Technical Case Study: Pallet buffer change for new AMR robot pallet delivery
Factory visit: Real work experience inside the factory
Solution: Designed an automatic pallet feeding station
Programing and Simulation Software: Fatory I/O
energy consumption, minimizing waste, and using renewable energy sources Digital Engineering: Artificial intelligence, Machine learning, IOT Packaging Engineering: Use less plastic and more recyclable. Safety Engineering: Risk assessments, safety training Innovation: The road to 4.0
Stock Manually operating Fork lift carrying Pallet from Stock to Buffer Area Waiting for the dispenser to be empty Incoming of Pallets and dropping to Buffer Zone 5 Picking the Pallets from Buffer Zone Manually feeding the Pallest to the Dispenser according to demand 6
15 x 12=180 kg weight handling capable arm is expensive! AGV forklift with feeding unit? -High purchase & maintenance cost So, we looked for something sustainable, feasible, compatible with existing infrastructure, IOT compatible..
delivers back when necessary. Integration with PLC makes it Intelligent. Intelligent Buffer conveyor To transfer the pallet stack to the intelligent conveyor. Curved Conveyor Keeps the operation area enclosed to avoid accidents. Safety Fence Turns 90 degrees to transfer the pallet stack to the intelligent buffer conveyor Turntable Conveyor top Receiving end is compatible with both manual and AMR operations AMR Conveyor Interface Compatible with the AMR that’s being used in other Unilever factories AMR Industrial automation Dispensing Unit The retroreflective sensor senses the presence of pallets at the necessary points. Sensors
with both Forklift and AMR operation Logical Analysis Depending on the presence of pallet in the dispenser, our PLC system decides whether to feed directly or to put on the buffer Conveyor Intelligent Buffer If there’s already pallet in the pallet Dispenser, the pallets are sent to the Buffer conveyors Feeding Dispenser As soon as the Dispenser is empty, pallets will be fed either from the receiving terminal or from the intelligent buffer depending on the availability 1st 2nd Internal operation
do not require extensive training to control and manipulate Simplicity All the proposed equipment are widely available in a competitive price, installation doesn’t require complicated Feasibility Less procurement, installation, operating, depreciation cost than current procedure and possible alternative solutions like Robotic Arm Cost efficiency PLC based control allows integration with existing infrastructure, and future upgradation to IOT system as part of the Industry 4.0 Roadmap. Compatibility No human intervention and unguarded mobile elements involved, leading to safer working environment Safety
= 480 min No of labor L = 1 Cost per shift, C= 1 x 8.33 x 8 = 133.28 Euro Time for feeding a stack T = 20% of shift time Cost of operation per shift Cp = 20% of 133.28 = 26.3 Euro Proposed operation Time for feeding one stack T = 2.5 min (max). Total no of pallet stack N= 480/2.5 = 190 Stack Saving per shift = 26 Euro Saving per Month = 26 x 24 = 624 Euro
per year: Apr. 7488€ • Payback period= 8000€ 7488€ = 1 𝑦𝑒𝑎𝑟 1 𝑚𝑜𝑛𝑡ℎ. • Considering the depreciation cost and overall unit productivity output proxy values the number would be significantly lower.