2007-01-16 Build to Order Palletizing in Real Time : The Missing Link (By Kevin Kozuszek, Kuka Robotics)

The missing link is a GateWay Communications Protocol Module (GCPM). This software tool serves as the real time brain that takes the order and inventory information contained in the WMS and translates it into actions for the hardware to use to produce the most efficient orders/mixed pallets. Until recently there has not been any software and hardware combination that has been robust and flexible enough to handle the wide variety of SKUs and palletizing options that the customer is looking to fulfill.

To fulfill an order a GCPM utilizes two simple order building functions: Depalletizing and Mixed Palletizing (order fulfillment). Here are the important steps.

The WMS sends an order to the GCPM " where it will create an optimized mixed pallet pattern. The optimized pallet pattern will begin in the bottom corner of the pallet and design a pallet pattern utilizing the WMS' information of what is in the order and what product is available on the floor to fulfill the order. The optimized pallet pattern indicates how those products will need to be orientated and arranged on the pallet to create a stable and efficient pallet density.

Once the mixed pallet pattern is created, the GCPM sends one copy of the pallet pattern to the robotic hardware and another to the WMS. The robot will take this pattern and begin to sequence the product picks by scheduling the product flow and building the pallet. The WMS will take its copy and update its inventory information.

Once the robot has begun to sequence its work load it will begin to depalletize from the source pallets and fulfill the order by re-palletizing the product on a new pallet..

All through this process the GCPM maintains a constant communications loop between the Robot, the GCPM and the WMS, updating what product is being taken out of inventory and what product is being used to fulfill the order. This allows for quicker start ups in the event the system goes down mid-way through the order fulfillment.

While there is constant communication between the robot, GCPM and the WMS, each area only keeps the information relevant for its operation. The WMS does not keep the details of the pallet pattern or of the location on the product on the pallet.

A vision system can be utilized to ensure the proper case position on the depalletized pallet and the pallet pattern. In this scenario the vision system acts as a sensor identifying the pallet pattern so the robot doesn't need to be re-taught the locations of the product on the inventory pallets.

Another way this system works together to increase robustness is by utilizing hardware such as 3D laser scanners that builds a library of product images. This means that the WMS would not need to have a database of product sizes to compare items to accurately identify cases.

Pick to Order Pallets

Having the capability to accept and fulfill customer's orders is a necessity that manufacturers and distributors can not afford to ignore due to logistical infrastructure. Bridging software and hardware capabilities to accomplish what customers are demanding is paramount. With this new communications protocol manufacturers can meet these demands efficiently.

Kevin Kozuszek is Director of Marketing at Kuka Robotics Corporation in Clinton Township, Mich