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Opex Perfect Pick Cortex Operator's Manual

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August 2020
Perfect Pick® Cortex™ Operator Manual
9146910OM-EN
Revision 20-01
Original Instructions
Cortex™
WARNING
Read this manual thoroughly before attempting to operate or service this
equipment. Keep a current copy for your reference.
®
© 2020 OPEX
Corporation
All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion
of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its
intended use without the express, written consent of OPEX Corporation.

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  • Page 1 © 2020 OPEX Corporation All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its...
  • Page 2 Fax: +1 856.727.1955 https://www.opex.com/ If you find errors, inaccuracies, or any other issues or concerns with this document, please contact the OPEX Technical Writers via email at: GroupTechwriters@opex.com For help with opexservice website-related issues, please contact the OPEX Web Developers via email at: GroupWebDev@opex.com...
  • Page 3 Table 1: Revision history for translated manuals Source Translation Details (click blue text to Date (English version) Revision go to that page) Language codes: German Spanish Italian Polish English French Japanese Document History Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 4: Table Of Contents

    2.6.4. Fully de-energizing AC power ............36 2.6.5. Restoring the machine to normal operation ........37 2.7. Ergonomics ................... 39 Chapter 3 Overview 3.1. Overview ....................42 3.2. Cortex Workflow ..................43 Table of Contents Perfect Pick Cortex™ Operator Manual OPEX Corporation...
  • Page 5 3.2.1. Cortex workflow ................44 3.3. 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.
  • Page 6 5.2.7. Last Zone Interruption ..............123 5.2.8. Container Collision ..............124 5.2.9. All interrupted zones ..............125 Chapter G Glossary G.1. List of Acronyms ................. 128 G.2. List of Terms ..................129 Table of Contents Perfect Pick Cortex™ Operator Manual OPEX Corporation...
  • Page 7 1. Introduction 1.1. About This Manual ........8 1.1.1.

  • Page 8: Introduction

    1.1. About This Manual This manual contains information about the OPEX Cortex™ system and its operational procedures and safety-related components, including: • safety information, safety hazards and precautions • component identification and function • system specifications • operation and use This information is required to ensure proper and safe operation of the machine.

  • Page 9: Safety Message Conventions

    Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. NOTICE Indicates information considered important, but not hazard related (e.g. messages relating to property damage). See important safety information in Chapter 2: “Safety”. Introduction Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 10 (This page is intentionally blank) Introduction Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 11: Safety

    2. Safety 2.1. Safety Guidelines ........12 2.1.1.

  • Page 12: Safety Guidelines

    This section provides safety guidelines to be observed when working with this equipment. The Perfect Pick HD® and OPEX Workstation adhere to the NFPA 79 electrical standard for industrial machinery, which provides safeguards to protect operators, equipment, facilities, and work-in-progress from fire and electrical hazards.

  • Page 13: Arc Flash And Electrical Safety

    NFPA 70E, Standard for Electrical Safety in USA customers: the Workplace refer to CSA Z462-15, Workplace Electrical Safety Canada customers: refer to British Standards BS EN 50110-1:2013 Operation of EU customers: electrical installations- General requirements Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 14: Electrostatic Discharge Precautions

    • After removing a circuit board, place it either on an ESD-grounded mat or into an electrostatic shielding bag. • Always store and ship circuit boards in electrostatic shielding bags. • Never place anything else in the electrostatic shielding bag with the board. Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 15: Personal Protective Equipment (Ppe)

    - Hearing protection (ear canal inserts) - Heavy-duty leather gloves - Leather footwear (AN) Check with local law and the specific job site to find out what additional PPE is required before starting. Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 16: Safety Labels

    Follow the safety precautions on all labels when operating and maintaining the Cortex system. Failure to follow these precautions may result in severe bodily injury or death as well as damage to the machine. Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 17: Workstation Labels

    “Arc flash and electrical safety” on page 13). Table 2-1: Arc Flash and Shock Hazard warning label Label location Description US (8165700) Front of Workstation Control Panel CA (8165710) AU, EU, JP (8165730) Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 18 Description All (6088000) MANUFACTURER: DRAWING NUMBER: 6055400 SERIAL NUMBER : CORPORATION ##### MOORESTOWN, NJ (USA) VOLTAGE: FREQUENCY: 480VAC 60Hz CURRENT: PHASES: 3P+E SCCR: BUILD DATE: 200kA 08/2020 Front of workstation control panel Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 19 2.3.1.3. Fuse Chart label Inside hinged cover of Workstation Control Panel (Table 2-3). Location: Identifies the correct fuses needed within the control panel. Purpose: Table 2-3: Fuse Chart label Label location Description All (6088100) Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 20 Front of Workstation Control Panel (Table 2-4). Location: Identifies that the system has met agency approval qualifications. The Purpose: ETL label is not an OPEX label; it is provided by Intertek after field inspection is completed. Table 2-4: Agency Approval label Label location...
  • Page 21 (Table 2-5). Used to identify each of the zone locations for containers/boxes. Purpose: Table 2-5: Zone label Label location Description All (N/A) Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 22 Location: Identifies the sensor cover tool, and the location where it is used. Purpose: Placing the cover in this location blocks a sensor and prevents containers from entering the OPEX Scan Tunnel. Table 2-6: Sensor Cover labels Label location Description...

  • Page 23: Perfect Pick Operator Station Labels

    Perfect Pick Operator Manual. 2.3.2.1. Machine Entry label Both sides of the Pick Station (Table 2-7). Location: Informs that only approved OPEX technicians and qualified personnel Purpose: can enter the machine. Table 2-7: Machine Entry label...
  • Page 24 Pick can become jammed and/or damaged by foreign objects. Table 2-8: Keep Hands Away label Label location Description US (7686000) CA (7686010) AU, EU, JP (7686030) Pick station Pick station left side right side Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 25 Location: Advises personnel to read Instruction Manual for safe use. Purpose: Table 2-9: Safe use notice label Label location Description US (8074300) Front of pick station CA (8074310) AU, EU, JP (8074330) Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 26 Front panel door where the UPS is located (Table 2-10). Location: Warns about residual electrical hazard inside, and to disconnect UPS Purpose: power before servicing. Table 2-10: UPS voltage warning label Label locations Description US (2850900) AU, CA, EU, JP (2850910) Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 27: Emergency Stops (E-Stops)

    The exact placement of the body of this device depends on the site. Usually, it is mounted to the OPEX scan tunnel. The pull-cord runs the length of the work station, just below the side of the conveyor area.
  • Page 28 75-meter version requires higher tension. This means the 75-meter version can be used in place of a 38-meter version if you account for the tension setting. Figure 2-1: Pull-cord E-stop Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 29: Light Tower

    Once the technician determines that the machine is operating properly, he/she will turn off the flashing blue light by exiting out of Maintenance mode, leaving only the solid green light. Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 30: Lock-Out Tag-Out (Loto) Procedures

    (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 complete and the machine is safe to operate. Figure 2-3: Examples of LOTO devices installed Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 31: Lock-Out/Tag-Out Devices Required

    The LOTO procedures require the use of the Lock-Out Station (Figure 2-4) or an equivalent kit. This kit includes: Wall mountable container 4 keyed-different padlocks 2 Hasps 12 tags 12 Cable Ties Figure 2-4: Lock-Out/Tag-Out Wall Mount Station Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 32: Loto - Machine Maintenance And Repair

    Power down the PPIWS and install the lockout device as follows: 1. Notify all personnel that you are about to begin the LOTO procedure. 2. Place the “Caution” sign on the monitor (Figure 2-5). Figure 2-5: Caution Sign Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 33 3. Turn off the power switch on the Workstation control panel (see Figure 2-6). Main power switch Figure 2-6: Main power switch - off 4. Disconnect the ECAT_IN cable (Figure 2-7). Figure 2-7: Remove this cable Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 34 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 or damaged. The key must be kept in the possession of that Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 35 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 Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 36: Fully De-Energizing Ac Power

    “LOTO - Machine Maintenance and Repair” on page 2. Customer’s site maintenance personnel only: shut off the main AC disconnect switch and install a Lockout-Tagout device (Figure 2-10). Figure 2-10: Example- AC main disconnect with Lockout/Tagout Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 37: Restoring The Machine To Normal Operation

    9. Reconnect the ECAT-IN cable. Note: The ECAT-IN disconnect/reconnect needs to be clean and in one motion; any noise on the line will cause the InTime to crash. Should this occur, contact OPEX Technical Support. Safety Perfect Pick® Cortex™ Operator Manual...
  • Page 38 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 affected persons that LOTO devices have been removed and equipment is now ready for use. Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 39: Ergonomics

    • Maintain an upright body posture. • Occasionally change the angle of your posture for greater comfort. • Avoid operating the machine for longer than a single 10-hour shift. If possible, stretch between breaks. Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 40 (This page is intentionally blank) Safety Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 41: Overview

    3.2.1. Cortex workflow ........44 3.3. The OPEX Integrated Workstation ......47 3.4.

  • Page 42: Overview

    3.1. Overview Cortex™ is an OPEX software system that interfaces with the customers main Warehouse Management System (WMS), providing “work flow” control at one or more OPEX Perfect Pick machines, with or without a workstation. The Cortex equipment control system keeps track of local tote/cell inventory, and utilizes color-coordinated pick-to-light order progress indicators making integration with warehouse management systems (WMS) quick and easy.

  • Page 43: Cortex Workflow

    Incoming Staging Conveyor Scan Tunnel Workstation Outgoing conveyor Figure 3-2: Workflow - right side configuration Note: The workflows shown are for an automatic conveyor system, as opposed to a manual table mode. Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 44: Cortex Workflow

    - where containers enter the Cortex system. There is a Incoming conveyor sensor located before the incoming conveyor used to detect that items are properly coming from the customer’s conveyor system (see Figure 3-3). Figure 3-3: Incoming/outgoing conveyors Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 45 - this is where the containers are presented to the operator. Workstation Containers rest in zones, where they are monitored by the Cortex system for more information. “The OPEX Integrated Workstation” on page 47 Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 46 This conveyor has one “integration” zone with a sensor used to detect that items are properly exiting the Cortex system to the customer’s conveyor system (Figure 3-3 on page 44). Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 47: The Opex Integrated Workstation

    3.3. The OPEX Integrated Workstation As individual items are picked from the Perfect Pick®, they are placed directly into shipping containers or boxes on the OPEX® Workstation. Each container moves quietly along the conveyors and across the zero-height transfers to and from its pick-to-light (PTL) location.

  • Page 48: Perfect Pick

    Cortex monitor iBOT with tote Break-Away panel Workstation Clear To Pick light (partially shown) Start button E-Stop switch Pick Station controls Put Away Complete light Figure 3-6: Perfect Pick - Operator Station Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 49: Cortex Computer

    This is the computer which runs all of the conveyor systems. If anything happens with this computer and/or there is any type of maintenance needed, please contact OPEX Tech Support to troubleshoot and resolve the issue. 3.4.3. Bin Locator Light This optional feature is used to identify the specific area within the tote where the operator is to pick the item.

  • Page 50: Cortex Software

    The WRTC communicates to the Workstations or conveyors telling them when to move, and tracks the movement through the Workstations/Conveyors relaying it back to the AC so the WUI and PTLs are informed of the container location. Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 51: Aisle Controller (Ac)

    Perfect Pick tote. The AC will also send information to the Pick to Lights (PTLs) on the Workstation to illuminate the correct zone with the same colored light as the WUI. Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 52: Understanding Zones

    Incoming Outgoing Figure 3-10: Zone numbering - Zones 1-12 are found within the OPEX Workstation*. Workstation zones Zone 1 is always closest to the operator, and zone 2 is behind zone 1. Odd numbers continue across the front, and even numbers are across the back.

  • Page 53: Zone Sensors

    These sensors only know they should either be blocked or unblocked - they do not carry the information of the barcode for container identification. Figure 3-11: Zone sensors Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 54 3.6.1.1. A note about the Induction zone This zone is the entrance to the Cortex system from the warehouse conveyor system. This zone also triggers the cameras in the OPEX Scan tunnel to start scanning for barcode identification for each container entering the system. A jam at this zone is different than a jam at any other zone in the system.
  • Page 55 OPEX controls that sensor). This is the method described above, and if clearing a jam in the Induction zone, one sensor has to be covered. • Method 2 - A hand-off relay is used to signal the status of the OPEX induction zone, controlled via software. This is effectively a “ready-to- receive”...
  • Page 56 (This page is intentionally blank) Overview Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 57: Operation

    4. Operation 4.1. Starting up the system ........58 4.1.1.

  • Page 58: Starting Up The System

    Host software does not start with the machine, you can start it manually. 1. If the Host software is not already running, double-click on the Perfect Pick icon (Figure 4-1) on the desktop, OR click Start > Programs > OPEX > PerfectPick to open it.
  • Page 59 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 selected user. 4. Click Login. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 60 One of the most common views is found by clicking the iBOTs tab (see Figure 4-4). Figure 4-4: Run Screen - iBOTs tab Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 61 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 hardware Start buttons located at the Pick Stations. The Perfect Pick system will enter a Running state. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 62: Starting The Cortex System

    To stop the AC, you can use the Aisle-Stop command, this is only used for troubleshooting purposes (Figure 4-8). Figure 4-8: Aisle-Stop Command To stop the WUI, click the Exit button on the WUI window. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 63 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 4-9: Aisle Controller Desktop Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 64: Operating The Cortex System

    Note: Because the Cortex is customizable to a client’s needs, screen shots shown in this chapter may vary in appearance from those in your system. However, functionality should be identical. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 65 Welcome screen shown in Figure 4-10. Figure 4-10: Cortex Welcome Screen 2. Enter your password, then click Enter on the keyboard, or the Login button to access the software. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 66 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). Order detail Container detail Figure 4-12: Cortex WUI example Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 67 Quantity Item image Figure 4-13: Cortex WUI screen - detail 6. The OPEX Workstation is located on either the left or right side of the Perfect Pick (for more details on the OPEX Workstation, see “The OPEX 47). As the containers advance toward the Integrated Workstation”...
  • Page 68 If the first container was completed, it would be transferred to the back conveyor and move on for further processing, such as the addition of items from another area, QC monitoring, or to have Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 69 The other containers would advance, and the color-coding would also advance to follow the containers. Labeler Figure 4-15: PTL Bar Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 70 (a labeler is shown in Figure 4-15 on page 69). 9. Figure 4-17 shows an example where 32 items are needed for the first container, and one is needed for the second container. These quantities are Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 71 WUI first. When all items have been added to that container, press its colored button on the light bar. In this example, it is the blue button. The monitor then points to the next container that needs the Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 72 Depending on your operation, your system may not require a printer. Dashes indicate completed order Identifies container by scanned barcode Figure 4-18: Order completed example Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 73: Pick Mode

    The OPEX Cortex Inventory Control System will provide information as to when the job is finished. 4.3.1. Pick 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:...
  • Page 74 Cortex is showing in that tote, to the amount of inventory removed for both the order and any missing product (Figure 4-20). Figure 4-20: Product missing Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 75 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 order. Figure 4-21: Product Damaged Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 76: Put-Away Mode

    This mode is used for restocking inventory. 4.3.2.1. Put-away Steps 1. The Workstation User Interface (WUI) will present a screen similar to the one in Figure 4-23. The monitor shows “PUTAWAY.” along with the number Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 77 (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: Putaway screen Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 78 Overfilling the tote will likely cause over-height jams in the machine. 3. When complete, the operator presses the corresponding PTL button or the container icon in the WUI (Figure 4-25) and the tote is taken away for storage in the PPA. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 79 Figure 4-25: Press the Container button Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 80 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 4-26: Product Missing Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 81 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 4-27). Figure 4-27: Product Damaged Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 82 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). Figure 4-28: Product will not fit Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 83: Workstation User Interface Tabs

    ID that corresponds to that line of work, the Container ID that the work is being performed to or from, and the time that the work for that line was completed (Figure 4-29). Figure 4-29: Order Info Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 84: Details Tab

    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 for later consideration (Figure 4-30). Figure 4-30: Selected tab Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 85: Work Queue Tab

    The operator can also access the Hot Actions screen from this tab (for more information, see “Hot Actions” on page 88). Figure 4-31: Work Queue Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 86: Options Tab

    4.4.5. Options tab Allows setting language, and access to logs (Figure 4-32). Figure 4-32: Options tab Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 87: System Status Tab

    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). Figure 4-33: System Status Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 88: Hot Actions

    - allows you rearrange items in a tote to different cells Reconfigure tote better used for more than two cell configurations. • - allows you to select the site to which the product is attached. Sequence Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 89: 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 is a cycle count. Figure 4-35: Awaiting cycle count Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 90 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 count - work queue Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 91 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 screen Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 92 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 Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 93 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 4-39: Remove Product Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 94 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 removed. Figure 4-40: Recalled items Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 95 (Figure 4-41). Figure 4-41: Cycle Count When you enter the item number, it will populate with all the Units of Measure (UOM), the smallest unit is “EACH” - in other words, one single Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 96 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 Count button. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 97 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 right corner. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 98 Figure 4-44 that the Work Queue tab text is red, indicating work present on virtual conveyor (if not red, then no work is present). Figure 4-44: Cycle Count - Work Present Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 99 A circular arrow above the containers indicates Cycle count (Figure 4-45). Figure 4-45: Circular arrows indicate cycle count Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 100: Audit

    LPN (License Plate Number), Order number, or a single item order Line (Figure 4-46). Figure 4-46: Audit window This makes correcting orders faster and more accurate than trying to guess what tote was used. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 101: Consolidate

    This frees up the cells of the tote to become available for new items (Figure 4-47). Figure 4-47: Consolidate window Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 102: Cubing

    Put-away was presented. So now the system thinks only zero of the item can fit, no matter what UOM is actually in the cell (Figure 4-48). Figure 4-48: Cubing window Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 103 “No room for remaining work” (Figure 4-49). Figure 4-49: Cubing Error Message To correct a bad cubing quantity 1. Select the Order Info tab to confirm the item number in the system. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 104 Figure 4-50: Cubing Quantity Settings 3. When you change the quantities, the text will change to red. In this case 48 items and two trays are the correct settings, so no changes were made. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 105 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. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 106 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. Figure 4-52: Dismiss the order Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 107: Reprint

    4.5.6. Reconfigure Tote This allows you to change the tote’s cell configuration from a certain cell type to another. An example would be making a four-cell tote into a two-cell tote. Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 108: Sequence

    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. Figure 4-54: Sequence window Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 109: Preventive Maintenance

    4.6. 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*) • Conveyor sensors (once a year*)
  • Page 110 (This page is intentionally blank) Operation Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 111: Troubleshooting

    5. Troubleshooting 5.1. Overview ..........112 5.2.

  • Page 112: Overview

    Cortex operator screen. You can see each zone for the conveyor and its status (Figure 5-1). Figure 5-1: Conveyor view Figure 5-2 shows the legend that appears at the lower left side of the screen when there is an interruption. Figure 5-2: Interruption legend Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 113 To correct this issue, inspect the sensor at Zone 1, and remove the unwanted blockage. Once the sensor at Zone 1 is cleared, the system will clear the stoppage and continue running. Figure 5-3: Stoppage example Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 114: Workstation Interruptions

    (do not pick up) the container to center it in the zone. Once centered, press the Start button on the OPEX workstation or conveyor. The light tower will change to a green state, and all interruptions will be removed from the conveyor view in the monitor.

  • Page 115: Missed Window

    1. Find and inspect the missed barcode. Make sure the number on the screen matches the number on the container. 2. If it is in the correct location, lift the container up for one second and set it back down centered in the zone. Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 116 The Box must be removed from conveyor/workstation window appears, with a prompt to keep or remove the missed window. 4. Click Remove and you are prompted with a Dismiss option. 5. Click Dismiss. Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 117: Interrupted Zones With Missed Windows

    (Figure 5-7). Note: When you have a red “!” symbol, you will need to press the green Start button in the middle of the workstation. Figure 5-7: Interrupted zone with missed window Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 118: Missed Barcode Read

    (Figure 5-8). Figure 5-8: Missed barcode read To resolve a missed barcode read: 1. Select the missed barcode in the orange zone(s). Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 119 Enter License Plate field (Figure 5-9). Figure 5-9: Enter barcode 3. Once entered, click the Keep button (Figure 5-10). Figure 5-10: Click Keep button Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 120: Unknown Containers

    1. Remove the container from the unknown zone. Note: When you have a red “!” symbol, you will need to press the green Start button in the middle of the workstation. Figure 5-11: Container not transitioning Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 121: Duplicate Scan

    The light tower shows blue and green. The conveyors are not allowed to have the same license plate on the workstations or conveyors at the same moment in time. Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 122 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 (Figure 5-13). Figure 5-13: Duplicate Scan Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 123: Last Zone Interruption

    This happens with automated Workstations and conveyors where the OPEX conveyor is excepting hand-off containers from a third-party conveyor were extra containers do not receive the signaling to stop entering the OPEX conveyor. The light tower is usually red or Blue/Red if a missed window is present.

  • Page 124: Container Collision

    In Figure 5-15, the yellow container with the interruption needs to be placed back into zone 15. Figure 5-15: Container Collision Then the container needs to be rescanned into zone 15 (Figure 5-16). Figure 5-16: Rescan container Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 125: All Interrupted Zones

    (Figure 5-17). To resolve, reset the E-Stop and press the Start button on the workstation or conveyor. If resetting the E-stop does not correct this, contact OPEX Tech Support. Figure 5-17: Interlock tripped Troubleshooting Perfect Pick® Cortex™ Operator Manual...
  • Page 126 (This page is intentionally blank) Troubleshooting Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 127: Chapter G Glossary

    G. Glossary G.1. List of Acronyms ........128 G.2.

  • Page 128: List Of Acronyms

    - Warehouse Management System. The WMS application supports the day-to-day operations in a warehouse. The WMS enables the management of tasks such as tracking inventory quantities and item locations. - Workstation User Interface - Transceiver XCVR Glossary Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

  • Page 129: List Of Terms

    - This is the identifier on a package that is made up of a series of lines. Barcode These are read by the OPEX scan tunnel and/or optional barcode reader to identify the package. - Bins, totes, or boxes are the terms used for the container in which the product gets delivered.
  • Page 130 - A collection of the settings and 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 site supervisor or IT department.
  • Page 131 - A layer of system software acting as the central coordinator Traffic Controller for the OPEX wireless network. - This is a computer monitor/user interface that does not Touch screen Monitor need a mouse or keyboard.
  • Page 132 (This page is intentionally blank) Glossary Perfect Pick® Cortex™ Operator Manual OPEX Corporation...
  • Page 133 Utilizing a vast global workforce of direct employees, OPEX serves a variety of industries including financial services, insurance, healthcare, government, retail, non-profits, utilities, telecommunication, service bureaus, educational institutions and fulfillment operations.
  • Page 134 Perfect Pick® Cortex™ Operator Manual OPEX Corporation...

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