Horizontal Carousel Basics

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1 Horizontal Carousel Basics

2 Horizontal Carousels What Are They? - Moving Shelving - Oval Track - Bring Product to Operator - Space Efficient No Aisles

3 Machine Parts Non-Moving Parts - Gearmotor Inside Machine Frame Structural Steel Feet

4 Moving Parts - Upper Chain Drives Supports Load Guides Bin Carries Load Lower Chain Guide Only Machine Parts

5 Upper Chain Support in 8 Places Low Wheel Load for Less Track Wear High Capacity Components

6 Drive Direct Drive Few Parts to Wear & Maintain Cycloid Gearmotor 200% overload capacity 500% shock load capacity Occasional Inspection

7 Maintenance Drives Occasional Inspection Upper wheels No lubrication required Lower wheels Glass-filled polypropylene No lubrication required No zerk fittings, anywhere

8 3 Tiers Controls Portable Handheld Controller Operator Interface Keypad Machine Control Unit (MCU) Accelerate, Brakes, etc. RCC Interface to Software Additional Keypad Functions ANSI MH24.1 E-Stops & Eyes

9 How Are They Organized? 1 Moves While 2 Is Picked From Light Guided Pick By Software or PHC

10 How Are They Organized? Cell Sizes to Suit Storage Need Each Cell Pointed To By Pick Light Tower

11 Benefits Summary Quicker Picking Reduce Travel Time Bring the Product to the Operator Sequence Picks Pick Light Advantage Reduce Search Time Increase Accuracy Save Floor Space

12 Quicker Picking The Missouri Advantage Recognize Instructions Shelf Picking 10% 10% 8% Travel (w alk, fork truck) Locate and Recognize Wait, Mark and Dispose Pick The Important Bit 15% 57% 3% 12% 4% 5% 76% Carousel Picking

13 Pick-To-Light - Towers for Carousel Locations - Batches for Orders REMSTAR

14 Batch Station - Standard Configurations

15 Software Fastpic 4 Others

16 How Does Batching Work? Group Orders Software Selects Shortest Path for All Picks No Confusion Use Lights

17 How Do They Save Space? Customize Cell Sizes Change Shelf Pitches Higher Density No Aisles Access One End Only Use All Clear Height See Handout

18 Space Savings ' 17.5' 44.9' 50.0' Shelving 3' x 1.5' x 7' Bays Carousel 24.5" x 18" x 8' Carriers Space Savings 1,839 square feet, or 65.6%

19 The Space Savings Tool Existing Shelving System Shelf Width Shelving Bay Height Bay Gross Capacity Utilization Factor Net Used Capacity (Bay) Shelf Depth (ft) (ft) (ft) (ft 3 ) (ft 3 ) % 9.45 Overall Shelving System Dimensions Effective No. Double No. Single Shelving No. Bays / End-of-Aisle # Turning Spaces Along Shelving Shelving System Shelving # Bays Product Cube Shelving Rows Rows Aisle Aisle Width Turning Area Aisle System Width Length Floor Space (ft 3 ) (ft) (ft) (ft) (ft) (ft 2 ) Horizontal Carousel System Carrier Width Carrier Depth Carrier Height Gross Carrier Cube Effective Product Cube Carrier Cube Utilization Gross Cube Required Total # Carriers Needed # Machines # Carriers Per Csl Carousel Capacity System Capacity (in) (in) (ft) (ft 3 ) (ft 3 ) (%) (ft 3 ) (ft 3 ) (ft 3 ) % Carousel Length Carousel Width Additional Depth Space Betw Carousels Carousel System Length Overall Carousel System Dimensions Carousel System Width Carousel Floor Space Clear Height Required Space Savings (ft 2 ) Space Savings % (ft) (ft) (ft) (ft) (ft) (ft) (ft 2 ) (ft) % Try More Than One Area in the Warehouse - Make A Table of Results Shelving Carousels Savings Option # Ceiling Height Shelving L x W x H # Bays Effective Product Cube Floor Space Carousel Model No. Machines Carriers per Carousel Carousel Space Used Space Savings Space Savings (ft) (ft) (ft 3 ) (ft 2 ) (bin size) (ft 2 ) (ft 2 ) % Sample 8.5' 3x1.5x % %

20 What We Do.. Ask Lots of (familiar) Questions! What Do They Want To Do (Order Pick, Save Space, Low Ceilings.) How Many People Are Doing This Now? How Much Are They Picking? How Much Space Is Available? What Are They Picking? How Much Storage Have They Now?

21 And Then Budgetary Sizing Roughly Size The System How Many Carriers? Estimate No. of Pickers Needed Select No. of Carousels Per Picker Select Carousel Length Verify With Simulation Estimate

22 INPUT INFORMATION NEEDED OUTPUT Simulate Input Parameters Get Estimate Iterate Required Total Lines // Day Picking Hours // Day No. of of Workstations No. of of Carriers // Workstation 120 No. of of Carousels // Workstation 3 No. of of Carriers // System 120 Carrier Width (in.) 24.5 Approx. Carousel Length (ft.) 44.6 Av. No. Carriers // Carousel Carousel Speed (FPM) Average No. of of Lines // Order No. of of Orders 0 No. of of Stops // Tote 1 Average Lines // Workstation 1.0 Average Time to to Pick or or Put Commonality 0% Lines Per Hour Needed Per Time to to Transition Batches 0 Workstation 0 Lines/Hour (Workstation) WORKSTATION Workstation Throughput INFORMATION Available No. of of Orders // Batch No. of of Lines // Batch WORKSTATION THROUGHPUT AVAILABLE 234 Available Throughput: Lines // Hour with NO Commonality No 328 Commonality 178 With Commonality Available Throughput: Lines // Hour with Commonality SYSTEM THROUGHPUT AVAILABLE Available Throughput: Lines // Hour with NO Commonality Available Throughput: Lines // Hour with Commonality No. Orders // Batch

23 If More Detail Is Required SKU Distribution Test Number: Flowrack Weeks/MOays/Week Unsure 1 mo? ft 3 ; Large Test fo Flow Total Total 5 Daily in Items, < 1 Day Test for Rack SalonQT Lines Store Total 6 week Total 1 Total Cases if> 1 SKU Size Pieces / Consumpt Carousel Items Case Qty Y Salon 6mo Qty mo Qty Qty week Qty Daily Qty Case (in 3 ) Day ion, ft 3 Items (ft 3 ) (ft3) Large Large USHIO Large Large Large Large ORS Large Large ELUX Large Large CRE Large Large Get SAL S 1 4 Customer Data Large Large DY LO Large Large OT A Large Large REIN Large Large Large Large N SHA Order Large Large Data. WER Large Large ENTE Large Large RBET Large Large NANA Large Large D CHO Large Large RED Cube Data Large Large A Large Large FLO Large Large OO Large Large NCIN Large Large Large Large FTER Large Large Case Flow Lanes Each Pick Flow Lanes Pallet Flow Lanes Pallet Pick - Large Items Carousel Items Analyze It

Commonly Asked Carousels Go Both Ways Questions Each Carousel Will Make Less Than One Full Revolution Each Per Batch of Orders Carousels are Very Reliable

24 Commonly Asked Carousels Go Both Ways Questions Each Carousel Will Make Less Than One Full Revolution Each Per Batch of Orders Carousels are Very Reliable Machines History Shows That Properly Maintained Carousels Have Very Little Down Time Software Does Not Break or Wear Out When Properly Tested and Implemented

25 Distribution Applications What Belongs in Handle One Month Supply per SKU 10 to 40% of the SKU s; up to 16FT 3 / SKU Top 15% in Flow Rack or Pallet Picking Others May be in Shelving Carousels? Excess Replenishment Demand is a Sign of Poor Slotting

26 Storing Stocking is Everything The Most Important Past of a Quality Design is the Replenishment Portion Random Storage is Always Better Multiple random locations typically will improve cube utilization, throughput and load balance Restock 5% of The SKU s Per Day

27 System Flow Keep Things Simple - Carts Often Work As Well As or Better Than Conveyor Few Restrictions to Material Flow and Work Zones Velocities In & Out Can Be Very High Much Less Expensive No Maintenance Work Zone Flexibility

28 Start Simple For Design, Concept and Initial Budget A Three Carousel Work Zone of 40 Bins Per Unit is a Good Start 3 Carousels Are Always Better Than 2 Operators Rarely Wait in a 3 or 4 Unit Design

29 Start Simple Shorter is always Better Beware Horizontal Carousels that are Too Long or Too Tall Always Design Excess Capacity Don t Exceed 80% of the Demand or the Cubic Capacity

Order Fulfillment Strategies for Low Velocity Inventory

Order Fulfillment Strategies for Low Velocity Inventory Presented by: Ken Ruehrdanz 2018 MHI Copyright claimed for audiovisual works and sound recordings of seminar sessions. All rights reserved. Order