McGRAW-HILL Distribution Center Upgrades Improve Shipping Capacity and Reduce Maintenance Requirements for Educational Publisher
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1 McGRAW-HILL Distribution Center Upgrades Improve Shipping Capacity and Reduce Maintenance Requirements for Educational Publisher Case Study
2 Distribution Center Upgrades Improve Shipping Capacity and Reduce Maintenance Requirements for Educational Publisher Leaders of Information Please note: Honeywell Intelligrated within this case study refers to Intelligrated, which Honeywell acquired in McGraw-Hill Education is one of the few leaders of the information age whose origins go back to the industrial revolution. In 1899, James H. McGraw created The McGraw Publishing Company, incorporating his technical and trade publications. A few years later, in 1902, John A. Hill started his own firm, The Hill Publishing Company. By 1909, the pair s mutual interest in science and technology led to an alliance, and the book departments of the two publishers merged to form the McGraw-Hill Book Company. Following Hill s death in 1916, the remaining parts of the companies combined to form the McGraw-Hill Publishing Company. Over the next few decades, McGraw-Hill steadily increased its textbook offerings for college-level students. By the mid-1930s, the company had developed specialties in business, management and the social sciences, adding to its core strengths in engineering and science. It was the baby boom, however, that prompted an educational publishing explosion at McGraw-Hill. Through expansion and acquisitions, McGraw-Hill established a major presence in the K 12 arena during the 1950s. Packing PAGE 2
3 IntelliSort shoe sorter The company and its educational publishing unit continued to expand throughout the latter half of the 20th century and into the 21st century through internal growth and acquisitions. In addition to its focus on primary, secondary and higher education, McGraw-Hill also became a leader in the areas of early childhood development, vocational training, professional development, educational assessment and reporting, lifetime learning and continuing education. Components of the System The McGraw-Hill Education facility located in Groveport, Ohio, is approximately 500,000 square feet. The system consists of a storage rack for picking full cases at a rate of 65 cases per minute. Full cases are picked to pallets in the rack aisles and delivered to spring-loaded pallet lifts. Operators unload the pallets by placing the full cartons onto a belt conveyor for transport directly to an IntelliSort sliding shoe sorter in shipping. Split cases are picked in one of ten single-level pick modules at a rate of 35 cases per minute. Each module consists of carton flow racks on one side of the module and bin shelving on the other. Operators erect cartons and apply a barcode label. Items are picked from the carton flow rack or bin shelving and placed into the shipping carton located on a gravity roller conveyor. PAGE 3
4 Upon completion, the carton can be pushed to the end of the gravity conveyor and merged onto the central take-away conveyor, or pushed down an early exit conveyor located in the center of the carton flow rack of each module. The early exit conveyor merges product onto a Honeywell Intelligrated motor-driven roller (MDR) take-away conveyor. All ten modules merge onto the central take-away conveyor for transport to quality control and/or packing. Each module has an empty corrugate belt conveyor supported on top of the carton flow rack. Empty corrugate is conveyed to a baler located near the shipping dock doors for easy disposal. Outbound split cases travel to a scanner and scale for weight checking. Cartons that are within weight tolerance bypass quality control and travel to one of four packing lines. Cartons that are out of tolerance travel to quality control for manual correction. Upon correction, the cartons are conveyed to packing where all split case cartons are dunnage-filled and sealed by a semi-automatic taping machine. Honeywell Intelligrated provided fresh ideas, state of the art equipment, and started up the system three weeks ahead of schedule allowing us adequate time to train our operations team for our peak season. Rick Sestrich, Senior Director of Operations, McGraw-Hill Education Sealed cartons travel to the shipping induction area located on a mezzanine structure where the barcode label is scanned via an overhead scanner. Honeywell Intelligrated InControlWare software directs cartons to the assigned shipping destination where they are diverted via an IntelliSort sliding shoe sorter to one of seven palletizing lanes, or to the fluid load lane for direct loading into outbound trucks. Loose product for the single pack and rush desk is picked from the split case pick modules and placed in totes. The totes, each equipped with a reflector, are inducted into the central takeaway conveyor and travel to the single pack spur divert located downstream of the weigh check station. If the reflector is in position 1, the tote is diverted to one of four single pack lines in a round robin fashion. If the reflector is in position 2, the tote will continue to rush processing. PAGE 4
5 Honeywell Intelligrated motor-driven roller conveyor Our relationship with McGraw-Hill goes back more than 20 years. During that time we have been involved in countless facility designs, expansions and modifications where function and flexibility were key. The professional design and implementation skills demonstrated by Honeywell Intelligrated were critical to the overall success of the project. The team relationship that we had with Honeywell Intelligrated was outstanding, said Dave Wolfe, Senior Vice President, TransTech Consulting, Inc. A stand-alone packaging system is centrally located in the facility where assemblies are put together. Finished assemblies are dunnage-filled, sealed by a taping machine, and palletized. Returns are processed independently of the main system. Product is unboxed and de-trashed from pallets at one of four stations. Books are placed onto a belt conveyor and carried to a computer operator. Product is then placed in cartons for storage in a carousel or on shelving. Partners in Success TransTech Consulting managed the system design of the new McGraw- Hill distribution center, and oversaw the project from the RFP to implementation. PAGE 5
6 Honeywell Intelligrated MHCS Honeywell International Inc.
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