DC Velocity - August 2011

are deposited onto conveyors for transport to the tray AS/RS. Eight Qubiqa (formerly Univeyor) layer picking machines depalletize cases, utilizing suction to remove layers from the incoming pallets. The cases in each layer are then deposited onto a conveyor, where they are singulated into a line and made ready for transfer onto trays. A second conveyor carrying empty plastic trays of two sizes travels in line directly below the case conveyor. The system assigns a tray of the appropriate size to each case. As the products reach the termination of the upper conveyor, the cases are gently dropped off its end onto a passing tray below. A vision system monitors the activity to assure that the transfers onto the trays have been completed without error.

The trays holding cartons of products are next conveyed to the large automated tray system. This mini-load AS/RS consists of 44 cranes (supplied by TGW Systems) and holds more than 400,000 trays. The cranes, which are designed for speed and efficiency, are engineered to handle either two larger trays or four smaller trays at a time. The cranes take the loads to assigned storage positions, with each position also able to hold either two large trays or four small trays.

portation costs. The wrapping process makes sure they’re secure. A label is added to the wrapped pallet and the load is picked up at the end of a spur by a lift truck that takes it to an assigned outbound dock.

One of the benefits of automation is that Supervalu has better knowledge of the cube of its products. And since the system is picking products in sequence, the company can build fuller pallets and better optimized loads.

“We now cube our loads better than in the past and have since seen a reduction in the total number of outbound loads, which has resulted in transportation savings,” explains Kroutch.

Overall, the automated system can handle some 10,000 cases an hour. It operates for 20 hours a day, seven days a week.

While the automated systems handle the majority of products flowing out of the facility, some piece picking is also performed using labels. These items are picked into totes. RF picking is also utilized in the picking of products not suitable for the AS/RS systems. These are stored in conventional pallet racks.

MADE TO ORDER

Products remain within the mini-load for two to three days until they are required for fulfillment. At that time, the system gathers trays of products needed for orders and conveys them to a system containing 44 sequence buffers. This buffer system contains 44 cranes (also supplied by TGW Systems) that act as elevators to move the trays into temporary holding positions, where they remain until the order is ready for release. At that time, each tray is released in sequence for building pallets. The sequence of cartons assures that the pallet load is built to be stable and with items grouped by family for ease of putaway at the stores.

Pallet building is completed in an area known as the COM (case order machine). This system employs a pushing mechanism as opposed to the common practice of using robotic grippers to remove cases from the trays. As trays bearing products enter one of the system’s 22 COMs, they pause on the conveyor. Metal fingers then rise from the conveyor below, poking through the small holes on the tray to gently lift the case above the tray surface. An arm then sweeps the product off the tray and onto an inline palletizing system. Heavier products typically are used for the bottom layer of the pallet, with cartons of different sizes added on top to create mixed-SKU pallets in layers that produce a stable load. Reusable plastic pallets are used for shipping.

Pallet loads next go to one of the facility’s four wrapping machines, supplied by Strema. The pallets built at the Lancaster facility are taller than typical pallet loads in order to improve cubing within the system and reduce trans-

ROOM FOR GROWTH

Since moving to the OPM, Supervalu has been able to feed nearly 200 Acme “Our fulfillment accuracy has been outstanding,” says Fritz.

Since the OPM takes only about 60 percent of the space required for conventional picking systems, space has been opened in the facility for future growth, including eventual expansion of the Witron systems. The OPM can handle more than 91 percent of the current SKUs, and Supervalu is looking at increasing that percentage as it works with vendors to package products in ways that are automation-friendly. Because of the smooth handling of the automation, safety has improved and product damage and shrinkage are down, as is the amount of labor needed for the Lancaster operation. Since the system picks in sequence, labor has also been saved at the store level in restocking shelves.

“Customers say they are amazed—that is the word that comes out all the time,” says Kroutch. “They see the efficient movement of our products, the smoothness, and how well the system handles the products without any damage. They also see the quality of the loads as they arrive at their back doors. The facility is now meeting our expectations and getting the ROI we need. And it is designed to give us the ability to grow.” ;