Pallet Sizing and Pucking for Pharmaceutical Order Fulfillment
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Solution Overview
Problem
High-volume pharmacies face challenges in efficiently managing and transporting diverse-sized prescription containers within automated systems, as existing solutions lack standardized methods for accommodating varying container sizes, leading to inefficiencies in fulfillment and shipping processes.
Innovation Solution
The implementation of a pallet sizing and pucking system that uses differently sized and shaped pucks to accommodate various container sizes, configured by a pallet sizing and pucking device, which determines the optimal arrangement based on prescription orders and utilizes a control subsystem to manage puck circulation among pucking stations for efficient container handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standardized pallets are used for transporting prescription containers, then transportation efficiency is improved, but containers of varying sizes cannot be accommodated effectively
Solution Approach 1:
The patent introduces pucks as intermediary elements between containers and pallets. These pucks serve as adaptors that fit into standardized cavities on the pallet while accommodating containers of various sizes. The puck acts as a mediator that translates between the standardized pallet interface and the diverse container shapes, enabling both standardization and versatility simultaneously.
Solution Approach 2:
The system segments the container support function into two independent components: the standardized pallet with fixed cavities and the adaptable puck that interfaces with containers. This segmentation allows the pallet to maintain a fixed, optimized structure for efficient transportation while the puck provides the necessary adaptability for different container sizes and shapes.
2Manufacturing precision
If manually configured pallet arrangements are used for different container sizes, then container placement accuracy is improved, but fulfillment process time increases
Solution Approach 1:
The system employs automated vision systems and control subsystems that enable the pallet configuration process to be self-directed. The system automatically detects container sizes, determines optimal puck placements, and guides the fulfillment process without requiring manual intervention for each configuration decision, thereby maintaining precision while reducing time loss.
Solution Approach 2:
The control subsystem pre-calculates optimal puck arrangements based on container characteristics before the actual pallet assembly begins. This preliminary planning allows the system to execute precise container placement rapidly without time-consuming manual adjustments during the fulfillment process.
3Adaptability or versatility
If diverse puck sizes are used to accommodate various containers, then container adaptability is improved, but system complexity increases
Solution Approach 1:
The puck circulation system is designed as a universal infrastructure that handles multiple puck sizes through standardized processes. The same circulation mechanisms, transfer stations, and control logic manage all puck types, eliminating the need for dedicated handling systems for each puck size and thereby reducing overall system complexity despite the diversity of puck dimensions.
Solution Approach 2:
The system manages puck diversity by treating puck size as a variable parameter rather than a structural distinction. The circulation system adapts its operations based on puck size parameters detected by vision systems, allowing a single standardized circulation infrastructure to handle multiple puck configurations without requiring complex specialized pathways for each size.
4Productivity
If automated puck circulation is implemented among pucking stations, then operational efficiency is improved, but system control complexity increases
Solution Approach 1:
The control subsystem implements continuous feedback loops where vision systems monitor puck locations, container characteristics, and fulfillment progress in real-time. This feedback enables the control system to dynamically adjust puck circulation and allocation decisions, achieving high operational efficiency through adaptive, data-driven control rather than rigid pre-programmed sequences.
Solution Approach 2:
The system replaces complex mechanical coordination for puck circulation with electronic control and vision-based monitoring. Instead of requiring intricate mechanical interlocking and synchronization mechanisms, the patent uses electronic signaling and software control to manage puck movement between stations, reducing mechanical complexity while maintaining operational efficiency.
Data Source
AI summary
A pharmaceutical order filling system uses pucks disposed on a pallet to accommodate a plurality of container sizes into which pharmaceuticals can be dispensed. An order processing device receives a pharmaceutical order and identifies a size of container into which a pharmaceutical in the pharmaceutical order should be dispensed. A pallet sizing and pucking device is configured: to configure a pallet with a plurality of pucks adapted to accommodate containers and to configure the pucks on a pallet in a manner that will facilitate efficient fulfillment of the pharmaceutical order.