DC Velocity - November 2010

materialhandlingupdate AUTOMATED SYSTEMS

WarehouseRx warehouse control system (WCS). Typically, the system uses a round-robin approach to assigning storage locations, so that product is spread evenly across the aisles.

Twelve storage/retrieval cranes operate within the system, one in each aisle. As the STVs discharge their loads, the cranes gather them up and deposit them in the predetermined locations. Collectively, the cranes, which can move loads of up to 1,200 pounds, handle 60 to 70 pallet loads an hour.

Since the system uses randomly assigned double-deep storage, one SKU may be placed in front of another (the cranes have the capability to shuffle pallets around to gain access to the right item). The WCS will also attempt to assign faster-moving SKUs closer to the aisle’s input/output station to save time during putaway and retrieval.

When pallets are needed to fill orders or replenish the facility’s pick modules, the WCS dispatches several cranes simultaneously to gather pallets from multiple aisles. The cranes deposit the loads at drop-off stations, where the STVs gather them up and ferry them to one of two conveyor outputs. Lift trucks then collect the pallets for transport. Pallets that will ship to customers as full loads are taken directly to the outbound shipping docks, while other loads are taken to the pick modules to be used for replenishment purposes.

Orders for wholesale and retail customers and for con-
sumers who place orders via the company’s website, pot-
sandpans.com, are filled in the pick modules, which are set
up to support both full-case and split-case picking. The
items selected are conveyed to one of two shipping sorters,
depending on where in the modules the picks were made.
One is a pop-up sorter supplied by Hytrol, while the other
is a sliding shoe sorter provided by Automotion. From
there, the cartons are sorted to outbound docks.

Putting a lid on it

As for how it’s all working out, Warcholski says the Fairfield facility has realized a number of benefits from the AS/RS. For one thing, the new setup has allowed the company to bring everything under one roof, which has greatly simplified the distribution process.

“When you manage multiple facilities, there is a lot of
jumping through hoops as you have multiple inventories to
manage,” says Warcholski. “It is much easier now to manage
the flow and our processes.”
For another, the setup has eliminated the need for double
handling. As a result, Meyer can now get its products to
market faster and is experiencing less product damage.

“It’s almost a slam dunk,” Warcholski says of the project overall. “As a company, we want to be on the cutting edge. This has allowed us to maximize our storage density and has shortened the window of time it takes to execute our orders.” ;

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