PART V | LESSON 23: RECOVERY, DIAGNOSTICS, AND THE OPERATOR MATERIAL HANDLING ACADEMY

Lesson 23 Worksheet: Recovery and Exception Routing

Give every failure a destination first, then size the hospital lane, then write the Riverside recovery note. Each is a carton, moving, that has to go somewhere real in the next second or two.

Exception-Routing Drill

Every entry in the handshake failure taxonomy needs a real destination at runtime, or it stops the line. For each failure mode below, write where the carton goes: a backup lane, recirculation on a loop, or the destination of last resort, the hospital lane.

Failure modeDestination and recovery at runtime
No-read
Lost track
No destination returned in the window
Reject criteria failed
Lane-full with no alternative
Unknown item the WMS doesn't recognize

Size the Hospital Lane

The hospital lane is a throughput element, sized for exception volume, not system volume. The method is one multiplication: system throughput times the expected exception rate. Fill in your own numbers.

Illustrative only. Any percentage you fill in here is a placeholder to show the method, not a measured rate for a real system.

  1. System throughput at the sort point:   cartons per hour.
  2. Expected exception rate:   % no-read +   % reject =   % routed to the hospital lane.
  3. Exception volume: throughput × exception rate =   cartons per hour the lane has to clear.
  4. Design check: the operator and the re-induction path have to move at least that many an hour, plus margin for a peak burst, or the lane backs up into the sorter.
RIVERSIDE PROJECT NOTES