 1300 can be implemented in a number of different forms, as shown in the figure. For example, it can be implemented as a standard server 1320, or multiple times in a group of such servers. In addition, it can be implemented in a personal computer such as a laptop computer 1322. It can also be implemented as part of a rack server system 1324. Alternatively, components from the computing device 1300 can be combined with other components in a mobile device (not shown), such as a mobile computing device 1350. Each of such devices can contain one or more of the computing device 1300 and the mobile computing device 1350, and an entire system can be made up of multiple computing devices communicating with each other.

The mobile computing device 1350 includes a processor 1352, a memory 1364, an input/output device such as a display 1354, a communication interface 1366, and a transceiver 1368, among other components. The mobile computing device 1350 can also be provided with a storage device, such as a micro-drive or other device, to provide additional storage. Each of the processor 1352, the memory 1364, the display 1354, the communication interface 1366, and the transceiver 1368, are interconnected using various buses, and several of the components can be mounted on a common motherboard or in other manners as appropriate.

The processor 1352 can execute instructions within the mobile computing device 1350, including instructions stored in the memory 1364. The processor 1352 can be implemented as a chipset of chips that include separate and multiple analog and digital processors. The processor 1352 can provide, for example, for coordination of the other components of the mobile computing device 1350, such as control of user interfaces, applications run by the mobile computing device 1350, and wireless communication by the mobile computing device 1350.

The processor 1352 can communicate with a user through a control interface 1358 and a display interface 1356 coupled to the display 1354. The display 1354 can be, for example, a TFT (Thin-Film-Transistor Liquid Crystal Display) display or an OLED (Organic Light Emitting Diode) display, or other appropriate display technology. The display interface 1356 can comprise appropriate circuitry for driving the display 1354 to present graphical and other information to a user. The control interface 1358 can receive commands from a user and convert them for submission to the processor 1352. In addition, an external interface 1362 can provide communication with the processor 1352, so as to enable near area communication of the mobile computing device 1350 with other devices. The external interface 1362 can provide, for example, for wired communication in some implementations, or for wireless communication in other implementations, and multiple interfaces can also be used.

The memory 1364 stores information within the mobile computing device 1350. The memory 1364 can be implemented as one or more of a computer-readable medium or media, a volatile memory unit or units, or a non-volatile memory unit or units. An expansion memory 1374 can also be provided and connected to the mobile computing device 1350 through an expansion interface 1372, which can include, for example, a SIMM (Single In Line Memory Module) card interface. The expansion memory 1374 can provide extra storage space for the mobile computing device 1350, or can also store applications or other information for the mobile computing device 1350. Specifically, the expansion memory 1374 can include instructions to carry out or supplement the processes described above, and can include secure information also. Thus, for example, the expansion memory 1374 can be provide as a security module for the mobile computing device 1350, and can be programmed with instructions that permit secure use of the mobile computing device 1350. In addition, secure applications can be provided via the SIMM cards, along with additional information, such as placing identifying information on the SIMM card in a non-hackable manner.

The memory can include, for example, flash memory and/or NVRAM memory (non-volatile random access memory), as discussed below. In some implementations, a computer program product is tangibly embodied in an information carrier. The computer program product contains instructions that, when executed, perform one or more methods, such as those described above. The computer program product can be a computer- or machine-readable medium, such as the memory 1364, the expansion memory 1374, or memory on the processor 1352. In some implementations, the computer program product can be received in a propagated signal, for example, over the transceiver 1368 or the external interface 1362.

The mobile computing device 1350 can communicate wirelessly through the communication interface 1366, which can include digital signal processing circuitry where necessary. The communication interface 1366 can provide for communications under various modes or protocols, such as GSM voice calls (Global System for Mobile communications), SMS (Short Message Service), EMS (Enhanced Messaging Service), or MMS messaging (Multimedia Messaging Service), CDMA (code division multiple access), TDMA (time division multiple access), PDC (Personal Digital Cellular), WCDMA (Wideband Code Division Multiple Access), CDMA2000, or GPRS (General Packet Radio Service), among others. Such communication can occur, for example, through the transceiver 1368 using a radio-frequency. In addition, short-range communication can occur, such as using a Bluetooth, WiFi, or other such transceiver (not shown). In addition, a GPS (Global Positioning System) receiver module 1370 can provide additional navigation- and location-related wireless data to the mobile computing device 1350, which can be used as appropriate by applications running on the mobile computing device 1350.

The mobile computing device 1350 can also communicate audibly using an audio codec 1360, which can receive spoken information from a user and convert it to usable digital information. The audio codec 1360 can likewise generate audible sound for a user, such as through a speaker, e.g., in a handset of the mobile computing device 1350. Such sound can include sound from voice telephone calls, can include recorded sound (e.g., voice messages, music files, etc.) and can also include sound generated by applications operating on the mobile computing device 1350.

The mobile computing device 1350 can be implemented in a number of different forms, as shown in the figure. For example, it can be implemented as a cellular telephone 1380. It can also be implemented as part of a smart-phone 1382, personal digital assistant, or other similar mobile device.

Various implementations of the systems and techniques described here can be realized in digital electronic circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms machine-readable medium and computer-readable medium refer to any computer program product, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term machine-readable signal refers to any signal used to provide machine instructions and/or data to a programmable processor.

To provide for interaction with a user, the systems and techniques described here can be implemented on a computer having a display device (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor) for displaying information to the user and a keyboard and a pointing device (e.g., a mouse or a trackball) by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form, including acoustic, speech, or tactile input.

The systems and techniques described here can be implemented in a computing system that includes a back end component (e.g., as a data server), or that includes a middleware component (e.g., an application server), or that includes a front end component (e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the systems and techniques described here), or any combination of such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication (e.g., a communication network). Examples of communication networks include a local area network (LAN), a wide area network (WAN), and the Internet.

The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

According to implementations of the present disclosure, a system for demonstrating distribution operations at a distribution center includes a pre-marked surface representing a workflow for the distribution center, the pre-marked surface defining a plurality of sections that represent the distribution operations at the distribution center and are configured to be assigned to a plurality of users who demonstrate the distribution operations; a plurality of instruction instruments configured to be randomly selected by the plurality of users, each instruction instrument being configured to initiate one of the plurality of users to perform an action at one of the plurality of sections that is assigned to the one of the plurality of users, the action being configured to cause another of the plurality of users to take an action at another of the plurality of sections; and a plurality of modular pieces representing components at the distribution center and configured to, based on selection of the plurality of instruction instruments, be interlocked with each other at the plurality of sections and delivered across the plurality of sections at the pre-marked surface.

In the system, the plurality of instruction instruments include a plurality of cards providing instructions configured to initiate the plurality of users to perform actions at the plurality of sections.

In the system, the plurality of instruction instruments include a die.

In the system, the plurality of users include first, second, third, fourth, and fifth users, and the plurality of sections includes first, second, third, fourth, and fifth sections that are assigned to the first, second, third, fourth, and fifth users respectively.

In the system, the plurality of users include a sixth user, and the interlocked modular pieces are assigned to the sixth user and delivered, by the sixth user, to each of the first, second, third, fourth, and fifth sections.

In the system, the first section corresponds to an inbound department at the distribution center, the second section corresponds to a storing department at the distribution center, the third section corresponds to a picking department at the distribution center, the fourth section corresponds to a packing department at the distribution center, and the fifth section corresponds to an outbound department at the distribution center.

In the system, the first section includes visual elements that depict: (i) at least one store, (ii) an automated conveyor belt configured to receive the plurality of modular pieces and extend across at least the first section and the second section, (iii) a manual dock, and (iv) a manual dock pallet staging area.

In the system, the plurality of instruction instruments include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the manual dock depicted on the pre-marked surface.

In the system, the plurality of instruction instruments include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the automated conveyor belt depicted on the pre-marked surface.

In the system, the second section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the first section of the pre-marked surface and move the plurality of modular pieces from the second section to the third section of the pre-marked surface, (ii) non-conveyable aisles, and (iii) conveyable aisles.

In the system, the plurality of instruction instruments include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the non-conveyable aisles depicted on the pre-marked surface.

In the system, the plurality of instruction instruments include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the conveyable aisles depicted on the pre-marked surface.

In the system, the third section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the second section of the pre-marked surface and move the plurality of modular pieces from the third section to the fourth section of the pre-marked surface, (ii) a full pallet staging area, (iii) a carton air staging area, and (iv) a re-palletization line.

In the system, the plurality of instruction instruments includes a die configured to be rolled, by the third user at the third section, to determine a zone amongst a plurality of zones at the re-palletization line depicted on the pre-marked surface, the zone being configured to allow the third user to perform at least one repalletization action with the plurality of modular pieces.

In the system, the fourth section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the third section of the pre-marked surface and move the plurality of modular pieces from the fourth section to a packing area depicted in the fourth section of the pre-marked surface, (ii) break pack aisles, and (iii) the packing area. The packing area is configured to receive the plurality of modular pieces that are ready to be transported to a designated store of a plurality of stores for receiving inventory, the inventory being represented by the plurality of modular pieces. The packing area includes a plurality of mods. Each of the plurality of mods is assigned to a store amongst the plurality of stores.

In the system, the plurality of instruction instruments include: a first subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces, the actions including breakpacking actions; and a second subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces that include packing actions.

In the system, the plurality of instruction instruments further includes a die configured to be rolled, by the fourth user at the fourth section, to determine a zone depicted in the fourth section of the pre-marked surface, the zone being configured to allow the fourth user to perform the actions with the plurality of modular pieces.

In the system, the plurality of modular pieces are stackable bricks. The action performed by the one of the plurality of users includes stacking the bricks according to instructions provided by an instruction instrument amongst the plurality of instruction instruments that is randomly selected by the one of the plurality of users.

In the system, the plurality of modular pieces are different colors and different sizes. The different colors and the different sizes indicate at least one of units of inventory at the distribution center, quantity of the inventory at the distribution center, size of the inventory at the distribution center, a store, type of supplies used at the distribution center as part of the workflow, or type of the inventory at the distribution center.

In the system, the components at the distribution center represented by the plurality of modular pieces include at least one of inventory, pallets, or warehouse equipment.

The system further includes an evaluation system configured to evaluate performance of the plurality of users, the performance being calculated based on the plurality of modular pieces being delivered across the plurality of sections at the pre-marked surface, the performance representing at least one of safety, quality, delivery, or productivity.

In the system, the performance is calculated based on units per hours.

The system further includes a computing system and a plurality of user devices in communication with the computing system over a network. The computing system is configured to transmit, to at least one of the plurality of user devices, instructions that, when executed, cause the at least one of the plurality of user devices to present in a graphical user interface (GUI) display electronic versions of (i) the pre-marked surface, (ii) the plurality of instruction instruments, and (iii) the plurality of modular pieces. The at least one of the plurality of user devices is configured to: receive first user input indicating selection of an instruction instrument amongst the plurality of instruction instruments; receive second user input indicating an action performed with the plurality of modular pieces according to the selected instruction instrument; and transmit, to the computing system, at least the second user input. The computing system is configured to deliver the plurality of modular pieces across a plurality of sections at the electronic version of the pre-marked surface based at least in part on the second user input.

In the system, the plurality of instruction instruments include instructions configured to initiate the plurality of users to perform actions that correspond to real-life scenarios of inbound components for the distribution center.

The system further includes a downtime chart, the downtime chart generated based on identifying times at which a work stoppage occurs while delivering the plurality of modular pieces across the plurality of sections at the pre-marked surface. The times represent times of overproduction and times of downtime amongst the plurality of users.

In the system, a dip or spike in the downtime chart represents at least one bottleneck experienced by the plurality of users while delivering the plurality of modular pieces across the plurality of sections at the pre-marked surface.

In the system, the fifth section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the fourth section of the pre-marked surface and move the plurality of modular pieces from the fourth section to the fifth section of the pre-marked surface, (ii) a non-conveyable staging area, and (iii) conveyor aisles that each correspond to a particular store for which the plurality of modular pieces are to be shipped in an outbound shipment from the distribution center.

In the system, the plurality of instruction instruments include a subset of cards providing instructions, to the fifth user at the fifth section, to perform actions with the plurality of modular pieces that include performing outbound shipment actions and trailer shipment actions.

According to implementations of the present disclosure, a method for demonstrating distribution operations at a distribution center includes providing a pre-marked surface having a plurality of sections, wherein the plurality of sections are configured to represent the distribution operations at the distribution center; providing a plurality of instruction instruments that are configured to be selected by a first user of a plurality of users, wherein a selected instruction instrument is configured to initiate the first user to perform an action at one of the plurality of sections defined at the pre-marked surface; and providing a plurality of modular pieces that represent components at the distribution center that are configured to, based on selection of the plurality of instruction instruments, be interlocked with each other at the plurality of sections and delivered across the plurality of sections at the pre-marked surface. Providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the first user to perform the action with the plurality of modular pieces based on the selected instruction instrument; responsive to performing the action with the plurality of modular pieces, cause the first user to deliver the plurality of modular pieces onto a conveyor belt represented at the pre-marked surface; cause the first user to select, from amongst the plurality of instruction instruments, a next instruction instrument to perform a next action with another of the plurality of modular pieces; and cause a second user of the plurality of users to deliver the plurality of modular pieces via the conveyor belt represented at the pre-marked surface to a section amongst the plurality of sections that is assigned to a third user.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the first user to select a threshold quantity of the plurality of modular pieces that satisfy one or more color and size criteria provided by the selected instruction instrument; and cause the first user to stack the selected threshold quantity of the plurality of modular pieces into a brick that is provided by the selected instruction instrument.

In the method, the brick represents inventory that is ingested into the distribution center and delivered across the plurality of sections at the pe-marked surface to represent movement of the inventory through the distribution center.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the third user to select, from amongst a second plurality of instruction instruments, a first instruction instrument configured to cause the third user to perform an action at the section that is assigned to the third user; cause the third user to perform the action with the plurality of modular pieces based on the first instruction instrument; and responsive to performing the action, cause the third user to deliver the plurality of modular pieces onto the conveyor belt represented at the pre-marked surface to a section amongst the plurality of sections that is assigned to a fourth user.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the third user to select, from amongst the second plurality of instruction instruments, a next instruction instrument to perform a next action with the another of the plurality of modular pieces.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause a fifth user of the plurality of users to deliver the plurality of gaming pieces via the conveyor belt visually represented at the pre-marked surface to the section amongst the plurality of sections that is assigned to the fourth user.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the fourth user to roll a die to determine a zone represented at the section that is assigned to the fourth user at which to perform an action with the plurality of modular pieces; cause the fourth user to perform the action with the plurality of modular pieces in the zone that is determined based on rolling the die; and responsive to performing the action, cause the fourth user to deliver the plurality of modular pieces via the conveyor belt represented at the pre-marked surface to a section amongst the plurality of sections that is assigned to a fifth user.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the fourth user to roll the die to determine a zone represented at the section that is assigned to the fourth user at which to perform a next action with the another of the plurality of modular pieces.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause a sixth user of the plurality of users to deliver the plurality of gaming pieces via the conveyor belt visually represented at the pre-marked surface to the section amongst the plurality of sections that is assigned to the fifth user.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the fifth user to select, from amongst a third plurality of instruction instruments, a first instruction instrument to cause the fifth user to perform an action at the section that is assigned to the fifth user; cause the fifth user to roll a die to determine a zone at the section that is assigned to the fifth user at which to perform the action with the plurality of modular pieces; cause the fifth user to perform the action with the plurality of modular pieces based on the first instruction instrument in the zone that is determined based on rolling the die; and responsive to performing the action, cause the fifth user to deliver the plurality of modular pieces to a packing mod depicted at the pre-marked surface. The packing mod corresponds to a store that is designated to receive inventory represented by the plurality of modular pieces.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause a seventh user of the plurality of users to deliver the plurality of gaming pieces via the conveyor belt visually represented at the pre-marked surface from the packing mod depicted at the pre-marked surface to a section amongst the plurality of sections that is assigned to an eighth user.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the eighth user to select, from amongst a fourth plurality of instruction instruments, a first instruction instrument to cause the eighth user to perform an action at the section that is assigned to the eighth user; cause the eighth user to perform the action with the plurality of modular pieces based on the first instruction instrument; and responsive to performing the action, cause the eighth user to deliver the plurality of modular pieces to a conveyor aisle depicted at the pre-marked surface that corresponds to a particular store for which the plurality of modular pieces are to be shipped in an outbound shipment from the distribution center.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the first user to move a modular piece having a first size and a first color onto an automated conveyor system defined at the section that is assigned to the first user at the pre-marked surface. The modular piece represents a breakpack flow in the workflow for the distribution center.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the first user to interlock a first modular piece having a first color and a first size with a second modular piece having a second color and a second size; and cause the first user to move the interlocked modular pieces onto an automated conveyor system defined at the section that is assigned to the first user at the pre-marked surface. The interlocked modular pieces represent a conveyable flow in the workflow for the distribution center.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the first user to interlock a first modular piece having a first color and a first size with a second modular piece having a second color and a second size; and cause the first user to move the interlocked modular pieces onto a manual dock system defined at the section that is assigned to the first user at the pre-marked surface.

In the method, the interlocked modular pieces represent a breakpack flow in the workflow for the distribution center.

In the method, the interlocked modular pieces represent a non-conveyable flow in the workflow for the distribution center.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: cause the first user to interlock a first modular piece having a first color and a first size with (i) a second modular piece having a second color and a second size and (ii) a third modular piece having a third color and a third size; and cause the first user to move the interlocked modular pieces onto a manual dock system defined at the section that is assigned to the first user at the pre-marked surface. The interlocked modular pieces represent a conveyable flow in the workflow for the distribution center.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to cause the third user to interlock a first modular piece having a first color and a first size with a second modular piece having a second color and a second size.

In the method, the interlocked modular pieces represent a full pallet that is non-conveyable at the distribution center.

In the method, the interlocked modular pieces represent a carton air that is non-conveyable at the distribution center.

In the method, providing the plurality of instruction instruments and the plurality of modular pieces is further configured to cause the third user to interlock a first modular piece having a first color and a first size with (i) a second modular piece having a second color and a second size and (ii) a third modular piece having a third color and a third size.

In the method, the plurality of modular pieces are configured to be delivered across the plurality of sections at the pre-marked surface in four rounds. Providing the plurality of instruction instruments and the plurality of modular pieces is further configured to: in a first round of the four rounds, cause a user amongst the plurality of users to win the first round based on performing actions with the plurality of modular pieces responsive to selecting instruction instruments amongst the plurality of instruction instruments more efficiently than other users amongst the plurality of users performing other actions with the plurality of modular pieces; in a second round of the four rounds, cause the user who won the first round to remove a threshold quantity of users from the sections depicted on the pre-marked surface to remove waste and increase throughput in the workflow at the distribution center; in a third round of the four rounds, cause at least one of the plurality of modular pieces to indicate buffer inventory and be placed along the workflow at the distribution center in at least one of the plurality of sections depicted on the pre-marked surface; and in a fourth round of the four rounds, cause the plurality of users to perform actions with the plurality of modular pieces that optimize operations in the workflow at the distribution center based on outcomes of the first, second, and third rounds.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of the disclosed technology or of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments of particular disclosed technologies. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment in part or in whole. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described herein as acting in certain combinations and/or initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. Similarly, while operations may be described in a particular order, this should not be understood as requiring that such operations be performed in the particular order or in sequential order, or that all operations be performed, to achieve desirable results. Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims.

Claims

1. A system for demonstrating distribution operations at a distribution center, the system comprising: a pre-marked surface representing a workflow for the distribution center, the pre-marked surface defining a plurality of sections that represent the distribution operations at the distribution center and are configured to be assigned to a plurality of users who demonstrate the distribution operations;a plurality of instruction instruments configured to be randomly selected by the plurality of users, each instruction instrument being configured to initiate one of the plurality of users to perform an action at one of the plurality of sections that is assigned to the one of the plurality of users, the action being configured to cause another of the plurality of users to take an action at another of the plurality of sections; anda plurality of modular pieces representing components at the distribution center and configured to, based on selection of the plurality of instruction instruments, be interlocked with each other at the plurality of sections and delivered across the plurality of sections at the pre-marked surface.

2. The system of claim 1, wherein the plurality of instruction instruments include a plurality of cards providing instructions configured to initiate the plurality of users to perform actions at the plurality of sections.

3. The system of claim 1, wherein the plurality of instruction instruments include a die.

4. The system of claim 1, wherein the plurality of users include first, second, third, fourth, and fifth users, and the plurality of sections includes first, second, third, fourth, and fifth sections that are assigned to the first, second, third, fourth, and fifth users respectively.

5. The system of claim 4, wherein the plurality of users include a sixth user, and the interlocked modular pieces are assigned to the sixth user and delivered, by the sixth user, to each of the first, second, third, fourth, and fifth sections.

6. The system of claim 4, wherein: the first section corresponds to an inbound department at the distribution center,the second section corresponds to a storing department at the distribution center,the third section corresponds to a picking department at the distribution center,the fourth section corresponds to a packing department at the distribution center, andthe fifth section corresponds to an outbound department at the distribution center.

7. The system of claim 6, wherein the first section includes visual elements that depict: (i) at least one store, (ii) an automated conveyor belt configured to receive the plurality of modular pieces and extend across at least the first section and the second section, (iii) a manual dock, and (iv) a manual dock pallet staging area.

8. The system of claim 7, wherein the plurality of instruction instruments include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the manual dock depicted on the pre-marked surface.

9. The system of claim 7, wherein the plurality of instruction instruments include a subset of cards providing instructions, to the first user at the first section, to perform actions with the plurality of modular pieces, the actions including using the automated conveyor belt depicted on the pre-marked surface.

10. The system of claim 6, wherein the second section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the first section of the pre-marked surface and move the plurality of modular pieces from the second section to the third section of the pre-marked surface, (ii) non-conveyable aisles, and (iii) conveyable aisles.

11. The system of claim 10, wherein the plurality of instruction instruments include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the non-conveyable aisles depicted on the pre-marked surface.

12. The system of claim 10, wherein the plurality of instruction instruments include a subset of cards providing instructions, to the second user at the second section, to perform actions with the plurality of modular pieces, the actions including using the conveyable aisles depicted on the pre-marked surface.

13. The system of claim 6, wherein the third section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the second section of the pre-marked surface and move the plurality of modular pieces from the third section to the fourth section of the pre-marked surface, (ii) a full pallet staging area, (iii) a carton air staging area, and (iv) a re-palletization line.

14. The system of claim 13, wherein the plurality of instruction instruments includes a die configured to be rolled, by the third user at the third section, to determine a zone amongst a plurality of zones at the re-palletization line depicted on the pre-marked surface, the zone being configured to allow the third user to perform at least one repalletization action with the plurality of modular pieces.

15. The system of claim 6, wherein the fourth section includes visual elements that depict (i) a conveyor belt configured to receive the plurality of modular pieces from the third section of the pre-marked surface and move the plurality of modular pieces from the fourth section to a packing area depicted in the fourth section of the pre-marked surface, (ii) break pack aisles, and (iii) the packing area, wherein the packing area is configured to receive the plurality of modular pieces that are ready to be transported to a designated store of a plurality of stores for receiving inventory, the inventory being represented by the plurality of modular pieces, andwherein the packing area includes a plurality of mods, wherein each of the plurality of mods is assigned to a store amongst the plurality of stores.

16. The system of claim 15, wherein the plurality of instruction instruments include: a first subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces, the actions including breakpacking actions; anda second subset of cards providing instructions, to the fourth user at the fourth section, to perform actions with the plurality of modular pieces that include packing actions.

17. The system of claim 16, wherein the plurality of instruction instruments further includes a die configured to be rolled, by the fourth user at the fourth section, to determine a zone depicted in the fourth section of the pre-marked surface, the zone being configured to allow the fourth user to perform the actions with the plurality of modular pieces.

18. The system of claim 1, wherein the plurality of modular pieces are stackable bricks, and wherein the action performed by the one of the plurality of users includes stacking the bricks according to instructions provided by an instruction instrument amongst the plurality of instruction instruments that is randomly selected by the one of the plurality of users.

19. The system of claim 1, wherein the plurality of modular pieces are different colors and different sizes, wherein the different colors and the different sizes indicate at least one of units of inventory at the distribution center, quantity of the inventory at the distribution center, size of the inventory at the distribution center, a store, type of supplies used at the distribution center as part of the workflow, or type of the inventory at the distribution center.

20. The system of claim 1, wherein the components at the distribution center represented by the plurality of modular pieces include at least one of inventory, pallets, or warehouse equipment.