AUTOMATED ONLINE SHIPPER CONVEYING TRANSFER SYSTEM … · 2018-09-29 · Automated Online Shipper Conveying Transfer System (OSCS) is designed to track the manufactured drug details

AUTOMATED ONLINE SHIPPERCONVEYING TRANSFER SYSTEM

USING IOT

K. Sai Prasad1, K. Sai Teja2,K. Shekar3, A. Giri4,

I. Surya Prabha5

1,2,3Department of Computer Scienceand Engineering, MLR Institute of Technology,

Hyderabad, [email protected],

[email protected],[email protected]

4Department of Computer Scienceand Engineering, Marri Laxman Reddy

Institute of Technology and Management,Hyderabad, India.

[email protected] of Information Technology,Institute of Aeronautical Engineering,

Hyderabad, India.

June 12, 2018

Abstract

Automated Online Shipper Conveying Transfer System(OSCS) is designed to track the manufactured drugdetails. It consists of critical data that will be used foranalysis of the produced materials in an organization.

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International Journal of Pure and Applied MathematicsVolume 120 No. 6 2018, 3499-3513ISSN: 1314-3395 (on-line version)url: http://www.acadpubl.eu/hub/Special Issue http://www.acadpubl.eu/hub/

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With the Utilization of this software we can trace theproduct history like batch number, Expiry date andmanufactured date of every drug produced in the industry.Access will be provided only for the users with theadministrator level so that the data is very well securedand less prone for the vulnerability.This is the briefintroduction of paper which describes about the aim of theOnline Shipper Conveying Transfer System. Thedevelopment of the application is made in C#, .Netlanguage and SQL Server 2014 as Database for storing thedata in backend. The detailed functionality of thedeveloped application will be shown and described belowfor understanding clearly to the users who are going toconsume this software application.

In order to serialize the Batches which are produced forcommercial usageas per the Indian Drug Rules andregulation act Batch production details should beuploaded to DAVA Portal (Drug Authentication andVerification Application). This paper provides acomprehensive solution which enables the organizations forachieving the output by automating the process fordelivering legacy services.Epedigree plays a key role inachieving the desired output. We will track the productinformation from one station to other station by using theRFID Tag’s.Keywords:Automatic Smart Packing, IOT, LineManagement, Password Policy, Conveying, Sorting,Scanning, Rejecting.

1 INTRODUCTION

Due to the frequent incidents of duplicating the medicines noticedlot of deaths around the world, presently industries areconcentrating and ensuring the safety and quality of its products.There is a growing demand across the world for developingtechnology to ensure the safety of their products [7].

The main objective of this application is

• To show how packaging can be automated which will impactthe supply chain.

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• To reduce the human effort by which organization can get theprofitable growth.

• Product details can be easily tracked such as batch numbermanufactured date and Expiry date. Benefits of the packagingsystems include:

• Increase in material flow and revenue.

• Elimination in producing the identical duplicate drugs withsame batch number.

• Reduce Head count which will leads in revenue growth.

• Increase profitability. Modifications in consumer preferences,government regulations, product contents and environmentalfactors are the influence factors over packaging projects.Managing these things effectivelywill add additional benefitfor the profitable brand growth.Varying levels of automationhave been adopted within groups such as Palletization andautomatic storage and retrieval systems [1].

The negative consequences which are impacting todayare many:Now a days Duplication of the products became more andmorewhich resulting damage to the Brand.Time and expense arewasted on packaging the products which are later found to beunfit for this purpose.

Survey:Counterfeit drugs entering the supply chain is a growing problemaround the world. Consumer and patient safety is cruciallyimportant within the healthcare and pharmaceutical industries.Vigorous action is being mandated by local, State, and Federalgovernments such as Californias e-pedigree law and the U.S.Federal legislation that requires the implementation of track-andtrace solutions. Xu et al. introduced a warehouse managementoptimization method based on varying SKU (storage keepingunit) levels by developing an RFID-enabled warehouse [2]. Radiofrequency identification (RFID) is an emerging technology thatcan expand the possibilities for data capture [5].

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History of Track and Trace:Tracking and tracing evolved in the postal and logistics sector toallow individual parcels to be moved with confidence within thecompanies concerned. Proprietary paper based systems weredeveloped at first, which then evolved during the 1970s intoautomated electronic systems as a result of increasinginternational trade and the development of technology solutions.This enabled the automated capture and storage of large volumesof data. Event data is the information associated with a trackingevent. EPCIS (Electronic Product Code Information Service) is aGS1 standard for event repositories. It defines the data to becollected by a track and trace systems and how it should beentered and accessed. Track and trace solution providers sitwithin the anti-counterfeiting and brand integrity market. Thismarket is highly fragmented and complex, covering differenttechnologies and industries.

However, our hypothesis suggests that the wavelength of RFradiation is too large to create a resonance big enough to alter theprotein structure of the drug [8].

Yoo et al. focused on development of a middleware platform inapplication of an RFID system for reverse logistics[9]. The workproposed a network infrastructure that supports logistic activitiesfrom the recycle to the disposal of product materials by addingreverse logistics to the existing forward logistics

In brief, it has been widely accepted that applications of RFIDtechniques create a better visualization and traceability ofinventory data therefore facilitating automation of storage andretrieval assignments in a warehouse [10]. Compared to aconventional warehouse using the barcode approach,implementation of RFID systems has also demonstrated asignificant improvement in warehouse data handling efficiency andspace utilization.

2 METHODOLOGY

By using the 2 dimensional barcodes are recommended due to thehigh fault tolerance and anti-corruption capabilities one can scanthese barcodes printed on the shippers with the hand held

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scanners to track and instantly access the complete information ofthe particular product which will increase the accountability andreliability of the material tracking system (MTS) theseeffectiveness depends on the RFID Tagging [6]. Proper technologyto integrate the database efficiently is the key to success whichresults in increased innovation, greater efficiency and improvedflexibility [11]. Sequence of Operation which will be performed forpalletizing the shippers.

Step 1: The labeled Shippers will be loaded on the Conveyorby the Operator or auto transfer from in feed line, and then theScanner scans the Barcode on the Label. After successfulscanning is done, the Shipper gets transferred on to the nextConveyor through lift.

Note: If the Label is not scanned, or the Label is notpresented User will get notification through Tower Lampindication.

Step 2: The Shippers from each Secondary Packaging Lines(Line 1 to Line 5) gets transferred to the Shipper Lift Conveyors.And it is elevated to the level of Lift Out feed Roller conveyor.

Step - 3: The Shippers from Lift Out feed Conveyor getstransferred on to the overhead modular Conveyor (HighwayConveyor).

Step 4: The Shipper from each Line transferred to the OverheadConveyor from either direction; then travels towards Palletizingarea (Robotic Palletization area)

Step 6: The Shippers received from Overhead Conveyor gettransferred to Declined Conveyor.

Step 7: The Shippers from the Declined Conveyor will gettransferred to the Sorting Conveyor through Modular Conveyorthen at the time of conveying then the Shipper will get scannedby Scanner to allocate the respective Pickup Station based onrunning batch information at each Room.

In case, after scanning, if the Shipper gets rejected(No read or unspecified batch); then the Shipper willreject through Rejection Conveyor.

Step 8: The Shipper received on the respective Pickup Station

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is picked by the Robot which places on the Pallet available atrespective Palletizing Station. Before Robot picks the Shippersfrom the Pickup Stations, the Empty Pallet will be fed at thePalletization Station by the respective Shuttle from respectiveDestacker based on the Pallet Type (information received fromthe E-Pedigree System and based on Material & Shipper Masterdata which is there in the database) and upon loading the EmptyPallet, unique track ID will be assigned for further trackingthroughout the Line. So the Shipper and Pallet information willbe made available in System upon completion of palletization ofthe shippers on the assigned pallet.

Step 9: After palletization, the finished Pallet gets transferredon Shuttle Cart.

Step 10: Shuttle Cart delivers the Pallet to the In feed Conveyorfor Automatic Wrapping and Strapping of the pallet.

3 EXPERIMENTAL RESULTS

Login Screen

Figure 1: Login screen

Soon after clicking on the application the above screen willpopulate to the user for providing the credentials like username

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and password. After validation of the username and passwordwhich was provided by the user the dashboard will be presentedto the user based upon the role of the user.

Administration: Role Based Access control (RBAC) isimplemented in this application.As per the role of each individuallogged in user the dashboard will be populated accordingly. Threetypes of user roles are provided in this application. Operator: usercan assess limited functions mainly production window andreports.

Supervisor: User can assess functions like creation of theproducts etc. in addition to the privileges provided to the UserLogin.

Super Admin: He has full privilege of the software. He canperform all the things such as creation, deletion and Grantingaccess.

Scanner:

Figure 2: Scanner image

This Scanner is used in the process ofsorting the variant drugsbased upon the product code with the barcode label scanned.

Shipper Label Data Verification by ScanningUpon Successful Scanning of the barcode label on the shipper thescanned data will be verified with the available data in the database.Upon successful Validation of data the shipper will move furtherand diverted to its designated station in case of any failure theshipper will be rejected.

Rejected Shipper should be re- introduced manually by theoperator.

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Password Policy21 CFR Part-11 Compliances are implemented in this applicationfor audit log management such as password change frequency,wrong password count, password encryption, inactive screen timeout.

Detailed Pallet ReportsIf User wants to check the no.of pallets produced he can check the

Figure 3: Pallet Reports

pallet details report by providing the batch number and productcode then the above screen will be populated with the details.

Table 1: Describing the Software specificationsS.No Component Version Purpose

1 MS SQL Server 2014 or above Database installed in this server2 .NET Framework 4.0 or above Used in the development of application3 Siemens S7 To communicate with PLC

Reports

Day wise and Trend Wise report will be captured and can bedisplayed as shown in the above fig: 5.

Batch Running Status:Status of the batch can be seen in the below screen. If useridentifies any issue he can cancel the batch or reject the batch as

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Figure 4: Batch production report

Figure 5: Day wise and Trend wise report

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per the organization norms.

Figure 6: Batch Production Status

Benefits of Automated Conveying Systems:

1. High performance with good quality

2. Accumulation of the products without any line pressure.

3. Diverting and Managing the work load.

4. Automated Management of Material Systems such asPlanning, Tracking Inventory Management and Monitoringof the Materials.

5. 21 CFR Part 11 Compliance, which is mandatory for US FDA.Electronic signature generation and audit log managementwill be captured.

6. Documenting product history from manufacturing to thecustomer

Strapping:Uses of Strapping include attaching items to pallets, skids.

Strapping is most often used in complete horizontal or verticalbands. Edge protectors i.e., Angle boards are used spread the loadat corners and reduce damage to the load by the tensioned strap[12].

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Figure 7: Hand Held Terminal Scanner

Figure 8: Example of a two dimensional Barcode

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4 CONCLUSION

Due to the frequent incidents of duplicating the medicines noticedlot of deaths around the world, presently industries areconcentrating and ensuring the safety and quality of its products.By serializing the products we can eliminate the duplications ofthe products by which we can stop the illegal activities. Everyproduct will have the tracking information. This kind of process isgrowing exponentially in the field of food and pharma by whichwe can detect the issues and tracing product history. There is agrowing demand across the world for developing technology toensure the safety of their products. Therefore efforts are carryingout in order to develop smart packing systems. Conveyors cansafely transport materials from one level to another, which whendone by human labor would be strenuous and expensive. Theseconveyors can be installed anywhere easily and are much saferthan using a forklift. They also have the advanced safety featureswhich can prevent the accidents.

Scope of Future Work:

Various industries will adopt this technology in order reducethe Malpractices by which the creditability of the brandreputation will not effect. As well as organizations saving theManpower cost by which the efficiency in terms of profit of theorganizations will be increased which leads for growth of industrialrevolution. Technologies like IOT, Industrial Automation 4.0 areused for achieving this kind of smart machines and providing goodopportunity for automation engineers to design implement andexecute such kind of smart mechanisms for the industrial growth.Therefore a particular case study carried out at package industrycan further be reinvestigated in many other process basedindustries like Food products sector, bottling plants or suchindustries where products are manufactured as per lots.

References

[1] Q. Wang, R. McIntosh, and M. Brain, A new-generationautomated warehousing capability, International Journal of

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Computer Integrated Manufacturing, vol. 23, no. 6, pp. 565-573, 2010

[2] Qian Wang, Saleh Alyahya, Nick Bennett, and HomDhakal, An RFID-Enabled Automated Warehousing SystemInternational Journal of Materials, Mechanics andManufacturing, Vol. 3, No. 4, November 2015

[3] T. C. Poon, K. L. Choy, H. K. H. Chow, H. C. W. Lau, F. T.S. Chan, and K. C. Ho, An RFID case-based logistics resourcemanagement system for managing order-picking operations inwarehouses, Expert Systems with Applications, vol. 36, no. 4,pp. 8277-8301, 2009.

[4] E. Sahin and Y. Dallery, A literature review on the impact ofinventory data record inaccuracies on inventory managementand the potential of the RFID technology to tackle this issue,Ecole Centrale Paris, pp. 1-16, 2007.

[5] C. M. Liu and L. S. Chen, Applications of RFID Technologyfor improving production efficiency in an integrated-circuit packaging house, International Journal of ProductionResearch, vol. 47, no. 8, pp. 2203-2216, 2009.

[6] W. K. Jehng, S. Peng, and W. H. Huang, Using LabVIEWto Integrate RFID system and database for supply chainefficiency improvement, International Journal of IntelligentControl and Systems, vol. 13, no. 3, pp. 189-195, 2008.

[7] I. Uysal, P. W. DeHay, A. E. Altunbas, J.-P. Emond, R.S. Rasmussen and D. Ulrich, ”Non-thermal effects of radiofrequency exposure on biologic pharmaceuticals for RFIDapplications,” in 2010 IEEE International Conference onRFID, Orlando, FL, USA, 2010, pp. 266-273.

[8] O. E. Cakici, H. Groenevelt, and A. Seidmann, Using RFIDfor the management of pharmaceutical inventory systemoptimization and shrinkage control, Decision Support Systems,vol. 51, pp. 842-852, 2011.

[9] J. Yoo and Y. Park, An intelligent middleware platform andframework for RFID reverse logistics, International Journal of

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Future Generation Communication and Network, vol. 1, no. 1,pp. 75-82, 2008.

[10] C. M. Liu and L. S. Chen, Applications of RFID Technologyfor improving production efficiency in an integrated-circuit packaging house, International Journal of ProductionResearch, vol. 47, no. 8, pp. 2203-2216, 2009.

[11] D. O. Fakorede Productivity Increase by Optimum Utilizationof Machines and Manpower Energy International Journal ofEngineering Research and Development e-ISSN: 2278-067X, p-ISSN: 2278- 800X, www.ijerd.com Volume 10, Issue 5 (May2014), PP.11-24.

[12] K. Sai Prasad, G. Prabhakar Reddy, N Chandra Sekhar Reddy,K. Sai Teja, An Automated Mechanism For Smart PackagingLine Management, International Journal of MechanicalEngineering and Technology, 8(6), 2017, pp. 813821.http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=6.

[13] FDA , Drug Supply Chain Security Act - Title II of the DrugQuality and Security Act of 2013, accessed February 2014(http://www.fda.gov/drugs/drugsafety.htm)

[14] US Securities and Exchange Commission - One HundredEleventh Congress of the United States of America, An Act- H.R. 4173, accessed January 2014.

[15] Track/Trace Solutions for the Healthcare and PharmaceuticalIndustries by SATO America.

[16] FDA, ”21 CFR Part 203 Compliance Policy Guide andGuidance for Industry: Prescription Drug Marketing ActPedigree Requirements Questions and Answers,” Food andDrug Administration fr15no06-7, 15 Nov 2006.

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AUTOMATED ONLINE SHIPPER CONVEYING TRANSFER SYSTEM … · 2018-09-29 · Automated Online Shipper Conveying Transfer System (OSCS) is designed to track the manufactured drug details