Zero-Variance Packing: ARM Robot Integration with Oracle ERP

Boostech collaborated with Kapal Api and several robotics vendors to develop an ARM robot system handling warehouse packing in a precise, integrated manner. We process data from production lines and robotic arms, then synchronize it with Oracle ERP, providing real time counts of processed lines and boxes while targeting zero variance between physical inventory and system records.

Overview

During the initial automation phase, Kapal Api adopted ARM robots for handling and packing operations. The main challenge was ensuring all production counters, boxes/pallets, and robot statuses were accurately recorded and automatically posted to Oracle without manual input. Boostech designed an end-to-end data architecture from shopfloor data acquisition, validation & reconciliation, to transaction posting in Oracle so operational decisions and warehouse planning are based on consistent numbers across shopfloor and ERP.

Challenge

• Multi Vendor & Multi-Protocol: Robot controllers and line devices generate data in different formats.

• Zero Variance Accountability: Eliminate gaps between physical counts and system records.

• Traceability: Track box → carton → pallet and origin line for audit and quality claims.

• Real Time Visibility: Supervisors need dashboards showing throughput, downtime, and anomalies.

• Robustness: Data must remain secure and auto sync once the network/ERP is back online.

Our Solution

1. Architecture & Integration

• Edge Data Acquisition: PLC/robot controller data collection via OPC-UA/MQTT/REST, tailored per vendor.

• Normalization & Validation Layer: Standardize tags, SKU mapping, units, and events (pick/place, seal, reject).

• Counting & Reconciliation Engine: Handles de-duplication, rework/reject processing, and auto recount.

• Two Way Oracle Integration: API/interface for posting transactions, updating on hand inventory, and providing feedback status.

• Fallback Store and Forward: Edge buffer ensures data retention during connection outages.

2. Operations & Governance

• Production & Warehouse Dashboard: Throughput per line/shift, OEE snapshots, exception lists.

• Labeling & Traceability: Carton/pallet ID (barcode/QR) linked to batch & origin line.

• Alert & Exception Handling: Detect mismatch, miss scan, or idle time with notifications to responsible PIC.

• SOP & Training: Guidelines for error handling, re-scans, and cutover to integrated processes.

Result

• Zero Variance: Physical vs system counts eliminated in warehouse packing.

• Single Source of Truth: Line, box, and pallet data consistent across shopfloor and Oracle.

• Faster Closing: Daily reconciliation accelerated with no repeated manual input.

• Real-Time Control: Supervisors monitor throughput, downtime, and anomalies instantly.

• Audit-Ready: Full traceability (line → box → pallet) simplifies audit and root cause analysis.

• Scalability: Multi vendor design allows additional lines/robots with minimal rework.