Pharmaceutical Vial Diversion Algorithm for Group Processing
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Solution Overview
Problem
Automated dispensing systems face inefficiencies in processing and routing pharmaceutical vials, particularly in multi-prescription orders, due to the need for group processing and maintaining gaps between vials, which increases travel and processing time.
Innovation Solution
An improved pharmaceutical vial processing system that employs a diversion algorithm allowing vials to travel in close groups by analyzing neighboring vials' destinations to determine when gaps are needed, reducing the likelihood of incorrect diversion and optimizing routing, thereby reducing processing delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vials are processed in groups to maintain organization for multi-prescription orders, then routing accuracy is improved, but processing time increases due to holding and reordering operations
Solution Approach 1:
The system segments the vial processing stream by identifying specific vials that need to be diverted based on their destination requirements. Instead of processing entire groups together, the system individually identifies and diverts vials at optimal points, allowing continuous processing of non-diverted vials while maintaining accurate routing for diverted ones.
Solution Approach 2:
The system performs preliminary identification of vials requiring diversion before they reach the diversion point. By analyzing vial destinations in advance and pre-positioning diversion commands, the system eliminates the need for holding and reordering operations, allowing vials to be diverted smoothly without disrupting the continuous flow of other vials.
2Reliability
If gaps are maintained between all vials to prevent incorrect diversion, then diversion accuracy is improved, but throughput decreases due to increased travel time
Solution Approach 1:
The system applies gap maintenance selectively only to vials that require diversion, rather than maintaining gaps between all vials. By identifying specific vials needing diversion and creating localized gaps only around those vials, the system ensures diversion accuracy is maintained while allowing continuous flow and high throughput for the majority of vials that do not require diversion.
Solution Approach 2:
The system uses optical scanning and image processing to create a digital representation of each vial and its destination information. This copied information is then used to determine diversion requirements and control the diversion process, eliminating the need for physical gap maintenance between all vials while preserving diversion accuracy through precise identification and control.
3Adaptability or versatility
If mechanical diverting devices are used to route vials to sorting stations, then routing functionality is achieved, but processing time increases due to engagement and disengagement operations
Solution Approach 1:
The system replaces traditional mechanical diverting devices with an optical identification and digital control system. Optical scanners read vial information, and a control system processes this data to determine routing requirements. This substitution eliminates the mechanical engagement and disengagement operations that cause processing delays, while maintaining full routing functionality through precise digital control of diversion timing and positioning.
Data Source
AI summary
An improved pharmaceutical vial processing system and method groups vials on an automated dispensing line according to diverting needs. The improved pharmaceutical vial processing system and method allows vials to travel in close groups. A diversion algorithm determines when gaps between vials are needed to reduce the likelihood that a mechanical diverting device engages the wrong vial to a new location on the dispensing line. The diversion algorithm identifies each vial that needs to be diverted to a target location and employs a “neighbor analysis” to determine whether a gap between neighboring vials is needed before a vial destined for the target station encounters a diverter. Vials that are destined for locations beyond the target station remain grouped. Vials that are behind a vial destined for the target station are held to introduce a gap between the vial destined for the target station and the remaining vials.