Loading Dock Pallet Reordering for Changing Vehicle Arrival Times
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Solution Overview
Problem
Existing supply chain management systems struggle to efficiently coordinate vehicle arrivals and pallet arrangements at loading docks, leading to inefficiencies in loading times and resource utilization in warehouses.
Innovation Solution
A warehouse and supply-chain coordinator system that determines estimated arrival times and adjusts pallet arrangements dynamically using robots to optimize loading dock operations, ensuring that vehicles are loaded in an order that minimizes wait times and maximizes throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If pallets are arranged in a fixed order at the loading dock, then the initial loading sequence is maintained, but vehicle wait times increase when arrival times change
Solution Approach 1:
The system dynamically adjusts pallet arrangements based on real-time vehicle arrival time updates. When a vehicle's estimated arrival time changes, the coordinator system automatically recalculates and repositions pallets to match the updated loading sequence, transforming a static arrangement system into a dynamic one that adapts to changing conditions.
Solution Approach 2:
The coordinator system continuously monitors vehicle arrival time estimates and uses this feedback to trigger pallet rearrangement operations. When arrival time data changes, the system receives feedback about the new timing conditions and automatically adjusts the pallet arrangement accordingly, creating a closed-loop control system.
2Productivity
If manual coordination of pallet arrangements is used, then system complexity is reduced, but loading efficiency and resource utilization decrease
Solution Approach 1:
The system enables self-service automation where the coordinator automatically manages pallet arrangements without requiring manual human intervention. The system independently monitors vehicle arrivals, determines optimal pallet positions, and coordinates robot operations to rearrange pallets, allowing the system to serve itself rather than requiring external manual coordination.
Solution Approach 2:
The patent replaces manual mechanical coordination with an automated computer-based system. Instead of human operators physically moving pallets or manually coordinating arrangements, the system uses computer algorithms to determine optimal arrangements and controls robots to execute the movements, substituting mechanical human labor with automated computational and robotic systems.
3Loss of time
If pallets are repositioned frequently to match vehicle arrivals, then vehicle wait times are minimized, but energy consumption and operational complexity increase
Solution Approach 1:
The system performs preliminary pallet positioning actions in advance of vehicle arrivals. By proactively arranging pallets based on predicted arrival times before vehicles actually arrive, the system minimizes the need for last-minute repositioning operations, thereby reducing overall energy consumption while still maintaining optimal arrangements when vehicles arrive.
Solution Approach 2:
The system changes operational parameters by monitoring vehicle arrival time estimates and only triggering pallet repositioning operations when actual changes in arrival timing occur. This parameter-based approach avoids unnecessary repositioning operations, reducing energy consumption while maintaining responsiveness to genuine changes in loading requirements.
Data Source
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AI summary
Systems and methods related to coordinating warehouses and supply chains are provided. Respective first and second estimated times of arrival at a loading dock of a warehouse are determined for respective first and second vehicles, where the first estimated arrival time is before the second estimated arrival time. A pallet arrangement at the loading dock is determined that includes a first pallet for the first vehicle and a second pallet for the second vehicle, where the first pallet is closer to the loading dock than the second pallet. The first estimated arrival time later changes to be after the second estimated arrival time. After the first estimated arrival time changes to be after the second estimated arrival time, a robot is instructed to modify the arrangement so that the second pallet is closer to the loading dock than the first pallet before the second estimated arrival time.