Material Handling Pallet Re-Planning for Missing Cases
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Solution Overview
Problem
Automated palletizing processes in warehouses face disruptions due to missing boxes in the sequence, leading to inefficiencies and instability in pallet loads, which conventional mitigation methods like delivering extra boxes or stopping the process result in reduced throughput and compromised load quality.
Innovation Solution
A real-time pallet load re-planning system that adjusts the initial pallet load plan by minimal modifications, such as rearranging adjacent cases or substituting with similar dimensions, to maintain stability and continuity in pallet building, even with missing cases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional mitigation methods are used (delivering extra boxes or stopping the process), then pallet stability can be maintained, but throughput and productivity are reduced
Solution Approach 1:
The system dynamically adjusts the pallet load plan in real-time based on which boxes are actually present. Instead of following a rigid predetermined sequence, the controller modifies the placement sequence adaptively, allowing the palletizer to continue operating without stopping while maintaining load stability through real-time re-planning.
Solution Approach 2:
The system changes the parameters of the pallet load plan (box placement positions, orientations, and sequences) based on the actual availability of boxes. When boxes are missing, the controller recalculates and modifies the placement parameters to accommodate the actual box set, thereby maintaining stability without requiring extra boxes or process stoppages.
2Manufacturing precision
If the palletizer stops to create a new pallet load plan, then load quality can be maintained, but time is lost and throughput decreases
Solution Approach 1:
The system performs preliminary re-planning actions continuously in the background based on real-time box availability feedback. Rather than waiting for a complete failure or stopping to re-plan, the controller proactively adjusts the load plan as boxes become unavailable, maintaining load quality without interrupting the palletizing cycle.
Solution Approach 2:
The system implements a feedback mechanism where the actual delivery of boxes to the palletizer is monitored in real-time. This feedback information is used by the controller to continuously update and refine the pallet load plan, ensuring load quality is maintained while avoiding stoppages by anticipating and responding to box availability changes dynamically.
3Stability of the object's composition
If a strict sequence is enforced for box delivery, then pallet structure integrity is maintained, but the system becomes vulnerable to disruptions from mechanical failures or inventory errors
Solution Approach 1:
The system transitions from a static, rigid sequence to a dynamic, adaptive sequence that responds to actual box availability. The palletizer controller continuously adjusts the placement sequence based on real-time feedback, allowing the system to maintain structural integrity while being resilient to mechanical failures, inventory errors, or other disruptions that prevent strict sequence adherence.
Solution Approach 2:
The system prepares multiple alternative pallet load plans in advance, accounting for potential box unavailability. When disruptions occur, the controller can switch to a pre-prepared alternative plan that maintains structural integrity, thereby cushioning against the impact of disruptions without requiring system stoppages or manual intervention.
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.