Distribution Center Action Timing Analysis Using Dummy Object Position Data
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Solution Overview
Problem
Existing management systems for distribution centers cannot effectively identify which specific 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 determine and address delays accurately.
Innovation Solution
A management method and system that determine the start and end timings of each action in object handling work using position data from dummy objects, calculate model and actual times for each action, and identify delays by comparing these times, allowing for the identification of problematic actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simulation results are compared with actual result data focusing on overall production line processes, then it is possible to evaluate production line performance, but it is not possible to evaluate whether or not the time required for each action is delayed with respect to the reference time
Solution Approach 1:
The patent segments the overall object handling work into discrete actions (e.g., picking, transporting, placing) and evaluates the time required for each individual action. This segmentation enables precise measurement of action-level timing to determine whether each action meets reference time standards, while still contributing to overall production line performance evaluation.
2Productivity
If evaluation items are set with a focus on the entire process of the production line, then it is possible to assess overall production efficiency, but it is not possible to determine which specific action has a problem when a delay occurs
Solution Approach 1:
The patent divides the production process into discrete actions and measures the time required for each action individually. This segmentation allows identification of which specific action is causing delays while maintaining the ability to assess overall production efficiency through aggregation of action-level data.
Solution Approach 2:
The patent establishes a feedback mechanism where actual action times are compared against reference times to determine compliance. This feedback loop enables real-time identification of problematic actions and provides basis for corrective measures to maintain productivity.
3Device complexity
If only overall production line data is collected and analyzed, then it is simple to implement the evaluation system, but it is not possible to identify which specific action of workers and robots is causing delays
Solution Approach 1:
The patent creates a multi-functional evaluation system that simultaneously performs overall production line performance evaluation and action-level timing analysis. The system collects detailed action data and compares it with reference times, enabling both comprehensive assessment and specific problem identification without requiring separate systems.
Data Source
AI summary
The method of the present disclosure comprises the following first to fourth steps. The first step is a step of determining a start timing and an end timing of each action of object handling work for a dummy object imitating an object handled in a distribution center, based on an analysis of position data of the dummy object when the dummy object is flowed to a distribution line of the distribution center. The second step is a step of calculating a model time required for each action based on the start timing and the end timing of each action. The third step is a step of calculating an actual time required for each action when the object is actually flowed to the distribution line. The fourth step is a step of calculating a difference between the actual time required and the model time required for each action.