Modular Variety Pack Assembly With Mobile Robotic Packing
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Solution Overview
Problem
The current variety pack production process is inefficient, leading to shortages of popular SKUs, high freight costs, wasted packaging, unreliable labor, erratic planning, and inventory management issues, as well as a lack of scalable options.
Innovation Solution
A mobile automated modular variety pack production system that includes modular frame sections with leveling, powering, anchoring, and transporting features, equipped with robotic equipment for automated assembly and palletization, and powered by a rechargeable battery system, allowing for flexible and efficient production in unconventional settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual labor is used for variety packing, then flexibility in assembly is maintained, but labor reliability deteriorates due to high attrition rates and frequent no-shows
Solution Approach 1:
The patent replaces manual labor with an automated robotic system that uses vision guidance and programmable logic to perform variety packing operations. The robotic arm with gripper mechanism automates the picking and placing of individual products into variety packs, eliminating dependence on human workers while maintaining operational flexibility through software control.
Solution Approach 2:
The system incorporates automated product identification and routing mechanisms that enable the packing process to self-regulate. The vision system automatically identifies products and their destinations, and the control system automatically directs the robotic arm to the correct locations, reducing the need for human intervention and decision-making.
2Ease of manufacture
If production lines produce single SKU at a time, then manufacturing simplicity is maintained, but productivity deteriorates due to frequent changeovers and wasted packaging
Solution Approach 1:
The system dynamically adapts its operation mode based on demand. The robotic arm can switch between picking from single-SKU containers and picking from multi-SKU mixing containers, allowing the system to optimize for either simplicity or variety depending on the current production requirements without requiring complete line reconfiguration.
Solution Approach 2:
The patent divides the product supply into separate containers for each SKU and uses a robotic arm to pick from these segmented sources. This segmentation allows the system to maintain organized, simple storage while enabling flexible combination of multiple SKUs in the variety packing process, eliminating the need for complete line changeovers.
3Reliability
If multiple freight destinations are used for product transport, then product availability is improved, but freight costs increase due to multiple transportation legs
Solution Approach 1:
The system consolidates multiple single-SKU shipments into a single variety pack shipment. By assembling diverse products at a central facility and packaging them together in variety packs, the system reduces the number of separate transportation legs required, combining multiple freight destinations into one consolidated delivery route.
Solution Approach 2:
The variety pack serves multiple functions: it satisfies diverse customer preferences for different flavors, reduces transportation costs through consolidation, and simplifies inventory management. A single variety pack can be shipped to one destination while containing products that would otherwise require multiple separate shipments to different locations.
4Object-affected harmful factors
If corrugate trays and shrink wrap are used for palletization, then product protection is improved, but packaging waste increases due to discarded materials
Solution Approach 1:
The system is designed to minimize the use of disposable packaging materials. By using standardized containers for SKU storage and implementing automated robotic picking, the system reduces the need for excessive protective packaging. The approach encourages recovery and reuse of packaging materials where possible, rather than discarding them after single use.
Data Source
AI summary
Aspects of the present disclosures are directed to product packing. 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.