Adım adım otomasyon

Gelen ürünlerin elleçlenmesi

Gelen ürünler genellikle zeminde, hatlar hâlinde yerleştirilir; bu alanlar derin istif alanları olarak da adlandırılır. Bu zemin tampon alanları çoğunlukla kamyon sürücüleri veya yükleme rampası personeli tarafından doldurulur.

Toyota’nın Autopilot AGV çözümü, gelen ürünleri mal kabul alanından alarak depolama alanına otomatik şekilde yerleştirebilir. Bu depolama alanı genellikle bir raf sistemi veya zemin tampon alanından oluşur.

Depoya yerleştirme süreçlerinde, her görev için en uygun ekipman tipinden yararlanmak amacıyla taşıma operasyonu birden fazla araç tarafından gerçekleştirilebilir. Örneğin taşıma işlemi için otomatik alçak kaldırmalı bir transpalet, depolama işlemi için ise bir reach truck kullanılabilir. Böylece her uygulama için en uygun ekipman çözümü sağlanır.

Görselde tipik bir yük alma istasyonu gösterilmektedir: zemin tampon alanı (bazı uygulamalarda konveyör).

Nasıl çalışır?

Taşıma görevleri çoğunlukla yükleme alanı sorumlusu tarafından, T-ONE’a bağlı bir tablet veya bir buton aracılığıyla başlatılır. Autopilot yükü aldıktan ve araç üzerindeki tarayıcı ürün kimliğini doğruladıktan sonra T-ONE, varış noktasını Depo Yönetim Sistemi’nden (WMS) alır.

WMS bulunmayan tesislerde ise T-ONE, varış noktası eşleştirme özelliği sunar. Bu özellik sayesinde T-ONE, yük üzerinden taranan değeri önceden tanımlanmış veriler ve kriterlerle karşılaştırarak doğru bırakma noktasını belirleyebilir. Varış noktasının önceden sabit olarak tanımlanması gerekmez; örneğin sabah ve öğleden sonra için farklı bırakma noktaları belirlenebilir. Bu da operasyonunuza özel kurallar oluşturma konusunda yüksek esneklik sağlar.

Sorunsuz yük elleçleme
Gelen ürünlerin sorunsuz şekilde alınabilmesi için yüklerin doğru şekilde konumlandırılması büyük önem taşır. Bu nedenle, ürünler depolama alanına yerleştirilmeden önce paletlerin konumunun görsel olarak kontrol edilmesini ve ürünlerde herhangi bir hasar olup olmadığının tespit edilmesini öneriyoruz.

Çalışanların ve kamyon sürücülerinin eğitilmesi, bu sürecin iyileştirilmesine ve otomatik operasyonların daha kesintisiz ve verimli şekilde yürütülmesine yardımcı olabilir.

Görselde tipik bir bırakma istasyonu gösterilmektedir: zemin tampon alanı, geleneksel veya yerçekimli akış raf sistemi ya da shuttle depolama sistemi (RS150 ve RAE).

Automated refilling of parts

The replenishment process is typically found in production sites, at assembly lines or in picking/kitting areas, where you need to refill parts. Pallets are picked up by Toyota Autopilots from floor buffers or racking in the storage area and taken to the production or picking areas.

A single pallet can be transported by an automated forklift truck, or a number of pallets can be towed at the same time by an automated tow tractor. Around busy areas, such as assembly lines, forkless solutions are a good alternative for smooth and safe pallet transport.

The image shows a typical pick-up station: floor buffer, conventional or gravity-flow racking, shuttle storage (RS150 with RAE).

How it works

For each replenishment task, the T-ONE automation software creates two transport orders. It combines the “point-to-point” and “empty pallet handling” flows: first taking away the empty pallet and then replenishing it with a full pallet. It can also start a loop transport with an automated tow tractor. You have the flexibility to choose between your machines’ Programmable Logic Controller (PLC) system or WMS to initiate these transport orders. You can also have an operator to initiate them via a tablet or a connected button.

In the image you see a typical drop-off station: work stations in production, racking.

Read more about automated tow trains >>

The takt time is not always equal within a production and therefore smaller buffers might be needed to store the semi-finished goods from time to time. T-ONE, Toyota’s automation software, will identify this need and create a temporary storage position where the Autopilots can safely place your goods. When needed, the system will send a new transport order to one of the automated vehicles to finish the “point-to-point transport” – optimising the solution to your needs.

Flexible cross-docking

In distribution centres these types of transports are often referred to as “cross-docking” flows, where goods are directly moved by Autopilots from inbound buffers to the outbound area, typically placed in deep stack buffers waiting to be shipped.

Moving empty pallets throughout your site

The empty pallet handling process is found in most operations where material has been replenished such as at assembly lines, picking or kitting areas or where waste needs to be handled.

How it works

Your empty pallets can be either taken by automated vehicles one by one from the assembly/picking/kitting station to a pallet dispenser; or empty pallets are brought to production for loading of finished goods. Another way to apply empty pallet handling in your operation is to have a pile of pallets, commonly stacked manually, transferred by an AGV from a floor buffer in a production area to another floor buffer at the empty pallet storage.

Automatically or on demand

You can choose to have the transport orders for this type of flow initiated by the machines’ PLC system or the Warehouse Management System. Alternatively, an operator can initiate them via a tablet connected to Toyota’s automation software (T-ONE), or a button.

In the image you see a typical pick-up and drop-off station: floor buffer, scrap station.

Read more about T-ONE >>

Getting ready to deliver

When products are produced and finished, automated vehicles can pick up the goods at the final station such as the end of a production line, a conveyor or directly at a production machine. When wrapping is required, the Autopilot will bring the goods to a wrapping station and then to the outbound area.

Storing of goods

The pallets may go straight away in the outbound buffer waiting to be shipped, but often they are stored for some time before being dispatched. When goods are brought to the storage, there’s in some cases a goods handover between machines, handled by a multileg order, to use the most suitable machine for each task. When produced in batches, automated forklifts will place the goods in gravity or shuttle racking. For non-batched goods conventional racking is common. Thanks to the wide range of solutions there’s always a perfect fit for your operations.

In the image you see a typical intermediate station: conventional or gravity-flow racking, shuttle storage (RS150 with RAE).

How it works

Orders to bring your goods to the outbound or storage are usually initiated automatically by an I/O signal e.g. a photocell or a scanner triggered by the load as it approaches the end of a conveyor. The task can also be given automatically by your production machines’ PLC system or manually by an operator via a tablet. The destination is decided by our automation software T-ONE either together with the WMS or via the destination mapping feature that can send a scanned value to a specific destination.

The image shows a typical drop-off station: floor buffer.

Read more about our shuttle operation >>

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