The challenge
Container unloading at this site was a fully manual operation. Each incoming container required up to eight operatives working simultaneously physically unloading boxes, scanning barcodes, and sorting products by hand. It was relentless, labour intensive work, with no opportunity to reduce headcount without directly impacting throughput.
The working conditions made the task even more challenging. Containers arrive at ambient temperature meaning freezing environments in winter, and in summer, containers exposed to direct sunlight can exceed 40°C. Combined with boxes weighing up to 18kg and handled repeatedly throughout a shift, fatigue and injury risk were constant concerns.
A further complexity was product identification. Many containers carried mixed stock with identical outer dimensions — the only way to distinguish one SKU from another was the barcode. Manual scanning at pace, in difficult conditions, introduced errors that rippled through downstream sorting and fulfilment.
The solution
Led controls and software delivery for a robotic palletising system integrating Boston Dynamics Stretch and Universal Robots UR20. The system uses Cognex vision integration for real-time object validation and barcode tracking throughout the automated container unloading process.
- Boston Dynamics Stretch integration for primary unloading operations
- UR20 robotic arm for palletising and placement
- Cognex vision system for object validation and barcode validation
- Managing relationships with 3rd party robot control vendors
Commissioning & delivery
Ran the technical FAT/SAT, resolving on-site integration issues to ensure smooth production handover. Applied structured development practices using GitHub, version control, and controlled release processes in a fast-paced delivery environment.
The result
Successfully delivered 4 fully functional robotic container unloading systems that improved throughput and reduced manual labor.