Ergonomic Tray Handling in Manual Picking Stations
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Solution Overview
Problem
Existing manual and automated loading methods require separate unloading of articles from trays, which is inefficient and ergonomic, especially when dealing with inhomogeneous items that need to be transported and stacked on load carriers.
Innovation Solution
A manual method where the tray frame is lowered in the picking station, allowing items to be pushed onto the picking table without manual lifting, enabling continuous tray usage from receipt to exit, and eliminating the need for separate unloading, with the tray edge or base plate being adjusted to match the picking table height for ergonomic placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If articles are manually lifted from trays to picking tables, then articles can be transferred for loading, but operator strain and ergonomic issues occur
Solution Approach 1:
The picking table is positioned at the same height as the tray, creating an equipotential working condition where articles can be transferred horizontally without vertical lifting. This eliminates the need for operator lifting effort while maintaining ergonomic performance during the picking process
2Productivity
If separate unloading stations are used for trays, then articles can be separated from trays, but process efficiency and productivity decrease
Solution Approach 1:
The picking station is designed to combine the functions of article presentation, selection, and transfer in a single location. The tray is positioned directly at the picking table, eliminating the need for separate unloading stations and intermediate transfer points, thereby increasing processing speed and productivity
3Reliability
If trays with raised edges are used to prevent item slippage, then articles remain secure during transport, but manual lifting becomes more difficult
Solution Approach 1:
By positioning the tray and picking table at the same height, the raised edges of the tray no longer create a lifting barrier. Articles can be pushed horizontally from the tray to the picking table without the operator needing to lift over the raised edges, maintaining article stability during transport while eliminating lifting difficulty
4Productivity
If automated picking stations are used, then loading efficiency increases, but adaptability to inhomogeneous items decreases
Solution Approach 1:
The system combines automated tray presentation and positioning with manual picking operations. The automated components handle the standardized tasks of tray conveyance and positioning, while the manual picking section handles the variable tasks of selecting and placing inhomogeneous items, achieving both high loading efficiency and adaptability to different item types
Data Source
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AI summary
The method involves setting the height of charge carrier (2) below the level of palette (8) such that the level of charge carrier is kept constant up to the end of the loading process. The articles (3) are raised from a tray (5) on palette at a certain height or edge of tray is lowered in the loading station (1) such that the articles are able to be pushed away manually from the tray by picking unit (7) without lifting. An independent claim is included for manual picking station for loading charge carrier with articles and/or load units in loading Station.