Distribution Center Action Delay Detection via Simulation and Vision
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Solution Overview
Problem
Existing management systems for distribution centers cannot accurately determine which actions in object handling work are delayed, as they focus on overall production line processes rather than individual actions of workers and robots, making it difficult to identify and address specific delays effectively.
Innovation Solution
A management method and system that calculates model times for each action of object handling work through simulation and determines actual times using camera image data, allowing for the identification of delays at the action level by comparing simulated and actual times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If simulation is used to calculate model times for each action, then productivity evaluation becomes more detailed, but device complexity increases due to additional simulation and camera analysis systems
Solution Approach 1:
The patent creates a virtual model (digital twin) of the distribution center that replicates the physical environment. This virtual model is used to simulate and calculate model times for various actions, allowing detailed productivity evaluation without interfering with actual operations. The camera system captures real-world data that feeds into this virtual copy, enabling comparison between simulated and actual performance.
Solution Approach 2:
The patent replaces manual time measurement methods with automated computer vision technology. Cameras equipped with AI algorithms automatically detect and measure action times, eliminating the need for manual observation and recording. This substitution reduces operational complexity while enhancing measurement precision and enabling granular analysis of individual actions.
2Measurement precision
If camera image data analysis is used to determine actual times, then measurement precision improves, but device complexity increases due to additional cameras and processing requirements
Solution Approach 1:
The camera system is designed to automatically perform detection, measurement, and analysis without requiring manual intervention. The AI algorithms embedded in the system enable it to self-process image data, automatically identify actions, and calculate time measurements. This automation reduces the need for additional processing equipment while maintaining high measurement precision.
Solution Approach 2:
The camera system serves multiple functions: it captures images for quality control, measures action times for productivity analysis, and provides data for both real-time monitoring and historical analysis. This multi-functionality reduces the need for separate dedicated measurement devices, thereby reducing overall system complexity while maintaining measurement precision.
3Loss of information
If detailed action-level analysis is implemented, then loss of information is reduced, but device complexity increases due to additional monitoring and analysis systems
Solution Approach 1:
The patent divides the distribution center operations into discrete, analyzable actions such as picking, packing, and transporting. Each action is independently detected and measured by the camera system, allowing detailed tracking of time and efficiency for each specific task. This segmentation enables comprehensive information collection without requiring a single complex monolithic system.
Data Source
AI summary
The method of the present disclosure comprises the following first to fourth steps. The first step is a step of calculating, by simulation, a model time requited for each action of object handling work for an object handled in a distribution center. The second step is a step of determining a start time and an end time of each action based on an analysis of camera image data obtained in the distribution center. The third step is a step of calculating an actual time required for each action from a time difference between the start time and the end time of each action. The fourth step is a step of calculating a difference between the actual time required and the model time required for each action.