Modular Mobile Packing Line for Flexible Variety Pack Assembly

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Solution Overview

Problem

The current variety pack production process is inefficient due to shortages of popular SKUs, high freight costs, wasted packaging, unreliable labor, erratic planning, and inventory management, as well as a lack of scalable options, leading to increased costs and complexity.

Innovation Solution

A mobile automated modular variety and multi-pack production line system that includes modular frame sections with leveling, powering, anchoring, and transporting features, equipped with robotic equipment for efficient SKU loading, singulation, packing, and palletization, and powered by a rechargeable battery system, allowing for flexible and efficient production in unconventional settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual labor is used for variety packing, then flexibility in assembly is maintained, but labor reliability and consistency deteriorate due to high attrition rates and frequent no-shows

Engineering Contradiction:

Improveassembly flexibilityVSAvoidlabor reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system enables self-service automation where the robotic assembly line operates autonomously without human intervention. The mobile production line performs variety packing tasks automatically, eliminating dependency on human workers while maintaining consistent operation. The system serves itself by integrating all necessary functions (loading, sorting, packing, palletizing) into a single autonomous unit.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical assembly operations are replaced with an automated robotic system. The mobile production line uses automated mechanisms for product handling, sorting, and packing instead of human hands and tools. This substitution eliminates labor reliability issues while maintaining assembly flexibility through programmable control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If multiple transportation steps are used to move products from manufacturing to variety packing, then production flexibility is improved, but freight costs and emissions increase dramatically

Engineering Contradiction:

Improveproduction flexibilityVSAvoidfreight cost and emissions

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

Multiple separate production facilities (manufacturing line and variety packing line) are merged into a single mobile production line unit. This consolidation eliminates the need for transporting products between separate facilities, reducing freight costs and emissions while maintaining production flexibility through the mobile design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mobile production line performs multiple functions (manufacturing, sorting, packing, palletizing) in a single integrated system. This multi-functionality eliminates the need for separate transportation steps between specialized facilities, reducing energy loss while maintaining the flexibility to adapt to different production requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If corrugate trays and shrink wrap are used for palletizing, then product protection during transport is improved, but packaging waste increases significantly

Engineering Contradiction:

Improveproduct protectionVSAvoidpackaging waste

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

The system eliminates the discarding of corrugate trays and shrink wrap by redesigning the palletizing process. Products are directly palletized without intermediate packaging materials, recovering the elimination of waste while maintaining product protection through proper palletizing techniques and protective barriers integrated into the system.

Inventive Principle:

Principle #34Discarding and recovering

4Manufacturing precision

If a fixed production line is used, then manufacturing precision is maintained, but adaptability to different SKUs and pack configurations deteriorates

Engineering Contradiction:

Improveproduction precisionVSAvoidSKU flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The production line transitions from a fixed configuration to a mobile, dynamically reconfigurable system. The mobile production line can be moved and reconfigured to accommodate different SKUs, pack configurations, and production requirements while maintaining manufacturing precision through automated control systems and programmable operations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The production line is divided into modular functional sections (loading, sorting, packing, palletizing) that can be independently adjusted and reconfigured. This segmentation allows the system to adapt to different SKUs and pack configurations while maintaining precision through standardized modular components with programmable control.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12240639B2Mobile automated modular product packing system and method

Publication Date: 2025.03.04 SOJO IND INC

AI summary

Product packing systems and methods are provided. A product packing system may include multiple product packing production sections and multiple modular frame sections. Each modular frame section may support one of the product packing production sections and be configured to connect to an adjacent modular frame section. An assembled product packing system may be transported to an installation location and moved to an installation site at the installation location.