Pallet Stack Guidance for Stable Warehouse Order Picking
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Solution Overview
Problem
The order picking process in warehouses is inefficient due to inconsistencies among order pickers, leading to unstable product stacks that can topple or be incomplete, causing delays and increased costs, despite existing optimizations like slotting and route optimization.
Innovation Solution
A stack assist system that includes a graphical display, camera, and laser guidance to optimize the arrangement of packages on a pallet based on parameters like footprint, weight distribution, and stability, integrated with a warehouse management system to provide user instructions and automated guidance for optimal stacking and route planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If order pickers manually arrange products on pallets, then flexibility in product selection is maintained, but stacking consistency and stability deteriorate due to varying picker skills and spatial awareness
Solution Approach 1:
The system introduces an intermediary computing device (wearable display or mobile device) that mediates between the picker's manual dexterity and the pallet stacking outcome. The device provides real-time visual guidance overlays showing the optimal placement location, orientation, and stacking sequence, allowing pickers to maintain flexibility while achieving consistent, stable stacks through augmented visual information.
Solution Approach 2:
The system implements feedback by capturing images of the pallet stack using a camera, analyzing the current stack configuration, and providing real-time visual feedback through the wearable display or mobile device. This feedback loop guides the picker to adjust subsequent product placements to achieve the desired stable configuration, progressively improving stacking consistency.
2Ease of operation
If order pickers work at varying rates due to individual differences, then individual picker autonomy is maintained, but overall productivity and consistency deteriorate
Solution Approach 1:
The system applies dynamics by providing personalized, real-time guidance that adapts to each picker's pace and skill level. The wearable display or mobile device delivers dynamic visual instructions that adjust based on the current stack configuration and the specific picker's progress, allowing each worker to maintain their natural rhythm while receiving tailored support to improve their effectiveness and contribute to overall team productivity.
Solution Approach 2:
The system enables self-service by empowering each picker with an autonomous guidance interface on their wearable display or mobile device. The system independently calculates optimal stacking arrangements and provides step-by-step visual instructions without requiring external supervision or standardized rigid procedures, allowing pickers to self-regulate their workflow while achieving consistent results.
3Speed
If unstable stacks are created, then faster initial stacking speed is achieved, but delays occur due to restacking and incomplete product capacity
Solution Approach 1:
The system applies preliminary action by calculating and displaying the optimal complete stack configuration before the picker begins stacking. The wearable display or mobile device shows the full planned arrangement, including all products and their precise placement locations, allowing the picker to anticipate and execute each placement in the correct sequence, thereby building a stable stack from the beginning and eliminating the need for restacking.
Solution Approach 2:
The system continuously provides feedback by capturing images of the developing stack, comparing it against the optimal configuration, and providing real-time visual cues through the wearable display or mobile device. This feedback ensures the picker remains on track to achieve a stable, complete stack, preventing instability issues that would require time-consuming restacking operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures consistent and stable product stacks, reduces restacking delays, and optimizes order picking routes, thereby improving productivity and reducing costs by minimizing travel time and ensuring all products are securely held on the pallet.
Implementation Method 1
package position indicator, such as a laser, configured to project a visual indication of location to place a package on the stacking surface
Data Source
AI summary
A stack assist system includes a stacking surface, such as a pallet, configured to receive a plurality of packages thereon. A graphical display is configured to display a visual representation of an optimized stack of packages on the staking surface. A package position indicator may indicate the location of a package to be placed on package stack. The system may receive package data from a warehouse management system and determine an optimized stack based on numerous considered and weighted parameters related to the packages. The stack assist system may further optionally include a mobile unit to travel through a warehouse, over an optimized path, to retrieve packages intended for a stack.