Sportswear warehouse logistics and packaging

Before the MASTERLY project: The picking of products for order preparation is still done manually by the operators: they take the correct number of items for each order and place them in another container to complete the order. The instructions are received from a screen or tablet. This results in highly repetitive work where a lot of time is spent moving through the shelves. The work can sometimes be alienating, poorly ergonomic and low mental incentive for employees.

With the MASTERLY solution: An autonomous robotic system will pick up the containers and take them to a dedicated picking station for the preparation of the order boxes. The robotic cell will receive order instructions from DEC’s management system and perform picking and placing activities in the boxes containing the orders, with the identification of the products using the instructions and codes on the tablet. A vision system will inspect the objects to determine the correct gripping point and a flexible and reconfigurable gripper will be implemented.

Overview of DECATHLON’s Use Case Status and Key Milestones after 1 Year in the MASTERLY Project

In the first year, the DECATHLON use case focused on automating single-reference container picking activities. Initial analysis identified high variability in product attributes, posing a technological challenge. To address this, products were reclassified into homogeneous groups to facilitate robotic picking. Key testing sessions involved evaluating grippers, optimizing picking logic, and assessing reliability and quality, including preliminary vision system trials within Decathlon warehouses.

Key Milestones and Achievements:

• Product Reclassification: Products were reclassified into groups to enable targeted robotic picking strategies, establishing the foundation for an adaptable picking process.
• Gripper and Vision System Testing: Various grippers, including vacuum and pneumatic types, were tested to identify suitable grasping mechanisms for Decathlon products. Initial vision system tests were also conducted.
• Simulation and Reliability Assessment: Simulations evaluated picking logic, reliability, and operational quality to ensure readiness for warehouse deployment.

Challenges and Solutions:

Due to the wide range of products, a flexible picking strategy was essential. For products that were uncategorized or for parameterized operations that failed, a training and testing station was created, allowing an operator to intervene as needed.

For more details, please visit: DECATHLON Use Case