Boxing Device Dynamic Stocking Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In boxing devices, productivity decreases and costs increase due to unnecessary discarding of packaging boxes when the type of packed product switches, as the existing systems lack efficient management of stocking quantities based on real-time operational data and user settings.
Innovation Solution
A boxing device with a controller that adjusts the stocking number of packaging boxes in real time based on packaging-machine-related information and user-set information, reducing the number of discarded boxes by optimizing the production line's operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of packaging boxes are stocked in the stocking space, then productivity is maintained when the box-making machine stops, but cost increases due to discarding boxes when product type switches
Solution Approach 1:
The stocking number is dynamically adjusted based on real-time operational conditions. The controller monitors whether the box-making machine is operating or stopped, and automatically adjusts the number of boxes in the stocking space accordingly. When the machine is stopped, the stocking number is increased to maintain productivity; when the machine is operating normally, the stocking number is reduced to minimize waste and cost.
Solution Approach 2:
The system changes the parameter of stocking number based on different operational states. By detecting the operating status of the box-making machine and the remaining quantity of products, the controller adjusts the stocking number parameter to optimize both productivity and cost efficiency throughout the production process.
2Loss of substance
If a small number of packaging boxes are stocked in the stocking space, then cost is reduced, but productivity decreases when the box-making machine stops
Solution Approach 1:
The stocking number is dynamically adjusted based on real-time operational conditions. The controller monitors whether the box-making machine is operating or stopped, and automatically adjusts the number of boxes in the stocking space accordingly. When the machine is stopped, the stocking number is increased to maintain productivity; when the machine is operating normally, the stocking number is reduced to minimize waste and cost.
Solution Approach 2:
The system performs preliminary actions by stocking an appropriate number of boxes before the box-making machine stops. The controller predicts when the machine might stop and ensures sufficient boxes are available in the stocking space in advance, preventing productivity interruptions while avoiding excessive stocking that would increase cost.
3Productivity
If packaging boxes are stocked in advance, then productivity is maintained during machine stoppages, but material utilization efficiency decreases due to discarding boxes
Solution Approach 1:
The controller continuously monitors the operating status of the box-making machine and the remaining quantity of products, using this feedback information to adjust the stocking number in real time. This closed-loop control ensures that boxes are stocked only when necessary for maintaining productivity, thereby improving material utilization efficiency and reducing waste from discarding boxes.
Solution Approach 2:
The stocking number is dynamically adjusted based on real-time operational conditions. The controller monitors whether the box-making machine is operating or stopped, and automatically adjusts the number of boxes in the stocking space accordingly. When the machine is stopped, the stocking number is increased to maintain productivity; when the machine is operating normally, the stocking number is reduced to minimize waste and cost.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Provided is a boxing device to restrain productivity decreases and cost increases. A boxing device (40) has a stocking section (711) to form a stocking space (SP) in which a plurality of cardboard boxes (B) made from a box-making sheet (FB) can be stocked, a packing section (713) in which the cardboard boxes (B) sent from the stocking space (SP) are placed, a boxing section (65), and a controller (90). The boxing section (65) performs a boxing action of packing a plurality of products (P) discharged from a bag-making and packaging machine (20) into the cardboard boxes (B) placed in the packing section (713). The controller (90), on the basis of weighing machine information and user-set information, executes a stocking number deciding process to decide a numerical quantity (stocking number (SV)) of cardboard boxes (B) stocked in the stocking space (SP). The weighing machine information is information relating to an operating condition of the packaging machine (packaging-machine-related information). The user-set information is information set by a user.