A Comparative Efficiency Simulation of Package Sorting Systems using Factory I/O

In recent years, automation and digitalization have revolutionized the manufacturing industry, leading to increased efficiency, productivity, and quality. Programmable Logic Controllers (PLCs) have played a critical role in this transformation by providing reliable and flexible control systems for a wide range of industrial processes. For example, the logistics industry relies heavily on automation. To explore automation in this industry, two designs are proposed for package sorting. Then the two designs are simulated in Factory I/O programmed with Control I/O function block programming. The two implemented designs are best represented by spokes and grids. Spokes are better at sorting packages efficiently at their exit and grids are better at sorting packages at entry. The combination of these designs produces an efficient design that quickly sorts packages but has a high initial cost. If there is a low package profit per shipment or the machine will have a short life cycle, the spoke sort is the most efficient design; however, if there is a high profit for each package shipped or a long-life cycle for the machine the combination sorter is the best design.