Artificial Intelligence

Automated pick-and-pack line with AI

Automating efficiently – for certain tasks, this is only possible with AI. The Erlangen equipment plant demonstrates how, together with Storopack. In collaboration with the packaging specialist, Siemens implemented a pick-and-pack line that operates automatically and highly efficiently thanks to AI.

Why does the Erlangen equipment plant rely on AI?

At first glance, the pick-and-pack line hardly stands out, as the solution integrates seamlessly into its surroundings. Only upon closer inspection does it become apparent that it prepares parcels for shipment almost without manual work: Automated guided vehicles deliver cartons, a case erector provides shipping cartons, and robots place product boxes into shipping cartons. At the end, a robot cushions, cuts, and seals cartons. The Auto.Protect solution uses AI to place protective material precisely – similar to a human.

Key benefits at a glance

125% increase in productivity

Productivity has increased by 125%. The automated material flow relieves the burden on logistics teams and eliminates manual processes, making logistics operations more flexible.

25% more capacity

The pick-and-pack line makes better use of all resources. It automates the packaging process within the same footprint where we previously worked manually, yet delivers 25% higher output.

25% reduced CO2 footprint

The line primarily uses paper as packaging material, and the cartons are cut and sealed to fit the specific format. This reduces packaging volume, saving space in trucks and thereby cutting CO2 emissions by around 25%.

Siemens digital Twin of production line (with Storopack)

Every day, between 600 and 1,000 shipments leave the logistics of the Erlangen equipment factory: individually packed boxes with different components in different sizes and different packaging options. Is it even possible to automate such a process in an economically viable way, especially when there is only limited space available? In fact, it would not have been practically possible to automate this process to such an extent with classic algorithms, explains Saber Mazeni, Packaging Logistics Manager EU at the packaging specialist Storopack: "Block and brace in particular, i.e. filling the gaps in the shipping box with protective material, is anything but trivial. To do this, the system has to record and process many parameters. Machine learning is simply a game changer here."

The solution Storopack developed jointly with Siemens is impressing not only the experts and teams on site – the press has also visited the facility in Erlangen. Artificial intelligence is at work at four different points in the process, ensuring that cartons are packed compactly and securely – entirely without human oversight. The AI mimics the way a human would handle the task: one AI uses a camera to "see" inside the carton and "recognize" where specific product packages can be placed, while a robot positions the product boxes accordingly. Another AI uses a camera to identify gaps within the carton, and a separate robot then fills those spaces with protective cushioning material.

Storopack's Auto.Protect solution is just one part of a highly automated process: Siemens uses its own AI solutions for bin picking and inserting the product boxes into the shipping boxes, explains Daniel Benke: "The robot is playing 'Tetris-in-the-Box', so to speak." The robots are integrated into the automation via the SIMATIC Robot Library; data processing runs on SIMATIC IPC. However, Siemens was also looking for partners for the demanding topic of block and brace, remembers Benke: "We formulated a list of our requirements, approached Storopack at a trade fair - and there they showed us a system solution that could do practically everything we needed: flexible format changes, format-specific packaging - it was clear to us that this was the right partner."

However, there were several challenges to overcome along the way, including integrating the system into its environment. "To address this, we use a simulation of the system featuring a digital twin. We can test everything within the model – from material flow to robot kinematics and collision detection," explains Daniel Benke. The digital twin also allows for the generation of training data for the various AI systems. Storopack had already laid the groundwork for the project with Siemens in this regard, having pre-trained an AI for the "block-and-brace" process. The vision system had also been pre-qualified to recognize various topographies and surface types. "This enabled us to implement a productive solution very quickly," says Saber Mazeni.

Thanks to the good preparatory work, the integration of the Auto.Protect system into the line went smoothly, says Saber Mazeni: "We were almost a little surprised ourselves at how well our system worked given the high requirements. We were able to pad the boxes with just a few adjustments, and Siemens was able to select and adapt presets for formats very quickly. This meant we could concentrate on optimizing the process." AI also opens up new possibilities beyond that: "The availability and reliability of employees is a recurring topic in customer discussions. Our Auto.Protect module is able to automatically process the majority of the portfolio of a typical e-commerce sender. For this purpose, we have developed an AI that can independently find and automatically implement packing strategies for protective and shipping packaging."

We are more productive, relieve our teams, have a higher output - and: We send less air from Erlangen. This saves space in the truck and therefore costs and CO2 emissions.

Daniel Benke, Project Manager Innovative Logistik, Siemens

For Daniel Benke, the bottom line is thoroughly positive: “We are more productive, relieve the burden on our teams, and achieve higher output – plus, we’re shipping less ‘air’ out of Erlangen. That saves space in the truck, thereby cutting costs and CO2 emissions.” Saber Mazeni is also proud of what Storopack and Siemens have achieved: “The result is truly excellent, especially regarding the system solution: we automatically erect the boxes, products are automatically fed in and placed inside, and finally, our Auto.Protect system ensures everything is protected and compact for shipping. It’s a showcase project we’re happy to show other customers – and when we mention that it’s up and running at Siemens, there’s really not much more that needs explaining.”