CERP Rouen. A Custom Project for Optimizing Logistics

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1 CERP Rouen A Custom Project for Optimizing Logistics

2 case study - CERP Rouen CERP Rouen is a company in the ASTERA group. CERP Rouen delivers to more than 600 pharmacies in the greater Paris area and beyond to all subsidiaries in France from its warehouse in Le Plessis-Robinson. SSI Schäfer has been the intralogistics partner for CERP Rouen right from the beginning of warehouse construction in 2000 and is responsible for implementing the logistics system. As a result of strong activity growth in 2010, CERP Rouen revenues rose by 16 %. In the face of steadily growing demand by their customers, the warehouse at Le Plessis-Robinson reached the limits of its capacity in Aim of the Project After an in-depth analysis of the order data, SSI Schäfer was able to design and develop a custom solution by bringing in new automated components. Two challenges arise from the retrofit: The installation and start-up of the system without disrupting operations as well as integration of the new system components into the existing structure. What makes this project especially interesting is in the combined usage of technology installed in 2000 and the new automated components from SSI Schäfer s product portfolio. The retrofit led to the integration of a new 1,590 meter long conveying system while keeping the 1,720 meters of existing conveyors.

3 t Address Insertion Goods-in work stations Schäfer Carousel System Solution by SSI Schäfer Material flow at CERP Rouen follows these steps: The supplier s goods are delivered in cartons on stacked pallets. After unloading, the cartons are placed manually onto the conveying system that leads to the work stations in the goods-in area. Picking according to the goods-to-man principle is the basis of this retrofit. Although CERP Rouen chose the automated S-Pemat system in 2000, the goal of the new project is to improve picking of items with a lower turnover rate. The Schäfer Carousel System (SCS) is thus used to replace a large part of the static racks. The combination of the SCS with the Pick to Tote work station enables picking of more than 50 % of the items with medium or slow turnover rates. After the orders are picked and before the goods are assigned to individual customers, the totes are conveyed to the picking stations in the shipping area. At the first picking station, where up to 1,800 totes per hour can be processed, the combined process of adding the address label and the lid is carried out. The next station ensures the totes are securely closed before delivery using a strapping process that hermetically seals the lid to the tote. Customer orders are transported to the pharmacies via delivery truck and larger amounts of palletized goods are sent to CERP Rouen s subsidiaries at the same time.

4 case study - CERP Rouen Implemented SSI Schäfer Systems and their Impact on the Client s Facility Ergonomic processes in goods-in The design of the goods-in process is the result of a close cooperation between CERP Rouen and SSI Schäfer. This combined two-stage process meets the specific needs of the company precisely. Next, the cartons from the supplier or the ones being transported on the conveyor are scanned so that the inserts can be assigned to cartons that they will be inserted into. After filling, the inserts are placed in the colli flow rack and are moved by gravity to the next step in the goods-in process. After the empty storage totes are registered at the scanning station, they reach the picking station where the picker removes the empty inserts and replaces them with the previously filled inserts in the colli flow rack. After they are filled, the storage totes are transported automatically to the Schäfer Carousel System. Pick-to-Tote u Schäfer Carousel System Softfall A-Frame

5 Schäfer Carousel System and Pick to Tote Work Stations The combination of the Schäfer Carousel System and the removal location at the Pick to Tote enables the high performance picking of items with medium and slow turnover rates. The goods stored in the carousel are transported to the picker at the Pick to Tote station, whereby a picking performance of 1,000 picks per hour can be achieved. The order and storage totes needed for this are also transported to the station according to a defined sequence. The Pick to Tote work station was designed according to two main criteria: According to ergonomic concept where the picker is the center point and error-free picking of orders. A light curtain is installed for this purpose above the insertion chute to ensure the correctness of the items, the quantity and for releasing totes for which picking is finished for transporting away. A-Frame At CERP Rouen, the S-Pemat that was installed in 2000 is responsible for picking orders for fast-moving items. Its collecting belt over 100 meters in length is the longest Pemat line that was ever built worldwide. The items are dispensed into a virtual window on the collecting belt; each Pemat channel has its own ejector. The items are transported to a filling point where they are loaded into the respective order tote. Softfall The innovative Softfall concept was installed for the first time by SSI Schäfer at CERP Rouen. This mechanism transports the empty totes without power from a higher level onto a lower one. The totes are gently transported downwards solely by gravity and air cushioning effect. The totes from the order start area on the upper floor are transported by softfall to the manual picking area for refrigerated products on the ground floor. Customer statement Over the years we have built up a relationship with SSI Schäfer based on mutual trust and cooperation and developed a partnership that goes far beyond a mere customersupplier relationship. Proof of this is the project at Le Plessis-Robinson in which we developed all feed-in lines for supplying items to goods-in work stations together. Jérôme Ibar, Director Automated Systems

6 case study - CERP Rouen Facts and Figures System Key Figures Warehouse size m² Number of references Number of totes / day Number of items / day Number of items picked Number of picks / day ``in warehouse ``SCS ``Automat Number of shifts / day 2 Scope of Delivery and Services Conveying system Picking ``Pick to Tote 2 ``A-Frame Schäfer Carousel System meters long with 33 modules System components Softfall Lidding and address insertion 2 Strapping machine 2 Software Solution WAMAS

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