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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.
Rapidly growing population and increasing amount of shipments induced by the e-commerce are two of the main reasons for the constantly rising urban freight traffic. Cities are therefore overwhelmed by a growing stream of goods and the available infrastructure, shared between people and goods traffic, often reached its maximum capacity. Phenomena such as traffic congestion, pollution and lack of space are direct consequences of this trend and their impact on the quality of life in the city is not negligible. City administrations are keen to evaluate innovative city logistics concepts and adopt alternative solutions, to overcome the challenges posed by such a dynamic environment, constrained in existing infrastructure. In this paper, a heuristic method based on the utility analysis is presented. Thanks to a modular approach accounting for stakeholders´ requirements, possible different scenarios and available technologies, the development of new city logistic concepts is supported. The proposed method is then applied to a case study concerning the city of Reutlingen (Germany). Results are presented and a brief discussion leads to the conclusion.
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.
Reacting to ever-changing business environments, in the last decade complex systems of systems accomplished giant leaps forward leading to great technological flexibility. However, this dimension of flexibility is often limited by the rigidity of super-ordinated planning systems. Especially when hybrid teams of automated and human resources are in place, the dynamic assignment of tasks taking into account ergonomics remains a challenge. After exposing a gap in the state of the art on the topic, this paper presents an approach to include ergonomics in dynamic resource allocation models. Combining and complementing existing approaches, the presented method monitors the actual ergonomic burden of the resources during a shift and it provides a linear optimization model to steer the resource allocation process.
Ambitious goals set by the European Union strategy towards the emission reduction of multimodal logistic chains and new requirements for intermodal terminals set by the evolution of customer needs, contribute to a shift in the driver for the infrastructure development: from economy of scale to economy of density. This paper aims to present an innovative method for designing a process oriented technology chain for intermodal terminals in order to fulfill these new demanding requirements. The results of the case study of the Zero Emission Logistic Terminal Reutlingen are presented, highlighting how this particular context enables the design and development of a modular concept, paving the way for the generalization of the findings towards the transfer to similar contexts of other European cities.
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.
The EU funded project RobLog recently developed a system able to autonomously unload coffee sacks from a standard container. Being the first of its kind, a further development is needed in order for the system to be competitive against manual labor. Financing this development entails a risk, hence a justified skepticism, which can be overcome by the longsighted view of the existing market potential. This paper presents a method to estimate the market potential of autonomous unloading systems for heavy deformable goods. Starting from the analysis of the coffee trade, first the current coffee traffic is investigated in order to calculate the number of autonomous systems needed to handle the imported sacks; Results are validated and the method is extended for the calculation of the potential of other market segments, where the same unloading technology can be applied.
The success of an autonomous robotic system is influenced by several interdependent factors not easily identifiable. This paper is set to lay the foundation of a new integrated approach in order to deeply examine all the parameters and understand their contribution to success. After introducing the problem, two cutting edge autonomous systems for the process of unloading of containers will be presented. Then the STIC analysis, a recently developed method for modelling and interpreting all the parameters, will be introduced. The preliminary results of applying such a methodology to a first study case, based on one of the two systems available to the authors, will be shortly presented. Future research is in the end recommended in order to prove that this methodology is the only way to efficiently and effectively mitigate the risk that stops potential users from investing in autonomous systems in the logistics sector.
Latest advancements in new technologies have made it possible to fully automate the in-plant material flow of small load carriers between the warehouse and the production or assembly line. However, none of methods available in literature fully addresses the planning and dimensioning problem of a logistic system based on these new autonomous technologies. This paper is set to present a method to estimate the fleet size of the new logistic system. After an overview on the state of the art, the method based on combinatorics and probability theory will be explained. A short discussion and suggestions for forthcoming research will conclude the paper.
The high system flexibility necessary for the full automation of complex and unstructured tasks leads to increased complexity, thus higher costs. On the other hand, the effectiveness and performance of such systems decrease, explaining the unfulfilled potential of robotcs in sectors such as intralogistics, where the benefits of a robotic solution rarely justify its costs. Taking the distance from the false idea that a task should be either fully automated, or fully manual, this aper presents a method for design of a lean human-robot interaction (HRI) withe the objective of the "right level of automation", where functions are divided among human and automated agends, so that the overall process gains in performances and/or costs. ... The 10 progressive steps of the method are presented and discussed with reference to their graphical tool: the House of Quality Interaction.