Abstract
Pick-To-Light Order Picking System is the operational process when an operator begins to pick the parts in a sequential manner by which the quantity of the parts is recorded. The design of an effective hybrid order picking process in an assembly line is assisted by an intelligent sensing system to improve pick efficiency, accuracy and increase productivity. This research compares between intelligent hybrid order picking versus order picking with pick confirmation system at parts assembly line. The results show that by our proposed system with the elimination of certain steps within the picking process, the better efficiency, accuracy, fewer miss-picks will occur in the system and the operator can perform more intelligently with required picking quantities. The development of this system can provide a low-cost solution with an intelligent order picking system for small and medium-sized enterprises (SMEs) and a fast-moving production assembly line in manufacturing.
Highlights
Automation technologies and advanced computing technologies have been widely used in manufacturingindustriesas akeycomponentinthe massiveenvironment'schangingforindustry4.0
Sustainable Advanced Manufacturing(SAM)[2]isofferingsupporttothistypeofSMEsto developtheprocess,product,andtechnology within manufacturingtechnologydevelopment.This researchaimstodevelopanentry-level,low-costpick-to-lightsystemthatenablesSMEstointroduce, set-upand maintain with minimalcapitalinvestmentandlittleprocessconfigurationknowledgea pick-to-lightsystem.Systemfunctionality willofferthelevelsofcontrol witnessedinhighvolume Originalequipment manufacturer(OEM) manufacturingfacilities.Thedevelopmentofanintelligence pick-to-lightsystemwithahybridsensingunitcandeterminethepickingpartsequenceandquantity topick-upwithoperatorassistancesoftwarewithintuitiveset-up(OASIS)
ConclusionTheaimofthisprojectistocreateaneasy-to-buildandeasy-to-usepick-to-lightsystemthat willbe installedatAdvancedElectric Machine(AEM)assemblyline,thatcanbeutilizedtoimprovetheir assemblylineproductionprocess(productivity)andimprovethequalityissues.Theresultsshowthe moreefficientandaccuratepickingprocessintroducedintheproposedsystembytheeliminationof theunnecessarystepsintheprocess.,theoperatorcan move moreintelligently with requiredpickingquantitiesandlower workload.Thedevelopmentofthissystemcanprovidealowcostsolution withanintelligentorderpickingsystemfor SMEsandafast-movingproduction assemblylinein manufacturing.Infuturework,severaladaptations,tests,andexperimentsatvarious assemblyprocesseswillbeconductedforpotentialdevelopmentinthefuture
Summary
Automation technologies and advanced computing technologies have been widely used in manufacturingindustriesas akeycomponentinthe massiveenvironment'schangingforindustry4.0. Processes,thereareanumberofsystemsonthe marketthatusepick-to-lightandsensorstoguidethe operatorthroughthescheduledsequenceofassembly.Evenbudgetentry-levelsystemscanruninto severalthousandsofpoundsforeachassemblystationandrequiresomeconfigurationknow-how, puttingitoutofreachofsomesmallerSMEs. Sustainable Advanced Manufacturing(SAM)[2]isofferingsupporttothistypeofSMEsto developtheprocess,product,andtechnology within manufacturingtechnologydevelopment.This researchaimstodevelopanentry-level,low-costpick-to-lightsystemthatenablesSMEstointroduce, set-upand maintain with minimalcapitalinvestmentandlittleprocessconfigurationknowledgea pick-to-lightsystem.Systemfunctionality willofferthelevelsofcontrol witnessedinhighvolume Originalequipment manufacturer(OEM) manufacturingfacilities.Thedevelopmentofanintelligence pick-to-lightsystemwithahybridsensingunitcandeterminethepickingpartsequenceandquantity topick-upwithoperatorassistancesoftwarewithintuitiveset-up(OASIS). The pick-to-light systems require operators to press an “acknowledge”buttonafterselecting workpiecesfromabinatfirstsettingrequirements. Oncethe switchispressed,thebin'slightisswitchedoffandthenewlightison.Suchlightsallowtheuserto realizewhatbinshavebeenviewedsequentially.Havingignoredthepickconfirmationbypressingthe push-buttonswitch,thesystem won’tknowthepartsaretakingawayfrombinsanditslikely consequencewillbetheincreaseoferrorratesforthepick-to-lightsystem[11]. Pick-To-Light Overview Pick-to-lightisanorder-performancesoftwarethatusesalphanumericdisplaysandbuttonsatstorage locationstodirect manual"selection"andrecordingproductsforassemblyorpackagingorre-packing orshipping[12].Theoperatorscansabarcodeinastandardpick-to-lightsystem[4][13][14][8],the operatorscansabarcode, whichisinadisposablebinoftemporaryworkpiececontainers.Typically, alphanumericdisplayswillilluminatelight-emittingdiodes(LEDs)toguidetheoperatortothecorrect locationandindicatethenumberofitemstobepicked.Theoperatortakestheitemsfromthebinand confirmstheactivity,usuallybypressingan“acknowledge”button. Aftercompleting theassemblyofthe mainpart,alllightswillbeoff,andthe mainOASIS menushowninFigure5will appearfornewtasks.Byclicking“ExitProduction”,OASISwilldisplaytheprintreportandexitthe operation. CreateBuildSequencemenuGUIs 4.Experiment Inprevious work,thepredominanttypeoferrorfortheexperimentalpick-to-lightsystem wasarisen fromskippingbinsin whichtheoperatorforgottopickthepartsfromthemratherthanpicking excessiveorinsufficientpartsfromarequiredbin.We implementedapick-to-light methodfor confirmationofpick-upacknowledgmentbyapush-buttonswitch.OurLEDscreensareusedbyour pick-to-lightsystemto directtheusertotheright bin. Flowchartofintelligenthybridpick-to-lightandconventionalpush-buttonswitchsystem WhenthePBpushbuttonispressedbytheoperator,itupdatesthedevicewiththenumberofitems pickedbytheoperator.Theprocesscomparesthenumberofitemspickedbytheoperatorbypush buttonswitchverification withthenumberofcomponentbalancesinthebinstodeterminethe operator'spickingerror.Inthiscase,theoperator mustcounttheremainingpartsinthebins manually andnotifythesystemattheendofthecycleorbeforerestockingthenewpartinthebin. Linebalancingforanassemblylineisveryimportant.After weimplemented our proposed methodandcalculatedprocesstimeateachstationintherespectiveline,tasktime∑t at stationSt3wasreducedafterimplementingthenewsystemwhichisshowninTable.
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