Modular Pharmacy Dispensing Layout With Direct Verification Routing
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Solution Overview
Problem
Existing product dispensing systems, particularly in smaller pharmacies, are inefficient due to the need for manual intervention at multiple stations, lack of station bypass capabilities, and require substantial floor space, making them unsuitable for pharmacies processing fewer than 1500 prescriptions per day.
Innovation Solution
A modular system combining automated and manual dispensing stations with a central conveyor assembly that allows direct routing of completed orders to verification without waiting at additional stations, enabling easy configuration and reconfiguration to fit space constraints, and integrating robotic and manual operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a sequential multi-station conveyor system is used, then all stations can be positioned around the perimeter, but totes must stop at every station and manual intervention is required at each stop, reducing throughput speed
Solution Approach 1:
The system is divided into multiple independent modules (robotic dispensing unit, manual dispensing stations, verification station, packaging station) that can operate independently. The conveyor is segmented into different lanes that allow totes to be routed to specific stations based on their contents, eliminating the need to stop at every station.
Solution Approach 2:
A computer control system acts as an intermediary that receives information from sensors at each station and automatically shunts totes with dispensing errors to a rejection station, eliminating manual intervention at each stop and improving throughput speed.
2Productivity
If fully automated dispensing systems are used, then thousands of prescriptions can be handled per day, but the system is not cost-efficient for smaller pharmacies processing fewer than 1500 prescriptions per day
Solution Approach 1:
The dispensing system is segmented into robotic and manual components, allowing smaller pharmacies to implement only the necessary level of automation. The robotic dispensing unit handles automated tasks while manual stations provide flexibility for smaller volume pharmacies, creating a cost-efficient solution for processing fewer than 1500 prescriptions per day.
3Adaptability or versatility
If a sequential conveyor system with all stations positioned around the perimeter is used, then comprehensive station functions are available, but substantial floor space is required which is not always available in smaller pharmacies
Solution Approach 1:
The system uses multiple conveyor tiers arranged vertically rather than horizontally, allowing comprehensive station functions to be positioned in a compact footprint. The first conveyor tier transports totes from packaging stations to document induction workstations, while the second tier handles transport from robotic units to manual stations and from manual stations to verification, eliminating the need for substantial floor space.
4Ease of operation
If manual intervention is required at each conveyor stop, then operator flexibility is maintained, but the throughput speed is limited and operations personnel must move around the pharmacy
Solution Approach 1:
Sensors at each station provide feedback to the computer control system, which automatically shunts totes with dispensing errors to a rejection station. This eliminates the need for operators to manually intervene at each stop, reducing time for manual handling and increasing throughput speed while maintaining operator flexibility for exceptions.
Data Source
AI summary
A system includes a central conveyor assembly including a first conveyor tier and a second conveyor tier, one or more product dispensing stations for dispensing one or more medications, and a verification station adjacent to the one or more product dispensing stations to verify a patient order of the one or more medications. The system is configured to receive the patient order for the one or more medications, determine a dispensing and routing itinerary for the patient order, route a dispensed medication in a transport carrier to the one or more product dispensing stations based on the dispensing and routing itinerary for the patient order. If the patient order is not complete, transfer the dispensed medication in the transport carrier to another product dispensing station for accumulating additional dispensed medications. If the patient order is complete, transfer the transport carrier containing the dispensed medication directly to the verification station.