topic Empty pallet back using operator when robot has removed boxes from pallet in FlexSim Forum

Empty pallet back using operator when robot has removed boxes from pallet

kwaghchoure — Thu, 07 May 2026 04:10:11 GMT

Hello everyone, I am new to flexsim and need support to toruble shoot the process flow logic. I created a simple process flow; Create pallet-->load pallet to station (op1) --> Load pallet with boxes (op2) --> move full pallet to another Queue (op1) --> unload boxes from full pallet to conveyor (robot)

Problem statement:

1. My op1 is not picking up empty pallet after robot has emptied the pallet

2. My boxes after unloading them to conveyor by robot are disappearing

3. HOW DO I OPTIMISE MY OPERATOR1 PROCESS FLOW. (any easy way to group operator activity by Decision)

4. Do i really need to have so many list or their is a way to optimize the list

Can someone help me updating the process logic please ?

Thank you.

Re: Empty pallet back using operator when robot has removed boxes from pallet

moehlmann_fe — Thu, 07 May 2026 07:06:44 GMT

1) The empty pallet is not pushed back to the correct list at the end of the robot flow (Decide activity and Push to List are not connected).

2) You swapped the load and unload activity. The item is first 'unloaded' onto the conveyor and then loaded by the robot -> All items accumulate in the robot.

3) I don't see much optimization potential here. I guess the task sequence could be implemented as a subflow to save a couple activities.

4) You could utilize partitions, essentially splitting the list into multiple 'sub-lists'. They can be specified in the Push to List and Pull from List activities. Note that a pull action can only access a single partition.

Re: Empty pallet back using operator when robot has removed boxes from pallet

kwaghchoure — Thu, 07 May 2026 21:55:49 GMT

Hello, thank for the feedback and model. This was super helpful.

I have modified the flow little bit to test another logic with 2 conveyor in parallel and ran into 3 different challenges.

Problem statement1: I am using decided function to tell operator which queue to load based on station pallet availability. Its loaded 1st & 2nd station but not 3rd one. Not sure why. Can you please look into my logic
Problem statement2: On my conveyor I have station which is inspection station. I have created custom code which I used in past on processor to label item as NOK =1 if bad part and NOK =2 if good part. This logic is not working, I am not getting error but item is not showing any label and its value
Problem statement3: Robot1 need to load the item based on NOK value 1 NOK value 2. I have two station for good parts and 1 station for bad part.
1. Robot is not loading parts on to pallet. Can you look in to the logic. Logic was working fine yesterday.
2. To load item into pallet based on its NOK value, should we use decided function with connection by case? what should be my condition in that case. Can you help to setup that part of decision logic please in my model.
  1. One thing to not, robot can only load one good and one bad pallet at same time. So i am guessing 1st I need to use decision to see which queue has a pallet. My scrip is not recognizing that decision condition as well. Can you see the decision on created on extreme is correct to see content. And how do we force the robot to load the same good pallet till its full before moving to next good pallet.

I greatly appreciate the support.

Thank you

Re: Empty pallet back using operator when robot has removed boxes from pallet

kwaghchoure — Tue, 12 May 2026 03:18:33 GMT

Hello, could someone please assist with my request? Being relatively new to FlexSim and having limited exposure to Process Flow, I am currently finding it challenging to set up the models correctly.

Thank you.