Centralized Cushion Supply System for Logistics
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Solution Overview
Problem
Existing cushion supply systems in logistic centers face high investment and operating costs due to the need for multiple cushion pad production devices and paper web stocks, with a high probability of failures such as paper jams leading to bottlenecks in dispatch operations.
Innovation Solution
A centralized cushion supply system with a single cushion source and a conveyor system that distributes cushion products to multiple packing stations, including stock withdrawal containers with sensors for monitoring filling levels, ensuring continuous operation and reducing the likelihood of bottlenecks by using a single cushion source and buffer stock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cushion pad production devices are used at each packing station, then each station can operate independently with its own paper web supply, but investment costs and operating costs increase significantly
Solution Approach 1:
Multiple cushion pad production devices are merged into a single centralized production device that supplies cushion pads to multiple packing stations through a conveyor system. This consolidation reduces the total number of devices and paper web stocks from many individual units to just one central unit, significantly lowering investment and operating costs while maintaining system functionality.
Solution Approach 2:
The centralized cushion pad production device is designed to serve multiple packing stations simultaneously, making it a universal device with multi-functionality. The device can supply cushion pads to any of the connected packing stations through the conveyor system, replacing the need for dedicated production devices at each station.
2Device complexity
If a centralized cushion supply system with a single production device is used, then investment and operating costs are reduced, but the probability of system failures increases
Solution Approach 1:
The conveyor system is designed to transport cushion pads in advance from the centralized production device to the packing stations, creating a buffer stock at each station. This preliminary action ensures that even if the central production device fails or requires maintenance, the packing stations can continue operating using the pre-delivered cushion pads.
Solution Approach 2:
The conveyor system acts as an intermediary between the centralized production device and the packing stations, decoupling their operations. This intermediary buffer allows the production device and packing stations to operate at different rates and provides time for fault recovery without immediate impact on packing operations.
3Productivity
If cushion pads are produced and ejected directly at each packing station, then immediate cushioning is ensured, but bottlenecks occur when paper jams or refilling is required
Solution Approach 1:
The conveyor system delivers cushion pads in advance from the centralized production device to the packing stations, building up a reserve stock at each station. This preliminary delivery ensures that packing operations can continue without interruption even when the central production device experiences paper jams or requires refilling, eliminating bottlenecks.
Solution Approach 2:
The system is segmented into a centralized production segment and multiple independent packing segments connected by a conveyor buffer. This segmentation allows the production and consumption of cushion pads to be decoupled, enabling continuous operation at packing stations even when production temporarily stops due to faults.
Data Source
AI summary
In a cushion supply system for a logistic center, for example a warehouse or a dispatch hall, which comprises a cushion source for providing cushion products, such as cushion pads, in particular paper cushion pads; several packing stations at which containers can be loaded with goods and filled with cushion products; and a cushion transport system, such as a belt conveyor, for transporting the cushion products from the cushion source to the packing stations, the one cushion source is configured to supply said plurality of packing stations.