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Perfect Pick® Cortex™

Operator Manual

 4. Operation

 4.1. Starting up the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  58

 4.1.1. Launching the Perfect Pick host software . . . . . . . . . . . . . . . . . .  58

 4.2. Starting the Cortex system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  62

 4.3. Operating the Cortex system. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  64

 4.3.1. Pick mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  73
 4.3.2. Put-away mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  76

 4.4. Workstation User Interface tabs . . . . . . . . . . . . . . . . . . . . . . . . . .  83

 4.4.1. Order Info tab  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  83
 4.4.2. Details tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  84
 4.4.3. Selected tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  84
 4.4.4. Work Queue tab  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  85
 4.4.5. Options tab  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  86
 4.4.6. System Status tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  87

 4.5. Hot Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  88

 4.5.1. Cycle Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  89
 4.5.2. Audit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  100
 4.5.3. Consolidate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  101
 4.5.4. Cubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  102
 4.5.5. Reprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  107
 4.5.6. Reconfigure Tote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  107
 4.5.7. Sequence  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  108

 4.6. Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  109

 4.6.1. Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  109
 4.6.2. Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  109

Summary of Contents for Perfect Pick Cortex

Page 1: ...blished or stored in a database or retrieval system other than for its intended use without the express written consent of OPEX Corporation August 2020 Perfect Pick Cortex Operator Manual WARNING Read...

Page 2: ...pex com https www opex com support service For other inquiries OPEX Corporation 305 Commerce Dr Moorestown NJ 08057 4234 USA Tel 1 856 727 1100 Fax 1 856 727 1955 https www opex com If you find errors...

Page 3: ...age codes Doc Rev Date Changes click blue text to go to that page 20 01 Aug 25 2020 Initial release Table 1 Revision history for translated manuals Source English version Date Translation Revision Det...

Page 4: ...ions 14 2 2 Personal Protective Equipment PPE 15 2 3 Safety Labels 16 2 3 1 Workstation Labels 17 2 3 2 Perfect Pick Operator Station Labels 23 2 4 Emergency Stops E stops 27 2 5 Light Tower 29 2 6 Lo...

Page 5: ...Controller AC 51 3 6 Understanding Zones 52 3 6 1 Zone sensors 53 Chapter 4 Operation 4 1 Starting up the system 58 4 1 1 Launching the Perfect Pick host software 58 4 2 Starting the Cortex system 62...

Page 6: ...ooting 5 1 Overview 112 5 2 Workstation interruptions 114 5 2 1 Interrupted zone stage sensor blocked 114 5 2 2 Missed window 115 5 2 3 Interrupted zones with missed windows 117 5 2 4 Missed barcode r...

Page 7: ...Perfect Pick Cortex Operator Manual 1 Introduction 1 1 About This Manual 8 1 1 1 Manual navigation 8 1 1 2 Safety message conventions 9...

Page 8: ...story can be viewed on page 4 Be sure to retain the latest electronic release of the manual for your reference The latest release can be downloaded in PDF format at www opexservice com authorized regi...

Page 9: ...tant safety information in Chapter 2 Safety DANGER Indicates a hazardous situation that if not avoided will result in death or severe injury The use of this signal word is limited to the most extreme...

Page 10: ...10 Introduction Perfect Pick Cortex Operator Manual OPEX Corporation This page is intentionally blank...

Page 11: ...ty Labels 16 2 3 1 Workstation Labels 17 2 3 2 Perfect Pick Operator Station Labels 23 2 4 Emergency Stops E stops 27 2 5 Light Tower 29 2 6 Lock out Tag out LOTO Procedures 30 2 6 1 What is Lockout T...

Page 12: ...ctrical wiring is hot any time the machine is plugged in Failure to use caution may result in severe bodily injury or death from electric shock Use caution to avoid contact with exposed non insulated...

Page 13: ...te to the job being performed Requirements for personal protective equipment such as face masks vests safety glasses and gloves may vary with the build site depending on local code and end user custom...

Page 14: ...onary measures must be taken while handling these devices Always wear an anti static wrist strap when handling circuit boards Always handle circuit boards by their edges never putting your fingers on...

Page 15: ...ing the period beginning with machine installation and commissioning prior to completion of the machine owner s customer s arc flash and electrical hazard assessment and labeling Arc Rated Clothing Mi...

Page 16: ...glish French labels for Canadian machines Graphics only labels for EU and various international machines no text Although they appear different the locations of these labels are identical Note Only th...

Page 17: ...e to follow all arc flash and electrical safety requirements per applicable standards This is a temporary label to be removed by the employer only after completion of arc flash and electrical hazard a...

Page 18: ...Purpose Identifies product electrical ratings machine serial number for U S Canada EU Japan Table 2 2 Ratings Serial Number label Label locations Description All 6088000 Front of workstation control...

Page 19: ...OPEX Corporation 2 3 1 3 Fuse Chart label Location Inside hinged cover of Workstation Control Panel Table 2 3 Purpose Identifies the correct fuses needed within the control panel Table 2 3 Fuse Chart...

Page 20: ...Location Front of Workstation Control Panel Table 2 4 Purpose Identifies that the system has met agency approval qualifications The ETL label is not an OPEX label it is provided by Intertek after fiel...

Page 21: ...Location Front edge of Scan Tunnel staging conveyor Workstation one at the end of the input conveyor one at the beginning of the output conveyor Table 2 5 Purpose Used to identify each of the zone loc...

Page 22: ...cation Front edge of Scan Tunnel Table 2 5 Purpose Identifies the sensor cover tool and the location where it is used Placing the cover in this location blocks a sensor and prevents containers from en...

Page 23: ...re described here Descriptions of all other Perfect Pick safety labels can be found in the Perfect Pick Operator Manual 2 3 2 1 Machine Entry label Location Both sides of the Pick Station Table 2 7 Pu...

Page 24: ...gonal track Table 2 8 Purpose Informs the operator to keep hands hair and loose objects away from any exposed moving parts of the machine The moving parts of the Perfect Pick can become jammed and or...

Page 25: ...fe Use Notice Location Front of the pick station on the computer access door Table 2 9 Purpose Advises personnel to read Instruction Manual for safe use Table 2 9 Safe use notice label Label location...

Page 26: ...e Present Warning label Location Front panel door where the UPS is located Table 2 10 Purpose Warns about residual electrical hazard inside and to disconnect UPS power before servicing Table 2 10 UPS...

Page 27: ...top for the Cortex system to be able to continue running Once you have disengaged the e stop you must hit the reset button and then the Start button on the main enclosure for the conveyor to start Not...

Page 28: ...s available supporting maximum lengths of 38 meters and 75 meters Aside from the maximum length the only difference is that the 75 meter version requires higher tension This means the 75 meter version...

Page 29: ...ure 2 2 Workstation Light Tower Note From Maintenance mode the machine is restarted which will bring the solid green light on in addition to the flashing blue light Once the technician determines that...

Page 30: ...rols electrical plug or remote electrical disconnect switch see examples in Figure 2 3 The LOTO devices must only be removed by the Authorized service personnel once they determine that the work is co...

Page 31: ...ut devices required 2 6 2 1 Lockout station The LOTO procedures require the use of the Lock Out Station Figure 2 4 or an equivalent kit Figure 2 4 Lock Out Tag Out Wall Mount Station This kit includes...

Page 32: ...o begin the LOTO procedure 2 Place the Caution sign on the monitor Figure 2 5 Figure 2 5 Caution Sign DANGER You must shut down and lock out the Perfect Pick Integrated Work Station PPIWS to prevent o...

Page 33: ...Operator Manual OPEX Corporation 3 Turn off the power switch on the Workstation control panel see Figure 2 6 Figure 2 6 Main power switch off 4 Disconnect the ECAT_IN cable Figure 2 7 Figure 2 7 Remov...

Page 34: ...ck to one of the holes in the hasp Each Authorized Employee working on the machine must have their own lock and that lock must have their name on it or an identifying tag that cannot be easily removed...

Page 35: ...Safety 35 Perfect Pick Cortex Operator Manual OPEX Corporation person You can also simply attach the lock to the red tab out on the main power switch Figure 2 9 Figure 2 9 Lockout switch with padlock...

Page 36: ...er s main disconnect switch An Authorized Employee or qualified electrician must proceed as follows 1 Complete all steps under LOTO Machine Maintenance and Repair on page 32 2 Customer s site maintena...

Page 37: ...fy operators and affected persons that the machine will be restarting 4 Make sure everyone is safely away from the machine 5 Verify all controls are set to the neutral or OFF position 6 Remove all LOT...

Page 38: ...on on the top of the Workstation Conveyor Figure 2 12 Note that the location for this button may vary Figure 2 12 Workstation Start button 11 Fix any discrepancies and then notify the operators and af...

Page 39: ...ask Listed below are some guidelines to help you minimize the risk of physical discomfort and injury while operating the equipment When at the pick station Maintain an upright body posture Occasionall...

Page 40: ...40 Safety Perfect Pick Cortex Operator Manual OPEX Corporation This page is intentionally blank...

Page 41: ...The OPEX Integrated Workstation 47 3 4 Perfect Pick 48 3 4 1 Cortex Computer 49 3 4 2 WRTC Computer 49 3 4 3 Bin Locator Light 49 3 5 Cortex Software 50 3 5 1 Workstation User Interface WUI 50 3 5 2 W...

Page 42: ...pick to light order progress indicators making integration with warehouse management systems WMS quick and easy At a minimum level Cortex consists of a Database server with backup functionality and a...

Page 43: ...Figure 3 1 Workflow left side configuration Figure 3 2 Workflow right side configuration Note The workflows shown are for an automatic conveyor system as opposed to a manual table mode Perfect Pick Wo...

Page 44: ...1 Cortex workflow 1 Incoming conveyor where containers enter the Cortex system There is a sensor located before the incoming conveyor used to detect that items are properly coming from the customer s...

Page 45: ...re 3 4 Figure 3 4 Scan Tunnel 3 Staging short conveyor located between the scan tunnel and workstation Once scanned the containers are positioned in zones where the system can better track their locat...

Page 46: ...orkstation container s to restock the Perfect Pick PUT mode or count the product contained within the Perfect Pick totes COUNT mode See Perfect Pick on page 48 for more information 6 Outgoing conveyor...

Page 47: ...ves quietly along the conveyors and across the zero height transfers to and from its pick to light PTL location Once the operator completes an order the container is transferred back to the client con...

Page 48: ...Operator Station Host monitor Host computer located behind door Pick Station controls Clear To Pick light Start button E Stop switch Put Away Complete light Cortex monitor Cortex computer located behi...

Page 49: ...or the Cortex system For more information on using the Cortex software see Operation on page 57 3 4 2 WRTC Computer This is the computer which runs all of the conveyor systems If anything happens with...

Page 50: ...ng design of the workstation area The WUI has a configurable amount physical virtual work zones Figure 3 8 Figure 3 8 Workstation User Interface 3 5 2 Warehouse Real Time Controller WRTC The WRTC comm...

Page 51: ...er holding product Put away orders or ready for product Pick orders The AC also sends information to the Perfect Pick as a task to present a tote holding or receiving product Data is requested to gath...

Page 52: ...the back Containers or boxes will only stop at zones 1 3 5 7 9 and 11 for either picking or replenishment Depending on your system setup the amount of zones may vary You may have as little as two zone...

Page 53: ...There may be more outgoing zones and or less workstation area zones which then shifts conveyor zones etc The numbering principle still applies in general but Zone 25 for example may not always be the...

Page 54: ...right next to our zone sensor for the warehouse conveyor system which indicates if the zone is clear for another container to enter Figure 3 12 Figure 3 12 Induction Zone sensor If an operator was to...

Page 55: ...s free to run their control signal through the relay contact this can be DC or AC An addition to this relay box is a safety relay which can be used for safety integration When it is required to shut d...

Page 56: ...56 Overview Perfect Pick Cortex Operator Manual OPEX Corporation This page is intentionally blank...

Page 57: ...Put away mode 76 4 4 Workstation User Interface tabs 83 4 4 1 Order Info tab 83 4 4 2 Details tab 84 4 4 3 Selected tab 84 4 4 4 Work Queue tab 85 4 4 5 Options tab 86 4 4 6 System Status tab 87 4 5...

Page 58: ...system s controls Used primarily by the OPEX technician or qualified personnel the Host software is used to select and run jobs remove insert iBOTs run diagnostic tests and view statistical reports on...

Page 59: ...Pick Cortex Operator Manual OPEX Corporation 2 The Login screen will appear Figure 4 2 Select a Username from the drop down list Figure 4 2 Login screen 3 If required enter the password for the select...

Page 60: ...ure 4 3 Figure 4 3 Main window 5 Click the Run button found in the Menu bar The Run screen opens The run screen offers several tabs for viewing different elements of the machine and its operational pr...

Page 61: ...vailable for conserving iBOT power and parking the iBOTs 7 On the top of the screen click START Figure 4 5 Figure 4 5 Start button location Alternatively you can start the Perfect Pick with the hardwa...

Page 62: ...6 Figure 4 6 Aisle Restart Command On systems with multiple stations front back the WUI Restart command is used to restart the WUI only as the AC only runs on one of the Cortex computers Figure 4 7 Fi...

Page 63: ...tex Operator Manual OPEX Corporation Note The Aisle Restart and Stop commands should only be initiated if the system is not processing any work at the time the commands are initiated Figure 4 9 Figure...

Page 64: ...in order requested containers located on the Workstation or a similar conveyor The operator could also be presented with a Put Away screen which is used for restocking inventory In this situation an...

Page 65: ...t Pick and Cortex as described in Starting up the system on page 58 When you start up the Cortex system it displays the Welcome screen shown in Figure 4 10 Figure 4 10 Cortex Welcome Screen 2 Enter yo...

Page 66: ...Press the green Start button at the Pick Station Figure 4 11 Figure 4 11 Start button 4 The iBOTs will move in preparation for the job and the monitor displays the WUI see example in Figure 4 12 Figur...

Page 67: ...tote Figure 4 13 shows a tote broken up into six parts Tote location and the operator is directed to pick from the front right quadrant Figure 4 13 Cortex WUI screen detail 6 The OPEX Workstation is l...

Page 68: ...place the picked part In Figure 4 15 there are four available locations which are identified by the PTL bar The light bar uses color coded buttons to assist in identifying the correct container In the...

Page 69: ...rfect Pick Cortex Operator Manual OPEX Corporation the items packaged for shipping The other containers would advance and the color coding would also advance to follow the containers Figure 4 15 PTL B...

Page 70: ...placed into the first container on the Workstation Figure 4 16 Place the item in the container Depending on your operation you might also have to bag the items and place a label on the bag a labeler i...

Page 71: ...the iBOT will exit the picking station returning the tote to the storage section Note In cases like the example in Figure 4 17 where the same item is needed in more than one container add the item s...

Page 72: ...bar button to send the container to the back conveyor on the workstation and advance for further processing such as the addition of items from another area QC monitoring or to have the items boxed fo...

Page 73: ...k mode 4 3 1 1 Pick Steps The operator scans the order to be picked The Workstation User Interface WUI will present the following screen Figure 4 19 Pick Screen At this point the Perfect Pick Aisle PP...

Page 74: ...ts until all items for an order are presented and confirmed picked 4 3 1 2 Pick Exceptions If the product is missing then the operator indicates how much product is missing from the tote that is prese...

Page 75: ...x Operator Manual OPEX Corporation If the product is damaged the operator will be presented with a screen as shown in Figure 4 21 and will indicate how many damaged items are being removed from the or...

Page 76: ...operator needs to indicate how many items will fit in the given carton Figure 4 22 Figure 4 22 Product will not fit 4 3 2 Put away mode This mode is used for restocking inventory 4 3 2 1 Put away Step...

Page 77: ...Perfect Pick Cortex Operator Manual OPEX Corporation of items to be replenished Figure 4 23 In this example there are 90 items to put away The operator scans the container to be put away Figure 4 23 P...

Page 78: ...lated 2 At this point the PPA will present the operator with a tote for putting the product into Fill the amount requested into the tote in the pick station 3 When complete the operator presses the co...

Page 79: ...Operation 79 Perfect Pick Cortex Operator Manual OPEX Corporation Figure 4 25 Press the Container button...

Page 80: ...ick Cortex Operator Manual OPEX Corporation 4 3 2 2 Put away Exceptions If the product is missing then the operator indicates how much product is put into the tote that is presented Figure 4 26 Figure...

Page 81: ...ex Operator Manual OPEX Corporation If the product is damaged the operator will be presented with a screen as above and will indicate how many damaged items are being removed from the order Figure 4 2...

Page 82: ...Operator Manual OPEX Corporation If the product will not fit in the tote either due to bulging or an over height error then the operator indicates how many items will fit in the given tote Figure 4 28...

Page 83: ...line detail of the order that is currently selected This includes item numbers quantity to be worked in that order current status of that line the line ID that corresponds to that line of work the Co...

Page 84: ...tion 4 4 2 Details tab The Details tab is not currently implemented 4 4 3 Selected tab This tab allows you to dismiss a selected container This will suspend any work that is planned for this container...

Page 85: ...ight when there are cycle counts awaiting completion as shown in Figure 4 31 The operator can then select how many virtual locations any waiting work can be assigned to The operator can also access th...

Page 86: ...86 Operation Perfect Pick Cortex Operator Manual OPEX Corporation 4 4 5 Options tab Allows setting language and access to logs Figure 4 32 Figure 4 32 Options tab...

Page 87: ...Cortex Operator Manual OPEX Corporation 4 4 6 System Status tab Shows the current status of all connected systems including Perfect Pick Workstation Conveyor Host Database and PTL Module Figure 4 33...

Page 88: ...s that contain that item Audit will bring only the totes that an order affected Consolidate allows you to move identical items from one cell of a tote to another with the intent of freeing cells for n...

Page 89: ...EX Corporation 4 5 1 Cycle Count Cycle Counts are created either by a Cycle Count order or manually 4 5 1 1 Count Steps When the work queue tab is red there is work waiting Figure 4 35 Most often this...

Page 90: ...rfect Pick Cortex Operator Manual OPEX Corporation When Start is pressed additional virtual locations are added to allow the cycle counts and audits a space to process Figure 4 36 Figure 4 36 Cycle co...

Page 91: ...ion 91 Perfect Pick Cortex Operator Manual OPEX Corporation Figure 4 37 shows the count screen The operator will be presented with a tote and need to validate the count in the tote Figure 4 37 Count s...

Page 92: ...92 Operation Perfect Pick Cortex Operator Manual OPEX Corporation 4 5 1 2 Count Exceptions Re count and confirm will display if the counts do not match Figure 4 38 Figure 4 38 Re count and confirm...

Page 93: ...ct Pick Cortex Operator Manual OPEX Corporation This is the screen displayed if product is removed from the container The Operator needs to select how many items are being removed Figure 4 39 Figure 4...

Page 94: ...Operator Manual OPEX Corporation The screen shown in Figure 4 40 is displayed if product is recalled and has to be removed from the container The Operator needs to select how many items are being rem...

Page 95: ...reate a cycle count manually 1 Select SKU for the item to check or Tote for a specific tote to check Figure 4 41 Figure 4 41 Cycle Count When you enter the item number it will populate with all the Un...

Page 96: ...n Perfect Pick Cortex Operator Manual OPEX Corporation item This is usually the UOM needed to select when creating a cycle count Figure 4 42 Figure 4 42 Item number entered 2 Click the Create Cycle Co...

Page 97: ...Perfect Pick Cortex Operator Manual OPEX Corporation A window will populate asking to confirm the cycle count Figure 4 43 Figure 4 43 Confirm Cycle Count Window 3 Click Create 4 Click Close in the top...

Page 98: ...Corporation 5 Click on the Work Queue tab so you can start your virtual conveyor Notice in Figure 4 44 that the Work Queue tab text is red indicating work present on virtual conveyor if not red then n...

Page 99: ...Operation 99 Perfect Pick Cortex Operator Manual OPEX Corporation A circular arrow above the containers indicates Cycle count Figure 4 45 Figure 4 45 Circular arrows indicate cycle count...

Page 100: ...count that will check every tote that has a specific item the audit will only check the totes that were used in relation to an LPN License Plate Number Order number or a single item order Line Figure...

Page 101: ...5 3 Consolidate Allows you to consolidate Items from one tote or cell that may have a few of the items and move them into another tote that may be more full This frees up the cells of the tote to beco...

Page 102: ...s that have been set to the incorrect quantities in a cell For example 48 items can fit in a cell but someone mistakenly told it zero can fit when a zero Put away was presented So now the system think...

Page 103: ...When an item has a bad Cubing quantity an error will pop up with No destination for remaining work or No room for remaining work Figure 4 49 Figure 4 49 Cubing Error Message To correct a bad cubing qu...

Page 104: ...Item number in the Cubing field and select Edit This will show the quantity settings Figure 4 50 Figure 4 50 Cubing Quantity Settings 3 When you change the quantities the text will change to red In th...

Page 105: ...Operation 105 Perfect Pick Cortex Operator Manual OPEX Corporation 4 If a change was made click Commit to set the values Figure 4 51 Figure 4 51 Cubing Quantity change 5 When complete click Close...

Page 106: ...rtex Operator Manual OPEX Corporation 6 Once a change has been made click Dismiss to dismiss the order and remove from the queue then rescan or reenter the item number to recreate the PUTAWAY request...

Page 107: ...ure 4 53 Cubing Item ready 4 5 5 Reprint This is only used for sites with labelers It allows for the reprinting of a label at the pick station should the original label be unusable 4 5 6 Reconfigure T...

Page 108: ...Cortex Operator Manual OPEX Corporation 4 5 7 Sequence This is where you select site specific storage The right storage must be selected or else the product might be inducted into the wrong account F...

Page 109: ...Preventive Maintenance 4 6 1 Mirrors Mirrors on the OPEX Scan Tunnel should be wiped with a clean lint free cloth about once a month 4 6 2 Sensors Workstation sensors should be wiped off twice a year...

Page 110: ...110 Operation Perfect Pick Cortex Operator Manual OPEX Corporation This page is intentionally blank...

Page 111: ...14 5 2 1 Interrupted zone stage sensor blocked 114 5 2 2 Missed window 115 5 2 3 Interrupted zones with missed windows 117 5 2 4 Missed barcode read 118 5 2 5 Unknown containers 120 5 2 6 Duplicate Sc...

Page 112: ...Conveyor view will help with identification of where the stoppage is and why the stoppage has occurred This screen can be accessed through the Cortex operator screen You can see each zone for the con...

Page 113: ...e stoppage is occurring Figure 5 3 shows an unknown container stoppage at Zone 1 This occurred because the sensor in zone one became blocked unexpectedly To correct this issue inspect the sensor at Zo...

Page 114: ...interrupted zone are squarely seated and centered in the zones Figure 5 4 Interrupted zone In Figure 5 4 Zone 17 is interrupted First inspect zone 17 and make sure the container is not skewed or bloc...

Page 115: ...topped This triggers the system to pause so that the Operator can confirm the container is in the correct location The light tower will change to blue or blue and green if a pick is still active Figur...

Page 116: ...cal container click the missed window on the monitor Figure 5 6 Figure 5 6 Select the missed window The Box must be removed from conveyor workstation window appears with a prompt to keep or remove the...

Page 117: ...first locate any skewed containers in or around the interrupted zone Then lift up the container presenting the missed window for one second and set it back in the zone The system will auto correct an...

Page 118: ...a missed barcode read and give the container a random number so it knows were this container is on the workstation The light tower will show blue and green indicating the workstation and conveyor are...

Page 119: ...Corporation 2 Once you select the missed barcode you are given an option to scan or type in the barcode or label in the Enter License Plate field Figure 5 9 Figure 5 9 Enter barcode 3 Once entered cli...

Page 120: ...omething blocked a sensor so the workstation or conveyor cannot confirm what is in the zone Figure 5 11 1 Remove the container from the unknown zone Note When you have a red symbol you will need to pr...

Page 121: ...c Click the Keep button d The system will return to normal operation 5 2 6 Duplicate Scan Sometimes containers are broken up into two or more for the same LPN License Plate number Similar to the carto...

Page 122: ...Operator Manual OPEX Corporation The new Duplicate container show in light blue must be removed from the conveyor and removed logically from the conveyor view until the first LPN orders are completed...

Page 123: ...eep other containers from entering the OPEX Conveyor while the jam is being cleared Figure 5 14 Figure 5 14 Lost Zone Interruption To clear the jam 1 After blocking the integrated sensor if it is pres...

Page 124: ...occurs when the system thinks a container entered a zone where another container exists In Figure 5 15 the yellow container with the interruption needs to be placed back into zone 15 Figure 5 15 Conta...

Page 125: ...ed zones This usually means an Emergency stop was pressed The light tower will change to red Figure 5 17 To resolve reset the E Stop and press the Start button on the workstation or conveyor If resett...

Page 126: ...126 Troubleshooting Perfect Pick Cortex Operator Manual OPEX Corporation This page is intentionally blank...

Page 127: ...Perfect Pick Cortex Operator Manual G Glossary G 1 List of Acronyms 128 G 2 List of Terms 129...

Page 128: ...ntify a container or box PPA Perfect Pick Aisle PTL Pack To Light RTC Real Time Controller SC Safety Controller SI Safety Input Module Guardian SO Safety Output Module Guardian SRCF Safety Related Con...

Page 129: ...e A set of subroutine definitions protocols and tools for building application software In general terms it is a set of clearly defined methods of communication between various software components Aut...

Page 130: ...methods the system will use to process items in a similar fashion from run to run In many cases you will only see one job which should be set up ahead of time either by an OPEX technician or your sit...

Page 131: ...des on the staging conveyor section before the imager entry sensor If the imager entry sensor is detecting an object waiting for an iBOT the staging sensor will stop the staging conveyor until the pre...

Page 132: ...132 Glossary Perfect Pick Cortex Operator Manual OPEX Corporation This page is intentionally blank...

Page 133: ...gh quality exceptional customer service stability stewardship and unwavering independence Utilizing a vast global workforce of direct employees OPEX serves a variety of industries including financial...

Page 134: ...134 Perfect Pick Cortex Operator Manual OPEX Corporation...

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