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The high system flexibility necessary for the full automation of complex and unstructured tasks leads to increased technological complexity, thus to higher costs and lower performance. In this paper, after an introduction to the different dimensions of flexibility, a method for flexible modular configuration and evaluation of systems of systems is introduced. The method starts from process requirements and, considering factors such as feasibility, development costs, market potential and effective impact on the current processes, enables the evaluation of a flexible systems of systems equipped with the needed functionalities before its actual development. This allows setting the focus on those aspects of flexibility that add market value to the system, thus promoting the efficient development of systems addressed to interested customers in intralogistics. An example of application of the method is given and discussed.
According to a recent survey the great majority of players in logistics are planning to adopt one or more robotic solutions until 2019. Technical solutions for automation of processes in logistics are often available as a market-ready product, but the lack of standardization and skepticism towards long term investments are often the reasons why these solutions are not implemented on a large scale. This paper is set to bridge the gap between the world of technologies and the one of applications in order to help investors, robot producers and system integrators to decide on which branch of logistics to set their focus. The three main branches Courier Express Parcel (CEP), contract logistics and production logistics are briefly defined and distinguished through their characteristic factors and parameters. Then a method based on the analysis of three parameters (operative costs, required performance and flexibility) in the three branches is set to identify the most convenient branch of logistics for investing in new technologies, namely the one in which the risk of investment is lower, the return is higher and faster. The conclusion of the method shows that higher labor costs, strict regulations and higher standardization make the production logistics the most suitable branch for investments in emerging automation solutions.
In standardized sectors such as the automotive, the cost-benefit ratio of automation solutions is high as they contribute to increase capacity, decrease costs and improve product quality. In less standardized application fields, the contribution of automation to improvements in capacity, cost and quality blurs. The automation of complex and unstructured tasks requires sophisticated, expensive and low-performing systems, whose impact on product quality is oftentimes not directly perceived by customers. As a result, the full automation of process chains in the general manufacturing or the logistic sectors is often a sub optimal solution. Taking the distance from the false idea that a process should be either fully automated, or fully manual, this paper presents a novel heuristic method for design of lean human-robot interaction, the Quality Interaction Function Deployment, with the objective of the “right level of automation”. Functions are divided among human and automated agents and several automation scenarios are created and evaluated with respect to their compliance to the requirements of all process´ stakeholders. As a result, synergies among operators (manual tasks) and machines (automated tasks) are improved, thus reducing time-losses and increasing productivity.
Powered by e-commerce and vital in the manufacturing industry, intralogistics became an increasingly important and labour-intensive process. In highly standardized automation-friendly environments, such as the automotive sector, most of efficiently automatable intralogistics tasks have already been automated. Due to aging population in EU and ergonomic regulations, the urge to automate intralogistics tasks became consistent also where product and process standardization is lower. That is the case of the production line or cell material supply process, where an increasing number of product variants and individually customized products combined with the necessary ability of reacting to changes in market conditions led to smaller and more frequent replenishment to the points of use in the production plant and to the chaotic addition of production cells in shop floor layout. This led in turn to inevitable traffic growth with unforeseeable related delays and increased level of safety threats and accidents. In this paper, we use the structured approach of the Quality Interaction Function Deployment to analyse the process of supply of assembly lines, seeking the most efficient combination of automation and manual labour, satisfying all stakeholders´ requirements. Results are presented and discussed.
The paper focuses on a recently introduced paradigm for the logistic process of picking, with respect to the man-to-goods and goods-to-man concept: the robot to-goods. First the task and system architecture of the fast deployable autonomous commissioning system are described, then the economic efficiency of the system is analysed in a real business case scenario using a simplified method, which is explained and discussed. The clearly positive net present value of the investment and the short payback period obtained in the business case prove how the robot-to-goods paradigm for the commissioning process, implemented through the automation of the forklift platform, is economically attractive for small and medium size enterprises.
Planning of available resources considering ergonomics under deterministic highly variable demand
(2020)
In this paper, a method for hybrid short- to long-term planning of available resources for operations is presented, which is based on a known or deterministically forecasted but highly variable demand. The method considers quantitative measures such as the performance and the availability of resources, ergonomically relevant KPI and ultimately process costs in order to serve as a pragmatic planning tool for operations managers in SMEs. Specifically, the method enables exploiting the ergonomic advantages of available flexible automation technology (e.g. AGVs or picking robots), while assuring that these do not represent a capacity bottleneck. After presenting the method along with the necessary assumptions, mainly concerning the availability of data for the calculations, we report a case study that quantifies the impact of throughput variability on the selection of different process alternatives, where different teams of resources are used.
In this paper it is first identified the trade-off among costs, flexibility and performances of autonomous robotic solutions for material handling processes, where adding value with automation is not as trivial as in production processes: hence the requirement for automated solutions to be simple, lean and efficient becomes even stricter. Then a method for modelling and comparing differential performances and costs of manual and autonomous solutions is developed. As a result of the method, a smart man-machine collaborative interface is designed and its impact evaluated on a specific case of study. Results are then generalized and prove the strong conclusions that in unconstrained environments, where full standardization cannot be achieved, the risk of investing in autonomous solutions can only be mitigated by creating a fast and smart man-machine collaborative interface.
Compared to the automotive sector, where automation is the rule, in many other less standardized sectors automation is still the exception. This could soon hurt the productivity of industrialized countries, where the unemployment is low and the population is aging. Phenomena like the recent downfall in productivity, due to lockdowns and social distancing for prevention of health hazards during the COVID19 pandemic, only add to the problem. For these reasons, the relevance, motivation and intention for more automation in less standardized sectors has probably never been higher. However, available statistics say that providers and users of technologies struggle to bring more automation into action in automation-unfriendly sectors. In this paper, we present a decision support method for investment in automation that tackles the problem: the STIC analysis. The method takes a holistic and quantitative approach tying together technological, context-related and economic input parameters and synthetizing them in a final economic indicator. Thanks to the modelling of such parameters, it is possible to gain sensibility on the technological and/or process adjustments that would have the highest impact on the efficiency of the automation, thereby delivering value for both technology users and technology providers.