Advancements in Pallet Inspection: How COOP is Revolutionizing Warehouse Logistics
To make pallet inspecting easier and more efficient, COOP automated the process with industrial robots from KUKA Robotics and an advanced pallet inspection system powered by artificial intelligence from KUKA System Partner IVISYS called PALLETAI. (Image: KUKA)
The Role of Pallets in Warehouse Operations
In today’s fast-paced logistics landscape, the efficiency of warehouse operations hinges on the seamless integration of automation technologies such as autonomous mobile robots (AMRs), conveyor systems, and sophisticated fleet management software. Despite the technologically advanced tools at our disposal, the humble pallet remains the unsung hero of these operations. The importance of a single defective pallet cannot be overstated—its presence can lead to disruptions that affect the entire supply chain.
Enter COOP, a Swedish cooperative food retailer that has mastered the art of pallet management through innovative technology. With approximately 800 stores scattered across Sweden, COOP has established a fully automated logistics center capable of processing thousands of items daily. This center, located in Kjula, Eskilstuna, utilizes a 600-meter electric train and employs a variety of material handlers, AMR shuttles, and robotic systems, prioritizing efficiency, worker ergonomics, and safety.
The Challenge of Manual Pallet Inspection
Pallet inspection is a pivotal task that ensures safety for both workers and products. Pallets undergo rigorous checks for broken boards, protruding nails, rot, and contamination, with additional assessments related to their structural integrity. This labor-intensive process often proves to be a daunting task for warehouse employees. Being responsible for lifting, rotating, and inspecting 30- to 70-pound pallets daily can lead to exhaustion, ultimately diminishing accuracy and speed as the day progresses.
Recognizing the shortcomings of manual inspections, COOP’s team faced a common challenge: the task was not only time-consuming but could pose risks to workers’ well-being.
The Transition to Automation
To overcome these challenges, COOP embraced automation by collaborating with KUKA Robotics and IVISYS to implement advanced inspection systems. The outcome is the PALLETAI system—an innovative solution that automates the inspection of pallets, substantially elevating both efficiency and workplace safety.
At the heart of this automation strategy are the KR QUANTEC-2 industrial robots. Capable of lifting and maneuvering pallets with remarkable speed and precision, these six-axis robots are engineered to handle a range of payloads from 120 kg to 300 kg. With a reach spanning from 2,700 mm to 3,900 mm, the KR QUANTEC-2 ensures swift movement to designated inspection cells and efficient pallet handling throughout the operation.
Sophisticated Inspection Capabilities
What sets the PALLETAI system apart is its reliance on artificial intelligence. The modular inspection system evaluates each pallet against predefined quality criteria, using high-resolution scans processed by 26 deep neural networks that analyze various aspects of the pallets. This analysis includes detecting critical defects such as cracks, mold, and discoloration.
Once the scans are completed, the robots sort the pallets, ensuring only high-quality pallets enter the supply chain. This proactive approach not only prevents potential disruptions but allows for better overall performance in operations.
The PALLETAI system evaluates every detail of the pallet to detect cracks and holes, ensuring that defective pallets are excluded from normal operations. (Image: KUKA)
Enhanced Efficiency and Worker Satisfaction
The impact of the PALLETAI system on COOP’s operations is profound. With an impressive throughput of 400 pallets per hour, the system elevates inspection capacities by up to fivefold compared to traditional methods. Furthermore, the sophisticated AI technology increases accuracy, significantly reducing errors in pallet classification.
One of the most notable benefits of this automation system is the enhancement of workplace conditions. Since introducing the automated inspection process, reports of worker sick leave in the inspection station have dramatically dropped. Employees can now focus on higher-level tasks related to monitoring and managing automated systems rather than exhausting manual labor.
A Vision for the Future
As COOP continues to innovate its operations, the facility is shifting its workforce towards higher-skilled roles. Employees are being upskilled to manage and operate these cutting-edge automated systems, paving the way for a new generation of specialists in warehouse technology.
This synergy between human expertise and robotic efficiency exemplifies the potential of modern automation. By reimagining pallet inspection through AI and robotics, COOP has not only improved its operational metrics but also redefined the roles of its workforce, leading to enhanced worker satisfaction and operational excellence.
This article was contributed by KUKA (Augsburg, Germany). For more info, visit here.