Auto-identification technology from SICK has solved a challenging parcel label reading application at Asda’s pioneering robotic sorting facility in Yorkshire. The digitalised solution helps to optimise efficiency by enabling operators to track a wealth of data right down to the level of individual parcels.
Constructed to fit within the existing footprint of the Asda Logistics Services (ALS) distribution centre at South Elmsall in West Yorkshire, the innovative parcel handling facility is the hub for Asda’s ‘toyou’ third-party collection and returns service, serving customers at more than 600 Asda stores across the UK.
By using 60 Geek+ Automated Mobile Robots (AMRs) and a digital sorting concept with the flexibility needed to respond to rapid changes in both forward and reverse volumes, integrator AMH Material Handling aimed to achieve 99.9% sorting accuracy.
Configuring the solution to meet Asda’s needs began with reliable identification of thousands of parcels an hour. AMH chose SICK Lector 652 image-based code readers to achieve an auto-identification solution that achieves high read rates, despite difficult and hard to read codes.
Reliable Barcode Reading
Each parcel is placed by an Asda colleague on one of four conveyor infeeds which travel up to meet the robots operating on the one metre-high platform. Two SICK Lector 652 image-based code readers are positioned at the top of each of four conveyors to read the barcode before the parcel transfers to a waiting robot. The robots then navigate using a grid of 2D codes to reach one of 34 different exit chutes positioned along each side of the platform.
The SICK sensors reliably read the barcode labels on the wide variety of irregular shaped parcels being sorted, no matter what their size, height or orientation. They read the labels accurately even in the case of poor-quality print or low contrast, or if they are creased, crinkled or damaged.
Pre-validation and Testing
SICK Lector 650 image-based code readers have a wide-angle lens and 2 megapixel resolution. Combined with advanced on-board image-processing technology, they achieve exceptionally high read performance, even with poorly printed or partially-destroyed codes, or where multiple codes are presented in a single image. The Lector’s dynamic focus was ideal for reading labels at irregular orientations and heights.
Data from the Lectors is processed via the logic unit of a SICK MSC800 modular system controller, enabling it to be integrated easily into AMH’s custom-designed software and systems.
Operating Flexibility
The data has been crucial in getting the best out of the automated sorting solution. A requirement of the read is an input into the IDC warehouse management system and each individual scanner can be interrogated.
Adam Mydlowski, General Manager of the Asda Yorkshire Cross-Dock Centre, explains: “Parcels arrive in many shapes and sizes, so accurate reading of the label is really important for us, and labels can be placed anywhere on the parcel. “Every barcode is recorded via the warehouse control system, so we can interrogate each individual scanner, and go through every barcode. Once we begin to fully utilise the data that is collected, it becomes powerful. Good reads, no reads, throughput error messages and downtime – that’s all useful information.
“For example, if there is a particular infeed that keeps stopping, I can investigate to see if the problem lies with the scanner, belt, operator or the barcode, that is helping us to get the most out of the whole operation. We have been able to really deep dive to achieve continuous improvements.”
Versatile Solution
Once the parcels are correctly identified, robot routes can be planned from anywhere on the grid. This means the system can be easily adapted or expanded in future, whatever the commercial challenge may be.
