Material handling system and method for products manually processed

Abstract

The present invention provides a material handling system and method for a product to be manually processed by an operator (O) at a work-station ( 10 ). The material handling system ( 100 ) includes: batch delivery means ( 20 ) for automatically delivering batches of the product to the work-station ( 10 ) on an “as required” or “on demand” basis for manual processing by the operator; and packing container delivery means ( 60 ) for automatically delivering individual packing containers ( 61 ) to the work-station on an “as required” or “on demand” basis for filling with the product after manual processing by the operator. Each batch of product is typically supplied in a batch container ( 21 ) and the system may further include batch container dispatch means ( 40 ) for automatically dispatching the batch containers ( 21 ) from the work-station ( 10 ) on an “as required” or “on demand” basis after the operator has finished manually processing the product it contained. The system also typically includes packing container dispatch means ( 80 ) for automatically dispatching product-filled packing containers ( 61 ) from the work-station on an “as required” or “on demand” basis.

1 . A material handling system for a product to be manually processed by an operator at a work-station, including: 
 at least one operator work-station including a work space at which an operator is able to receive a batch of product and to manually process said product and place said product in a packing container; and    computer-controlled batch delivery means for delivering batches of product to said work-station, said batch delivery means including means for identifying when a batch of product is required at said operator work-station and means for automatically delivering batches of the product to said operator work-station on an “as required” or “on demand” basis for manual processing by the operator; and    computer-controlled packing container delivery means for delivering packing containers to said work-station, said packing container delivery means including means for identifying when a packing container is required at the work-station and means for automatically delivering individual packing containers to said operator work-station on an “as required” or “on demand” basis for filling with the product after manual processing of the product by the operator.    
   
   
       2 . A material handling system according to  claim 1 , wherein each batch of product is provided in a batch container, and the batch delivery means includes a shuttle device for transporting one of the batch containers from a product supply station to the work-station when the work-station is identified as requiring the product batch.  
   
   
       3 . A material handling system according to  claim 2 , wherein the batch delivery means includes a mechanism for transferring the batch container from the shuttle device to an access position for the operator at the work-station.  
   
   
       4 . A material handling system according to  claim 3 , wherein the batch delivery means includes a batch container buffer for accommodating a batch container of product adjacent the work-station.  
   
   
       5 . A material handling system according to  claim 1 , wherein the packing container delivery means includes guide means for directing delivery of the packing containers to a filling position at each of the operator work-stations.  
   
   
       6 . A material handling system according to  claim 5 , wherein the guide means is in the form of a chute that extends from a packing container conveyor to the work-station.  
   
   
       7 . A material handling system according to  claim 6 , wherein the packing container delivery means includes a packing container buffer for accommodating a plurality of packing containers adjacent the work-station.  
   
   
       8 . A material handling system according to  claim 1 , wherein the packing container delivery means includes a packing container buffer for accommodating a plurality of packing containers in the guide chute.  
   
   
       9 . A material handling system according to  claim 1 , wherein the batch delivery means is adapted to deliver the batches of the product to an access position at the work-station within easy reach of the operator, and the packing container delivery means being adapted to deliver the individual packing containers to a filling position at the work-station within easy reach of the operator.  
   
   
       10 . A material handling system according to  claim 9 , wherein the work space takes the form of bench space immediately in front of the operator, and wherein the access position to which batches of product are delivered is adjacent to the work space in front of and within easy reach of the operator, and the filling position to which the packing containers are delivered is adjacent the work space to one side of the operator where the operator can fill the packing container with the product after that product has been manually processed.  
   
   
       11 . A material handling system according to  claim 1 , further including packing container dispatch means for automatically dispatching product-filled packing containers from the work-station on an “as required” or “on demand” basis.  
   
   
       12 . A material handling system according to  claim 11 , wherein the packing container dispatch means includes a mechanism to remove the product-filled packing container from the filling position at the work-station, and an actuator device for use by the operator to actuate the removal mechanism when that filled packing container is ready for dispatch.  
   
   
       13 . A material handling system according to  claim 12 , wherein the removal mechanism of the packing container dispatch means is adapted to discharge the product-filled packing container to a conveyor for carrying that container to a final packaging station.  
   
   
       14 . A material handling system according to  claim 1 , wherein each batch of product is provided in a batch container and further including batch container dispatch means for automatically dispatching the batch containers from each work-station on an “as required” or “on demand” basis.  
   
   
       15 . A material handling system according to  claim 14 , wherein the batch container dispatch means includes a mechanism to remove a batch container from a batch container access position at the work-station at which said operator accesses said batch containers, and an actuator device for use by the operator to actuate the removal mechanism when that batch container is ready for dispatch.  
   
   
       16 . A material handling system according to  claim 15 , wherein the mechanism to remove the emptied batch container from the access position is adapted to transfer said emptied container to a conveyor, said conveyor carrying said emptied container to a batch container return station.  
   
   
       17 . A material handling system according to  claim 1 , wherein said system includes a plurality of separate operator work-stations.  
   
   
       18 . A material handling system according to  claim 1 , wherein the material handling system is in the form of a processing line having a plurality of separate operator work-stations, said batch delivery means and said packing container delivery means delivering said batches of product and said packing containers along a substantially common, primary line of direction of said processing line.  
   
   
       19 . A material handling system according to  claim 18 , wherein the operator work-stations are spaced apart along the processing line with the work-stations located on both sides of the processing line.  
   
   
       20 . A material handling system according to  claim 1 , wherein the system is in the form of a processing line having a plurality of separate operator work-stations provided therealong, the processing line including a plurality of transport mechanisms mounted one above the other along its length, the transport mechanisms including at least one transport mechanism for delivery of batches of product to said operator work-stations, and a transport mechanism for delivery of packing containers to said operator work-stations.  
   
   
       21 . A material handling system according to  claim 1 , wherein said operator work-station includes a cover plate having an aperture therein, and wherein individual packing containers are delivered to said operator work-station below said cover plate, so that said operator can fill a said delivered packing container through said aperture of said cover plate, a rim of said container pressing against said cover plate about a periphery of said aperture.  
   
   
       22 . A material handling method for a product to be processed manually by an operator at a work-station, the method including the steps of: 
 providing at least one operator work-station including a work space at which an operator is able to receive a batch of product and to manually process said product and place said product in a packing container;    automatically delivering discrete batches of the product to said operator work-station for manual processing by the operator, said batches being delivered on an “as required” or “on demand” basis using a computer-controlled delivery means in accordance with a signal from means at said work-station that identifies when a batch of product is required; and    automatically delivering individual packing containers to said operator work-station for filling with said product after said product has been processed by said operator, said packing containers being delivered on an “as required” or “on demand” basis using a computer-controlled delivery means in accordance with a signal from means at said work-station that identifies when a packing container is required.    
   
   
       23 . A material handling method according to  claim 22 , further including the step of: automatically dispatching each product-filled packing container from the work-station on an “as required” or “on demand” basis.  
   
   
       24 . A material handling method according to  claim 22 , wherein each batch of product is supplied in a batch container and the method further includes the step of: automatically dispatching the batch container from the work-station on an “as required” or “on demand” basis.  
   
   
       25 . A food handling system for processing and packaging meat, including: 
 a plurality of operator work-stations, each work station including a work space at which an operator is able to receive a batch of meat and to manually process and package said meat;    a batch-delivery mechanism for delivering batches of meat to said operator work-stations;    a packing container delivery mechanism for delivering packing containers to said operator work-stations for filling with meat by said operator; and    a controller for operating said batch-delivery mechanism and said packing container delivery mechanism so as to provide batches of meat and packing containers to said operator work-stations on a demand basis;    wherein said controller identifies when an operator work-station requires a batch of meat and when an operator work-station requires a packing container; and    wherein said controller operates said batch-delivery mechanism to supply a batch of meat to an operator work-station when said controller determines that a batch of meat is required at said operator work-station, and said controller operates said packing container delivery mechanism to deliver a packing container to an operator work-station when said controller determines that a packing container is required at said operator work-station.    
   
   
       26 . A food handling system for trimming and packaging meat, including: 
 a transport mechanism, a controller and a plurality of operator work-stations situated along said transport mechanism;    wherein each said operator work-station provides a work-space at which an operator is able to receive a batch of meat and to manually trim said meat and manually package said meat into a packing container;    wherein said transport mechanism includes:    a batch container delivery mechanism for delivering batches of meat to said operator work-stations in batch containers;    a packing container delivery mechanism for delivering packing containers to said operator work-stations for filling with meat by said operator;    a batch container dispatch mechanism for removing an empty batch container from said operator work-stations; and    a packing container dispatch mechanism for removing a packing container that has been packed with meat from said operator work-stations;    wherein said controller identifies when an operator work-station requires a batch of meat, a packing container, the removal of an empty batch container or the removal of a packed packing container; and    wherein said controller operates said delivery and dispatch mechanisms of said transport mechanism so as to provide batch containers and packing containers to said operator work-stations on a demand basis and so as to remove empty batch containers and packed packing containers from said operator work-stations on a demand basis.    
   
   
       27 . A material handling system for the manual processing of a product by an operator at a work-station, including: 
 a plurality of operator work-stations, each of which provides a work-space at which an operator is able to receive batches of product and to manually process said product and manually package said product into a packing container;    a transport mechanism including:    a batch container delivery mechanism for delivering batches of product to said operator work-stations in batch containers;    a packing container delivery mechanism for delivering packing containers to said operator work-stations for filling with product by said operator;    a batch container dispatch mechanism for removing empty batch containers from said operator work-stations; and    a packing container dispatch mechanism for removing packing container that has been packed with product from said operator work-stations;    wherein each said operator work-station includes an operator-controlled actuator for requesting the removal of an empty batch container and an operator-controlled actuator for requesting the removal of a packed packing container; and    wherein said transport mechanism is operated in accordance with the actuation of said operator-controlled actuators, so as to remove empty batch containers and packed packing containers from said operator work-stations on a demand basis, and so as to deliver batch containers of product and packing containers to said operator work-stations on a demand basis.    
   
   
       28 . The system of  claim 27 , wherein said batch container delivery mechanism includes a batch container buffer at a work-station, such that when an operator requires a batch of product, a batch container of product stored in said batch container buffer is delivered from said batch container buffer to an access position of said work-station, and a batch container of product is delivered to said batch container buffer from a source of batch containers of product.  
   
   
       29 . The system of  claim 27 , wherein said packing container delivery mechanism includes a packing container buffer at a work-station, such that when an operator requires a packing container, a packing container stored in said packing container buffer is delivered from said packing container buffer to a filling position of said work-station, and a packing container is delivered to said packing container buffer from a source of packing containers.  
   
   
       30 . The system of  claim 27 , wherein said batch container delivery mechanism supplies a batch container of product to an access position of a work-station, said access point being adjacent said work space and in front of said an operator.  
   
   
       31 . The system of  claim 27 , wherein said packing container delivery mechanism supplies a packing container to a filling position of said work-station, said filling position being adjacent said work space to one side of said operator.  
   
   
       32 . The system of  claim 27 , wherein said operator work-stations include a cover plate having an aperture therein, and wherein said packing container delivery mechanism supplies a packing container to a work-station such that said packing container is provided below said cover plate, so that an operator can fill said packing container through said aperture, a rim of said packing container pressing against said cover plate about a periphery of said aperture.  
   
   
       33 . The system of  claim 27 , wherein said operator-controlled actuators are knee-activated actuators.  
   
   
       34 . The system of  claim 27 , including a sensor for monitoring for the presence of a batch container at an access position at said work-station, and a sensor for monitoring for the presence of a packing container at a filling position at said work-station, wherein said transport mechanism provides a batch container of product to said access position when said sensor indicates that there is no batch container at said access position, and wherein said transport mechanism provides a packing container to said filling position when said sensor indicates that there is no packing container at said filling position.