For each new collection, the Barcelona facility performs two completely different types of
distribution. When a new collection is ready,
large shipments are sent to all outlets within a
few weeks so that the collection can be introduced worldwide at about the same time.
These first shipments of the collection, called
“initials,” represent very high volumes and are
processed within a tight delivery window.
Once the collection begins to sell, the facility shifts gears and sends out “repeats” to
restock products on store shelves. The repeat
orders, which are a fraction of the size of the
initials, are shipped more frequently to ensure
stores are kept stocked.
Distributing orders as dissimilar as the initials and the repeats requires material handling systems that are extremely flexible. The
systems also have to be able to track the entire
inventory with precision and know how it is to
be allocated to orders.
After experiencing growth of about 40 percent annually, Desigual’s managers realized several years
ago that the company’s manual distribution processes
wouldn’t be able to keep up with demand much longer. In
2010, the company worked with SSI Schaefer to design a
highly automated system that could handle the diverse distribution tasks required by Desigual’s seasonal collections.
The design took into account the fluctuating volumes, the
high SKU count, and the need to balance workload.
The solution features a one-of-a-kind picking and sorting
solution supported by conveyors and automated storage
and retrieval systems (AS/RSs), along with sophisticated
software to manage it. In combination, these systems allow
the facility to select and distribute some 100,000 articles of
clothing daily.
“In our old manual operation, it took 100 people to do
30,000 pieces a day,” recalls Sergio Castresana, Desigual’s
logistics manager. “Now, we do 100,000 pieces each day
with fewer people. And we have a lot of control, and our
service rates are very high.”
FAST FLOW-THROUGH
The facility is engineered to flow goods through the operations with minimal human intervention. Pallets holding
uniform-sized cartons of products are stored in a nearby
warehouse located about three miles away. The pallets are
trucked to the facility and offloaded using pallet jacks. The
loads are then taken to a receiving area, where boxes are
removed from the pallets and placed onto plastic trays. A
tray ID and a box bar code are scanned to “marry” the tray
to the product it holds. A worker also opens the top of each
box so that the items, which are pre-ticketed, can be easily
removed later in the process.
The box is next sent through a banding machine, which
places a plastic band around it to add strength and to maintain its integrity so that it won’t bulge on the sides. This
assures that it will be a uniform size and won’t catch on anything as it passes through the conveyors and other automated systems.
Conveyors, supplied by SSI Schaefer Peem, then transport
the trays to an AS/RS. This system contains six aisles and
90,000 tray storage locations. The building housing the
AS/RS is rack supported and covers 9,400 square meters, or
101,180 square feet. Despite their small footprint, the racks
are capable of storing 3 million articles of clothing.
A crane in each aisle gathers the boxes as they arrive and
deposits them into the racking, with faster-moving items
placed closer to the near ends of the aisles. When items are
needed for orders, the same cranes collect the trays and
their boxes and deposit them onto takeaway conveyors for
transport to the main sorting system.
The boxes of products are delivered to four pick stations
that act as induction points for the sorter. The source tray
holding the box is automatically scanned as it arrives, and a
lighted display above the station tells the worker how many
items to pick from the box. Since the tops of the boxes were
removed at receiving, the products, most of which are folded garments in polybags, are easily retrieved.
Workers use both hands, quickly alternating, to select
items one at a time from the source box. They place each
product onto an induction conveyor belt within the station
that feeds the sorter. A sensor detects the motion of the
worker’s hands as items are pulled out of the source box,
automatically counting down the remainder needed from
that carton and showing that number on a lighted display.
This allows for extremely fast picking, as it frees workers
from having to worry about color, style, or SKU numbers.
All they have to do is follow the prompts. This design makes
it possible for just a few workers to select 3,600 pieces an
hour from about 900 source boxes, on average.
