Product Dispenser Sensor System to Reduce Wastage and Overstuffing
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Solution Overview
Problem
In workplace service areas, significant product wastage occurs due to attendants' lack of knowledge about dispenser fullness, leading to overstuffing, jamming, and inefficient refill practices, resulting in costly wastage.
Innovation Solution
A system with sensors in product dispensers communicating with a control station to detect product levels and transmit visual or audio messages encouraging patrons to use the fullest dispensers, optimizing product usage before refills.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the attendant overstuffing the dispenser with a full refill during scheduled maintenance visit, then the dispenser is filled to maximum capacity, but it results in jamming of the dispenser or overuse of towels by patrons
Solution Approach 1:
The system uses sensors to continuously monitor product levels in dispensers and provides real-time feedback to both attendants (via alerts when refilling is needed) and patrons (via display messages showing which dispensers are fullest). This feedback mechanism prevents overstuffing by enabling refills only when necessary and at optimal levels, while also guiding patrons to use dispensers with adequate product supply, thereby maintaining reliability without sacrificing quantity.
2Quantity of substance
If the attendant carrying sufficient refill supplies for worst case scenario, then all service areas can be covered, but it becomes an overly burdensome task depending on the number of service areas and types of dispensers
Solution Approach 1:
The system enables self-service operation where dispensers automatically monitor their own product levels and communicate needs to the central controller. Sensors detect when product is low and generate refill requests, eliminating the need for attendants to manually check each dispenser. The system autonomously manages product inventory across multiple service areas, significantly reducing attendant workload while ensuring adequate refill supply availability.
3Ease of manufacture
If the attendant establishing a fixed route between service areas for filling dispensers, then the refill process is systematic, but it leads to significant wastage when dispensers are not actually depleted
Solution Approach 1:
The system dynamically adjusts refill routes and schedules based on real-time product level data from sensors in each dispenser. Rather than following a fixed predetermined route, the controller optimizes the attendant's path by identifying which dispensers actually need refilling and in what order, based on current product levels and usage patterns. This dynamic routing minimizes unnecessary travel and prevents refilling dispensers that still have adequate product, thereby reducing wastage while maintaining organized refill processes.
4Reliability
If the dispenser having an overstuff-prevention device, then it prevents jamming, but it requires discarding the remaining towels in the dispenser to load a new full refill
Solution Approach 1:
The system performs preliminary monitoring of product levels using sensors that continuously track consumption. By detecting when a dispenser is approaching low levels before complete depletion, the system proactively generates refill alerts, allowing attendants to refill at the optimal moment. This preliminary detection prevents the need for overstuffing and eliminates the need to discard remaining product, as refills are timed to coincide with actual depletion needs while maintaining reliable operation.
Data Source
AI summary
A system and method are provided for improving product usage prior to refill of product dispensers in service areas that include a plurality of such dispensers. Via a sensor configured with each of the product dispensers and a control system in communication with the sensors, a product level or amount condition of product in each dispenser is detected. Based on the information from the sensors, a visual or audio message is generated and transmitted to the patron that encourages the patron to use a first product dispenser that has a greater product fill amount as compared to a second product dispenser in the same or a different service area.