Robotic depalletizing of homogenous pallets by picking complete layers or groups of same-size cases from known patterns has been a well-established practice. Recent advances in AI-driven vision software have enabled industrial robots to perform mixed-case depalletization, lifting heavy cases with precision, according to OSARO Inc. The San Francisco-based company today launched the OSARO Robotic Depalletization System.
“Depalletizing is one of the most labor-intensive workflows in a warehouse,” explained Ash Sharma, managing director at research firm Interact Analysis. “More than 3 billion pallets will be depalletized this year globally, requiring one-quarter of a million FTEs [full-time equivalents].”
Handling mixed-case or partial-layer loads demands sophisticated machine-learning vision technology, said OSARO in a release. The company added that its SightWorks Perception enables a robot to select and use various end-of-arm tools (EOAT) and determine the exact grasp position to prevent any interference with nearby objects.
Robotic Depalletization System uses vision for precise picks
The OSARO Robotic Depalletization System is equipped with SightWorks to recognize, select, and successfully grasp the varied sizes and materials of unevenly stacked packages commonly found on mixed-case pallets that arrive at a loading dock. It added that the vision software can recognize foreign objects or damaged boxes.
It can also alert workers so they can remove hazards before injury or further damage. The vision-guided depalletization system can increase efficiency, improve safety, reduce labor costs, and minimize inventory shrinkage, claimed OSARO.
The system’s baseline features include:
- Mixed-case box recognition on complex pallets — identifies center, dimensions, orientation, damage score, and error conditions
- Foreign object detection — identifies foreign objects such as box cutters, tools, and tape dispensers
- Damaged box detection — identifies damaged or structurally unsound boxes to avoid risky picks
- Protruding box detection — identifies boxes that are within a defined distance beyond the pallet coordinates
- Flexible deployment — built on skids that can easily be moved with a forklift within or between facilities
The OSARO Robotic Depalletization System is now available for the unloading of mixed-case pallets in third-party logistics (3PL) operations, distribution centers, and e-commerce fulfillment warehouses. In September 2023, OSARO announced a collaboration with FANUC for warehouse automation.
Depalletizing is a key warehouse workflow, says OSARO
Pallets are a universal necessity in warehouses but pose serious injury risks, mainly because of their size, weight, handling procedures, and potential for structural failure, noted OSARO. Unloading them is slow, hard work that can be dangerous and cause damage to sometimes fragile boxed products that are stacked unpredictably.
OSARO said its vision system can quickly determines case angles, which cases are on top, and which should be picked first. The system then selects the appropriate end-of-arm tool to successfully grasp each package without interfering with adjacent cases.
“While automated depalletization for uniform pallets has been available for some time, OSARO’s new intelligent robotic system addresses an increasingly common scenario at the receiving dock: palettes stacked with an unpredictable variety of boxes and shrink-wrapped packages of different shapes, sizes, and weights,” stated Derik Pridmore, CEO of OSARO. “Our robotic depalletization system can safely unload these pallets and deliver up to 40% cost savings when compared to manual labor. And, as more shifts are added, savings will increase significantly.”
Robots can improve safety, reduce physical toll on workers
Another strong reason for automating depalletization is the need to reduce reliance on manual labor due to a persistent worker shortage, OSARO said. This shortage is made even worse by the fact that depalletization jobs are unpleasant and require more and more overtime or weekend work, it added.
In general, depalletization is the task that requires the most work from people and puts them at the biggest risk of getting hurt, said OSARAO.
The U.S. Occupational Health and Safety Administration (OSHA) reported that these kinds of injuries cost the economy between $45 billion and $54 billion a year. This includes the costs of compensation, lost wages, and lost productivity, as well as other costs like having to pay other workers overtime to cover workers who aren’t there.
