Designing a rudimental automated picking system
Discussion
I am trying to make picking and packing more efficient where I work and would love to come up with some kind of automated system but I have no idea if its even possible without spending ridiculous amounts on it….
The place I work at sells coffee and the part that is time consuming is one section that is jars of coffee. There are about 40 different types of coffee jars (all the same size) and people always buy a combination of them (usually 3 or 6 of all different combinations – outer box is always the same). We have currently done both ‘pick lists’ and then wrapping and packing and also have people in the middle of the isle picking each order individually (the products are not too far away from each other so is still pretty efficient).
However, I still would love something more automated…
In the first instance, in my head I am envisaging the following - you can then make it a lot more automated if the concept works:
If you give each coffee a number, then when you get the order, you type the corresponding numbers into a system, say coffees: 2, 14, 28, 5, 17. It then sends a message to open the gates (a bit like ski racing gates at the top of a hill) where the jars are kept (each coffee type being in a different ‘pen’). The jars then slide down gently to the bottom. All the packer would need to do it take the required jars off and put them into a box and stick the label on and send it. This could be done quickly for all the orders so that the products are already all lined up and ready to be taken off and into the box.
Is this even feasible? Is there something off the shelf that can be bought that will do this for me without costing the earth - the company is tiny so cant spent silly money on this project? Or should I just tell people to work even harder than they already are (sadly not an option because they work extremely fast as it is!)
Any guidance much appreciated!
The place I work at sells coffee and the part that is time consuming is one section that is jars of coffee. There are about 40 different types of coffee jars (all the same size) and people always buy a combination of them (usually 3 or 6 of all different combinations – outer box is always the same). We have currently done both ‘pick lists’ and then wrapping and packing and also have people in the middle of the isle picking each order individually (the products are not too far away from each other so is still pretty efficient).
However, I still would love something more automated…
In the first instance, in my head I am envisaging the following - you can then make it a lot more automated if the concept works:
If you give each coffee a number, then when you get the order, you type the corresponding numbers into a system, say coffees: 2, 14, 28, 5, 17. It then sends a message to open the gates (a bit like ski racing gates at the top of a hill) where the jars are kept (each coffee type being in a different ‘pen’). The jars then slide down gently to the bottom. All the packer would need to do it take the required jars off and put them into a box and stick the label on and send it. This could be done quickly for all the orders so that the products are already all lined up and ready to be taken off and into the box.
Is this even feasible? Is there something off the shelf that can be bought that will do this for me without costing the earth - the company is tiny so cant spent silly money on this project? Or should I just tell people to work even harder than they already are (sadly not an option because they work extremely fast as it is!)
Any guidance much appreciated!
Definitely feasible but i don't think there would be something suitable and off the shelf. The off the shelf systems I can think of would probably be expensive because they would be designed to do much more than you are trying to do and you would only be using 10% of its capacity. If you aren't in a hurry this sounds like an excellent project for a university intern or a design project that you could probably get done for little or no cost other than the making of it. What sort of volume are you talking about? How many orders per day? Is it running 3 shifts or just one?
Thanks ZBC. It is only for a few hundred orders a day max at the moment but am fascinated with the idea of making it automated to see if it can then be replicated elsewhere. Uni Intern or design project is a good shout. Wonder if a local Uni or college would want it as a project? Do they do these things? Definitely not a pressing need - I have had this idea for a year and done nothing about it...!
thewharftrader said:
Thanks ZBC. It is only for a few hundred orders a day max at the moment but am fascinated with the idea of making it automated to see if it can then be replicated elsewhere. Uni Intern or design project is a good shout. Wonder if a local Uni or college would want it as a project? Do they do these things? Definitely not a pressing need - I have had this idea for a year and done nothing about it...!
My experience is that they were always very keen to have interesting practical projects. If you want to drop me a line with a location I might know some of the local unis that might be interested, and if you really aren't in a rush and can wait ten years I'd love it as a retirement project 
Sounds like an interesting project. If you are going to automate the picking, it would be worth automating the 'entering the numbers' part as that should be quite easy (depending on your current systems).
To turn the question around, how much would you be willing to pay for such a system?
To turn the question around, how much would you be willing to pay for such a system?
Would you get a lot of the efficiency without the complexity by simply having a led / lamp at each coffe storage location which lit up if that coffee needed to be picked? I would think walking down an aisle without having refer to a numbered list, just picking whatever was lit would be pretty quick.
My first thought is a series of chutes, each loaded with a different product, these feed onto a conveyor via gates controlled by the operator's selection. A barrier across the conveyor then deflects the group of jars down a chute into the packing area.
Have you tried contacting any of the relevant trade magazines or websites, such as this one?
Packaging World
The journalists who work for them should have a pretty good idea of what their advertisers can offer.
A visit to a trade show (when they are back on) is always time well spent, even if it doesn't seem so at the time.
Processing and Packaging Machinery Association
There are also companies who sell used process equipment which may be adapted to your needs; which may make an over budget project affordable. Google 'secondhand process machinery'.
Have you tried contacting any of the relevant trade magazines or websites, such as this one?
Packaging World
The journalists who work for them should have a pretty good idea of what their advertisers can offer.
A visit to a trade show (when they are back on) is always time well spent, even if it doesn't seem so at the time.
Processing and Packaging Machinery Association
There are also companies who sell used process equipment which may be adapted to your needs; which may make an over budget project affordable. Google 'secondhand process machinery'.
Edited by GliderRider on Tuesday 19th January 01:37
Shrek595 said:
Would you get a lot of the efficiency without the complexity by simply having a led / lamp at each coffe storage location which lit up if that coffee needed to be picked? I would think walking down an aisle without having refer to a numbered list, just picking whatever was lit would be pretty quick.
I did some work for a ready made meal company who had stock on shelves that did exactly this. Telesales uploaded the orders onto the pick system, picker picked order, rolled order to end of line, label prints off, package stacked for each van round. The lights also had some colour variations but I cant remember quite what they were.
The company were part of a national franchise with depots all over the country, so it's not a particularly unique idea.
We are based in Surrey. At the pace this might happen, it could be a great retirement project for me as well in about 10 years!!
Totally agree that this will not be unique. It is more finding something that can be build for a tiny company rather than spending six figures for a big production line. In terms of spend, I have absolutely no idea, lol. For a rudimentary system, say £10k - although I could easily be out by a factor of 10 even for the most basic thing.
The gates and chutes thing was what I had in my head. I also agree you could make it more automated than typing in the numbers. Ie. In the morning for example, I can produce an excel spreadsheet of the orders and what each order needs. You would just upload that into the system and it would rattle through them.
Thanks for the links - will do more research there. TBH, I am struggling to even describe what I mean other than a automated picking “thingy”. Sadly Google doesn’t respond too well to “thingys” which is annoying as I know what I mean! Lol
Totally agree that this will not be unique. It is more finding something that can be build for a tiny company rather than spending six figures for a big production line. In terms of spend, I have absolutely no idea, lol. For a rudimentary system, say £10k - although I could easily be out by a factor of 10 even for the most basic thing.
The gates and chutes thing was what I had in my head. I also agree you could make it more automated than typing in the numbers. Ie. In the morning for example, I can produce an excel spreadsheet of the orders and what each order needs. You would just upload that into the system and it would rattle through them.
Thanks for the links - will do more research there. TBH, I am struggling to even describe what I mean other than a automated picking “thingy”. Sadly Google doesn’t respond too well to “thingys” which is annoying as I know what I mean! Lol
You're really just asking for a giant vending machine with a conveyer belt of packing boxes at the bottom 
The technology is already there for rows of different product SKUs and an automated picking / dispensing system based on a chute number or a code.
The technology is already there for rows of different product SKUs and an automated picking / dispensing system based on a chute number or a code.
Edited by eltawater on Tuesday 19th January 19:33
Like Eltawater I thought along the lines of a Vendo-type machine, but what put me off was the time they take to fill, particularly if they are the type with a rotating screw feeder. As there are clearly other types available, they could be a good source of parts to make what you need.
Something like this Vendo machine would yield a huge number of parts with which to experiment, rather than paying a fortune for all new parts from RS Components or whoever.
Vendo machine for parts or not working
As you wouldn't need the refrigeration side of things, you could have all the dispensers on one level, thus reducing the chances of any coffee jar breakage.
Something like this Vendo machine would yield a huge number of parts with which to experiment, rather than paying a fortune for all new parts from RS Components or whoever.
Vendo machine for parts or not working
As you wouldn't need the refrigeration side of things, you could have all the dispensers on one level, thus reducing the chances of any coffee jar breakage.
Edited by GliderRider on Tuesday 19th January 20:31
Sadly whilst the vending machine is a great analogy, it is too small in practice. It would need to hold 2000+ jars....
Yes, we have the picking table in the middle of the isle with the bestsellers closest to it. We have also taken the products off pallets and onto smaller shelves so that it is much closer for people to walk to each blend. We have it down to 6 steps max to any blend.
Yes, we have the picking table in the middle of the isle with the bestsellers closest to it. We have also taken the products off pallets and onto smaller shelves so that it is much closer for people to walk to each blend. We have it down to 6 steps max to any blend.
Along the lines someone else has said above. Work out the most popular combos and then offer discounted price for the pre-picked packs.
Or if the bespoke picks are packs of 6 then make the pre-pack a pack of 7 or 8 means you'll cover more popular combos with just one selection box and again offer it at a cheaper price per jar, per gram etc.
You could price the 7/8 box the same as bespoke but throw in a "gift" in the box something coffee related, or you could make the 7/8packs in a presentation tin so it looks nice on their shelf.
Or do both of the above and see which sells better.
Or if the bespoke picks are packs of 6 then make the pre-pack a pack of 7 or 8 means you'll cover more popular combos with just one selection box and again offer it at a cheaper price per jar, per gram etc.
You could price the 7/8 box the same as bespoke but throw in a "gift" in the box something coffee related, or you could make the 7/8packs in a presentation tin so it looks nice on their shelf.
Or do both of the above and see which sells better.
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