@anthony.johnson I just used the process flow merge controller from your article "Process Flows for Two Types of Merge Controller" - specifically the Fixed Gap version. It works fine for one of the two merges in my model, but the second merge actually uses accumulating slug conveyors, and these don't always work as well.Specifically, if items are continuing to arrive, it appears that the slug conveyor will continue to add them to the slug after it has been released. The result is that these extra items tend to collide with items from the next lane released. (Or you could look at it as the next lane is released to early, because it didn't know about the added cartons).
I spent some time experimenting with some of the time calcs in the process flow, but wasn't able to get it to work consistently enough. Can you suggest a way to either stop the slug conveyors from adding the extra items, or for the next release to account for them?