Pallet Load Re-Planning for Missing-Box Palletization
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Solution Overview
Problem
Automated palletizing processes in warehouse logistics are disrupted by missing boxes, leading to inefficiencies and reduced throughput due to the need to maintain strict sequence and stability of pallet loads, which conventional mitigation methods often exacerbate.
Innovation Solution
A real-time pallet load re-planning system that adjusts the initial pallet load plan to accommodate missing boxes by rearranging adjacent cases, substituting with similar dimensions, or swapping layers to maintain stability and continuity of the palletization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If boxes are delivered in a strict sequence defined by the pallet load plan, then pallet stability and transportability are ensured, but throughput is reduced when boxes are missing or delivery is delayed
Solution Approach 1:
The system dynamically adjusts the pallet load plan in real-time based on box availability. When boxes are missing or delivery is delayed, the controller automatically resequences the pallet load plan to accommodate the changed conditions, allowing the automated palletizer to continue operating without stoppage while maintaining pallet stability.
Solution Approach 2:
The system changes the sequence parameter of the pallet load plan based on real-time box delivery status. By modifying the delivery sequence parameter rather than maintaining a fixed sequence, the system can adapt to missing boxes or delays without compromising pallet stability or reducing throughput.
2Reliability
If the automated palletizer waits for missing boxes to maintain sequence integrity, then pallet stability is preserved, but operation is disrupted and throughput decreases
Solution Approach 1:
The controller proactively detects missing boxes before they cause disruption and preemptively resequences the pallet load plan. This preliminary action allows the automated palletizer to continue building pallets without waiting for missing boxes, thereby preserving both stability and throughput.
Solution Approach 2:
The system continuously monitors box delivery status and provides feedback to the controller. When a box is detected as missing or delayed, the feedback triggers automatic resequencing of the pallet load plan, enabling the system to adapt in real-time without operation disruption.
3Reliability
If conventional mitigation methods are used (delivering extra boxes, manual palletization, or creating new pallet load plans), then missing box issues are addressed, but palletizing efficiency and throughput are reduced
Solution Approach 1:
The automated palletizer system performs self-correction by automatically detecting missing boxes and resequencing its own pallet load plan without external intervention. This eliminates the need for manual palletization or creating entirely new pallet load plans, thereby maintaining high palletizing efficiency while ensuring pallet load integrity.
Solution Approach 2:
The system maintains continuous automated palletization operation by dynamically adjusting the pallet load plan in real-time. Instead of stopping for manual intervention or creating new plans, the system continuously adapts the sequence to accommodate missing boxes, preserving both efficiency and integrity.
Data Source
AI summary
A material handling system for handling, placing packages onto pallets destined for an order store, the material handling system comprising, a storage array with storage spaces for holding packages therein, an automated package transport system communicably connected to the storage array for storing packages within the storage spaces of the storage array and retrieving packages from the storage spaces of the storage array, an automated palletizer for placing mixed packages onto a pallet to form a pallet load of mixed packages, the automated palletizer is communicably connected to the automated package transport system which provides individual packages from the storage array to the automated palletizer for forming the pallet load of mixed packages, the pallet load of mixed packages including more than one composite layers of mixed packages, a controller operably connected to the automated palletizer, the controller being programmed with a pallet load generator with an initial pallet load.