AUTOMATIC ORDERPICKING

Transcription

1 AUTOMATIC ORDERPICKING TREND OR ONLY A NICHE APPLICATION Jan van der Velden Logimat Slide 1, draft logimat Jan van der Velden

2 l CONTENT l Introduction Man-to-goods systems Goods-to-man systems Automatic orderpicking Examples - Fresh food - Fast moving consumer goods - Industrial supplies - Fashion Conclusions Slide 2, draft logimat Jan van der Velden

3 l INTRODUCTION l receiving storage picking packing consolidation shipping Material flow Customers Requirements Slide 3, draft logimat Jan van der Velden

4 l INTRODUCTION l Warehousing cost (traditional warehouse) Receiving Orderpicking Storage Shipping Orderpicking most expensive component in warehousing Slide 4, draft logimat Jan van der Velden

5 l INTRODUCTION l Specification orderpicking Travelling Searching Extracting Paperwork/other Most time needed for travelling Slide 5, draft logimat Jan van der Velden

6 l MAN-TO-GOODS SYSTEMS l Orderpicking Single order, single zone 1 picker, 1-n orders Supported by carts Limited to medium # SKUs Medium # lines per order Zone picking Single order, multiple zone 1 tote contains 1 order Pick pack is possible High # customers Small to limited # lines per order Limited to medium volume per order Batch picking Two steps, multiple zones Step 1: batch picking Step 2: Sorting to orders Medium # customers High # lines per order Minimal distance Slide 6, draft logimat Jan van der Velden

7 l GOODS-TO-MAN SYSTEMS l Compact picking Warehouse with miniload cranes - Classical frontzone solution - Dynamic replenishment of pickface High # customers Limited # lines per order Especially for slow and medium movers (B and C articles) Order Distribution System (ODS) Single step, multiple zones 1 tote is linked to 1 order Orders have a static location, products travel through the system (Reversal of zonepick) High # customers Limited # SKUs Medium # lines per order More items per pick Slide 7, draft logimat Jan van der Velden

8 l AUTOMATED PICKING l Supplier Retail DC Outlet Consumer Pallet Palletlayer Carton/tote Item Scope automated picking Slide 8, draft logimat Jan van der Velden

9 l AUTOMATED PICKING l Reasons automatic picking - Scarcity of labour - Ergonomics - Short delivery times - High accuracy - Cost reduction - Regulation Slide 9, draft logimat Jan van der Velden

10 l FRESH FOOD l Production (daily) Labelling Tote filling Storage Picking Characteristics - Pressure of retailers Cost reduction Short delivery times High quality/freshness High accuracy Standards (e.g. HACCP, BRC) Sequence requirements on pallets / rollcages - Efficient space utilization - Scarcity of labour - Tracking & tracing (EC 1760/2000) Shipping Slide 10, draft logimat Jan van der Velden

11 l FRESH FOOD l Production (daily) Labelling Pick & place robot Robot portion loading (AEW Delford) Tote filling Pick & place robot Automatic tote filling (ABAR) Slide 11, draft logimat Jan van der Velden

12 l FRESH FOOD l Storage Picking Micarna Batzenheid (Ch) - Automatic orderpicking - Automatic labelling - Palletizing in route and store sequence Rack Stack System (RSS) - automatic picking full totes - automatic stacking Manual picking of items Slide 12, draft logimat Jan van der Velden

13 l FRESH FOOD l Flexibility - Possibility to work in advance - High performance because of working in stacks - At peakdays, the percentage full stacks and full totes increases Attention points - Standard totes - Assortment Slide 13, draft logimat Jan van der Velden

14 l FRESH FOOD l Shipping Automatic palletizing - route sequence - store sequence Gantry Robot (Güdel) Slide 14, draft logimat Jan van der Velden

15 l FAST MOVING CONSUMER GOODS l Receiving Put away Storage Picking Pallets: Layers: Cases: Items: Superfastmovers Fastmovers Mediummovers Slowmovers Characteristics - High throughput - Short delivery times - High accuracy - Store friendly delivery - Efficient space utilization - Scarcity of labour - Efficiency - Broad assortment - Variety in products, packaging, weight etc. Shipping Slide 15, draft logimat Jan van der Velden

16 l FAST MOVING CONSUMER GOODS l Layer picking Slide 16, draft logimat Jan van der Velden

17 l FAST MOVING CONSUMER GOODS l Flexibility - Layers gives enormous flexibility on stacking different products - Capacity hardly influenced by carton size Attention points - Selection of gripper - How to process small % of non-mechanisable SKU s Slide 17, draft logimat Jan van der Velden

18 l FAST MOVING CONSUMER GOODS l DLS (Dynamic Logistic System) Slide 18, draft logimat Jan van der Velden

19 l FAST MOVING CONSUMER GOODS l Flexibility - Overcapacity individual modules Attention points - High investment per SKU, so make sure SKU range doesn t grow significantly in the near future Slide 19, draft logimat Jan van der Velden

20 l FAST MOVING CONSUMER GOODS l Case Order Machine (Witron) - Fully automatic picking of cases on pallets and rollcages - Software generates optimal pallet stacking - Broad article range (cases on tray), independent of product characteristics - High accuracy - No people involved - Attention point: Arrival in right sequence Slide 20, draft logimat Jan van der Velden

21 l INDUSTRIAL SUPPLIES l Automatic roll cage / pallet loading Gantry robot Würth s-hertogenbosch (NL) Robot on track Borstlap Tilburg (NL) Slide 21, draft logimat Jan van der Velden

22 l FASHION l Full Case picking (Nike, Laakdal, Belgium) Miniload storage of cartons on tray Automatic retrieval, labeling and shipping Slide 22, draft logimat Jan van der Velden

23 l CONCLUSIONS l Automatic orderpicking is at breakthrough Many new developments Broad applicable - different process areas - different industry groups Focus on carton / case picking Item picking remains manual Slide 23, draft logimat Jan van der Velden

24 l CONCLUSIONS l Handling must be stationary, product on the move Pay-back of 3 years is realistic if operated in: - 2 shifts for simple processes such as layer picking - 4 shifts for complex processes such as rolcontainer loading in a prescribed sequences from a large range of SKU s Slide 24, draft logimat Jan van der Velden

25 l CONCLUSIONS l A Warehouse with many logistic operators Logistic Factory with few machine oprators Be Aware of this Transformation Slide 25, draft logimat Jan van der Velden

26 Slide 26, draft logimat Jan van der Velden