S02 - VASAP_Tucson Industry Day Introduction v6.pdf

VA CMOP Tucson Industry Day Presentation Solicitation Information| Tucson, AZ November 23rd, 2021

Current State

Current Tucson Pharmacy Profile

• Typical Order Make-up

• Assume profile remains constant as volumes increase. More Orders of the same make-up.

Order Profile by Order Type

Tote Puck

Percent of Total Orders 68.7% 31.3%

Percent of Total Containers 81.8% 18.2%

Avg RXs per Order 1.89 1.15

Std Dev of RXs per Order 1.52 0.45

Max RXs per Order 36 9

Avg Containers per RX 1.34 1.07

Std Dev of Containers per RX 0.92 0.40

Max Containers per RX 93 30

Avg Containers per Order 2.53 1.23

Std Dev of Containers per Order 2.36 0.64

Max Containers per Order 93 29

Avg Pages per Order 6.41 5.11

Std Dev of Pages per Order 3.43 1.40

Max Pages per Order 93 30

Current Tucson Daily Order Type Volumes

• Puck Orders will be Handled by Puck Pack Area

• Tote Orders will be Handled by Tote Pack, Marriage and A-Frame Areas

Daily Throughput Requirements by Order Type

Tote Puck

Avg Orders per Day 32,216 14,683

Std Dev of Orders per Day 2,502 1,471

Max Orders per Day 39,214 18,079

Avg RXs per Day 60,786 16,896

Std Dev of RXs per Day 3,892 1,629

Max RXs per Day 72,330 20,344

Avg Containers per Day 81,479 18,102

Std Dev of Containers per Day 4,901 1,754

Max Containers per Day 95,419 22,105

Current Tucson Daily Volumes

• Average of 18 production hours / day over a 2 shift operation

• Two staggered shifts in the pharmacy, beginning at 6 pm/7 am and at 2:30 pm/3:30 pm.

• Each shift is 8.5 hours from start to finish and includes a 30-minute lunch and two 15-minute breaks.

Packing Daily Throughput Requirements

Avg Orders per Day 46,899

Std Dev of Orders per Day 3,111

Max Orders per Day 55,748

Avg RXs per Day 77,682

Std Dev of RXs per Day 4,837

Max RXs per Day 89,738

Avg Containers per Day 99,581

Std Dev of Containers per Day 5,890

Max Containers per Day 114,941

Tucson Growth Volumes – Design Year 2032

• Tucson Design Year is 2032

• Target of 41K Tote Orders per Day & 19K Puck Orders per Day

• Total Daily RX target of 100K Scripts per Day

Solicitation Focus Areas

• BASE : Pack Station Upgrades & Tote Sort

• OPTION #1: ADD Tote Marriage, Robotic

De-Puck & A-Frame Recirculation

• OPTION #1A: ADD A-Frame In/Out Feed

Upgrades

BASE OPTION:

Tote SAP and Sorter

• Upgraded Packing Area:

• 8 Semi-Auto Packing Stations

• 2 Manual Stations

• Tote Sortation System to feed packing

• Tote Recirc

• Tote Takeaway System

• Completed Package Takeaway

BASE OPTION:

Puck SAP

• Upgraded Packing Area:

• 6 Semi-Auto Packing Stations

• 3 Potential Future Upgrades (not in scope)

• Puck Sortation by Order

• Empty Puck Return

• Puck Recirc Loop

Semi-Automated Packaging

• Tote Diverts – Totes diverts must be able to handle 35 to 40 Totes per minute and be low profile to accommodate an over/under conveyor configuration.

• Tote Stations Share Take-Away Conveyors

• Tote Stations Queues MUST HAVE Tote Indexing Capability (Zones)

• Print-Ahead REQUIRED

• Empty Tote Return is Automatic

Tote Pack Station Concept Puck Pack Station Concept

• Puck Stations MUST HAVE Local Order Accumulation

• Print-Ahead REQUIRED

• Empty Pucks Return is Automatic

Tote Pack Station Concept Puck Pack Station Concept

Concept Rendering for Pack Stations

Tote Pack Station Concept Puck Pack Station Concept

Puck Logic Overview

Inbound

Pucks

Outbound

Empty Pucks

Loop Entry

Point

SAP

Station

Recirc Loop

Empty Puck

Removal

Loop Exit

Point

Loop Exit Point Conditions:

Single Puck Order: If there is an available space for the puck in any bank.

Multi-Puck Order:

1. All siblings present in loop

2. Family has already seized a queue

OR

2. There is an empty space capable of holding full family, seize it for family

Loop Entry Point Conditions:

If there is capacity in the loop, the puck will enter.

Otherwise, the puck will pass the decision point and re-enter the same zone after a specified delay time.

Inbound Order Characteristics:

Single-Puck Orders:

• Majority of Puck Orders

• Single Puck

Multi-Puck Orders:

• Minority of Puck Orders

• Order’s pucks are “spread” evenly across a given time based on their size

• Pucks may be intermingled with other orders

Puck Controllable Factors:

• Inbound Puck Flow:

• Volume

• Makeup

• Mix / Spread

• SAP Cycle Time

• Recirculation Loop Capacity

• Total SAPs Operational

• SAP Dedication:

• Singles Only

• Multis Only

• Either

Puck Slug-Building Queues

Bank

SAP

Slug-

Building

Queues

The last queue in each bank is reserved for puck orders of size larger than 5.

Each bank keeps track of the age of its orders and releases the oldest once it’s cleared for release. An order’s age is calculated based on:

• Singles – Entry time

• Multi – Entry time of final sibling

Operator

Empty Puck

Removal

Tote Logic Overview

Inbound Totes

Outbound

Empty Totes

Routing

Decision

Point

SAP

Station

Tote Recirc

Empty Tote

Removal

Tote Controllable Factors:

• Inbound Tote Flow:

• Volume

• Makeup

• SAP Cycle Time

• Routing Method

• Total SAPs Operational

• SAP Dedication:

• Super Totes Only

• Non-Super Totes Only

• Either

Manual

Station

BASE: Tote Sorter Concept

• Diverts must not restrict the flow of totes through the pack line and meet the future tote volumes.

• Diverts must fit within the MDR frames of the new conveyor system in the tote area.

OPTION #1:

Add Automated De-Puck and Tote Marriage Robot

• Upgraded Tote Marriage area includes:

• De-Puck Robots

• De-Puck Exceptions

• Manual UOU Dispense Stations

• A-Frame Exception Stations

• Recirculation from A-Frame to Exception Stations

• Recirculation of the Tote Marriage Area

• De-Puck Bypass

OPTION #1:

Automated De-Puck and Tote Marriage Robot

• Robotic De-Puck / Tote Marriage

MUST Handle 150 to 200 bottles in queue (buffer) for EACH robot.

• Robot must handle bottles without damaging pills inside bottles.

• Robots must place / drop bottles into totes below accurately AND without damage.

• Robots must handle multiple vial sizes.Robotic De-puck for Consideration

Current Tote Conveyor System & Upgrades

• The current conveyor system routes empty totes to the tote marriage area.

• The totes can be diverted into one of two tote marriage lanes or pass through to the A-frame modules.

• The totes pass through both A-Frame modules and are sent on to tote labeling.

• The conveyor as the ability to bypass the first A-Frame and divert into the second A-frame, however the site has experienced issues with congestion at the diverts and has created a fixed the path to include both A-frames. This adds considerable cycle time to each tote.

• There is limited recirculation of totes and overflow totes that need to recirculate to the A-frame modules must travel the entire system to return back into the A-frame area. This also adds considerable cycle time to each tote that is recirculated.

• The manual tote dispenses and tote exceptions are after the tote labeling area and are down stream of dispensing and labeling. This is a sub-optimal location for these operations.

Tote Conveyor: OPTION #1

OPTION #1

Option #1 adds a full-length tote recirculation loop that connects back to the tote marriage area. This option does not change the in-feed/out-feed of the A-Frame modules and would tie into existing tote conveyor supporting the A-Frames. The recirculation line is shown below:

**This is the least invasive option to cure the current conveyor issues. It would still require totes to pass through both a-frames and could still create recirculation issues causing totes to recirculate the entire tote conveyor.

Current Tote Distribution in A-Frames

• Approximately 20% of the Totes require BOTH A-Frames

• Approximately 80% of the Totes will only route through one A-Frame

Tote Conveyor: OPTION #1A

OPTION #1A

• Independent A-Frame In-Feed Lines – Each A-Frame will have an in-feed divert that is separate and prior to the A-Frame out-feeds. NOTE: in order to prevent tote congestions as totes are entering and exiting the a-frame modules, the in-feed and out-feed conveyors must be separated.

• Independent A-Frame Out-Feed Lines – Each A-Frame will have an out-feed exit that is down stream of BOTH A-Frame in-feeds. The out-feeds will exit and return to the main pass through line for recirculation or continuation to tote labeling.

• A-Frame Crossover – A-Frame 1 will have a cross-over line that allow totes requiring dispenses from both A-Frame modules to enter A-Frame 2 without interfering with the exiting or entering tote flow.

• In/Out Feed Separation - The in-feeds to the A-Frame modules will be raised above the floor level to separate the in-feed flows from the out-feed flows to reduce tote congestion.

• Spacing for Out Feeds - The out-feed merges are separated to reduce tote congestion.

The illustration below shows the proposed upgrades to the A-Frame Feed Conveyor for OPTION #1A:

**In addition to the ability to route order totes to either A-Frame 1 OR A-Frame 2 OR Both A-Frames 1 and 2, there needs to be the ability to allow all totes to pass through both A-Frames mirroring the current A-Frame tote flow.

If the tote flow becomes unbalanced or excessive tote congestion occurs, the conveyor system must be able to overcome the imbalance by creating a fixed path through both A-Frame units. Although this is not the optimal flow of totes through A-Frame dispensing the ability to switch between the optimized flow and current flow is required.

OPTION #1A: Aframe Logic Overview

Inbound

Totes

Totes to

Labelling

Manual and

Exception

Recirc Loop

Aframe Main

Entry Points

Aframe Main Entry Point

Conditions:

• Tote requires handling by the upcoming Aframe and has not yet been through it

• There is sufficient capacity in the

Pre-Aframe Accumulation

• If either condition is not met, tote will continue past the entrance.

Aframe 1 to Aframe 2

Direct Transfer

Totes that require handling by both Aframe 1 and 2 have the ability to transfer directly to

Aframe 2 after being processed by Aframe 1 by a dedicated belt.

They receive priority entrance onto the Aframe 2 belt over totes waiting at the pre-

Aframe accumulation.

Inbound Tote Characteristics:

• Required Handling:

• Aframe 1 Only

• Aframe 2 Only

• Both Aframe 1 and 2

• Possible Required Handling:

• Manual

• Exception (must be handled in Aframe first)

Aframe Controllable Factors:

• Inbound Tote Flow:

• Total Volume

• Hourly Volume

• Makeup

• Recirculation Loop Capacity

• Aframe Capacity

• Pre-Aframe Accumulation Capacity

• Manual Handling:

• % Totes

• Handling Time

• Exception Handling:

• % Totes

• Handling Time

• Handling Stations:

• On/Off

• Capacity

A1 to A2

Direct

Aframes

Recirculation Criteria:

Tote has not been handled by:

• All required Aframes

• Manual, if required

• Exception, if required

Aframe Belt Behavior:

Through all runs, both

Aframe belts are run constantly and have no accumulation

Thank you!

Tim Burnham Director, Govt. Programs St. Onge Company

Byron Abshier CMOP National Engineer

Domingo Laborin COR VA CMOP Tucson

Mrs. Esperanza Roberts Contracting Specialist Network 15 Contracting Office Esperanza.Roberts@va.gov

Brian Guistwhite Pharmacy SME St. Onge Company