The Many Personalities of Shuttle Technology Track 3 Session 7
Philip Puite Senior Operations Planner Dematic philip.puite@dematic.com 616-913-6596 www.dematic.com 2
Abstract What was once thought to be a fast storage device is now the 20-tool Leatherman of DC designers. Here we will hear how this invention has evolved to be the answer to sequence, buffer, make toast, sort and feed picking and robotics in today's demand-driven supply chains. Included will be examples and design guidelines for each application of the modern shuttle system. 3
Agenda Shuttle System Overview Shuttle System Sequencing Shuttle System Buffer Shuttle System Sortation Key Takeaways Conference Cloud Questions 4
What is a Shuttle System? Shuttle System is a micro-load ASRS with multiple carriers per aisle Material Handling Institute (MHI) definition of micro-load ASRS: - Typical loads are less than 100 pounds - Loads can be in cartons, containers, totes, or trays - Flexible load sizes 5
Shuttle System Components: Shuttle moves product to and from of the storage position Shuttle conveyor moves product from the lift to the shuttle pick and drop position Lifts moves product from storage level to buffer conveyor Buffer conveyor delivers and takes away product from the conveyor system to Shuttle Aisle 6
Shuttle System Example: 7
Shuttle System Sequence What you want When you want it in the exact Order you want it - Types of Sequencing: - Level 1 To a Goods to Person (GTP) Workstation Large number of SKUs routed to a common pick location - Level 2 Container Specific Sequence for placement into outbound containers 8
Shuttle System Sequence Example: 9
Manual Picking / Sequencing Walking and Searching Duplicate Handling 10
Shuttle Sequence Level 1 11
Shuttle Sequence Level 2 Sequenced based on Store Aisle configurations Build aisle ready store containers Planogram variance by store Shelf codes: aisle, shelf, location Product codes: department, product family, brand 12
When to Consider Sequencing Need to bring SKUs to a common pick location Reduce dependency on picking a large number of SKUs Increase Pick Productivity Need for Store Aisle Replenishment 13
Shuttle System - Buffer Order fulfillment Increase batch size Smaller pack modules Shipping Buffer prior to loading outbound trailers Reverse stop sequence Work in process (WIP) Manage Process Flows 14
Buffer - Order Consolidation ASRS Picking Manual Picking Shuttle Buffer Consolidates All Split Case Areas Shuttle Picking 15 Metro Order Processing Solution October 6, 2010 Company Confidential Copyright Dematic 2010 15
Buffer - Shipping Consolidation Shuttle Buffer Synchronize and Sequence Full Cases Manual Picking Shipping Robotic De-Layering 16 Metro Order Processing Solution October 6, 2010 Company Confidential Copyright Dematic 2010 16
When to Consider a Buffer Need to manage process flows Increase Pick Productivity by creating a large batch Reduce dependency on picking areas Sequence outbound loads Need to hold WIP 17
Shuttle System - Sortation Replenishment of flow lanes Inter-Aisle Transfer (IAT) Advanced Automation 18
Sortation to Flow Lanes Store inventory on opposite side of flow lanes Replenishment of fast moving SKUs without labor Minimize flow lane length 19
Shuttle Sortation to Flow Lanes 20
Shuttle Sortation IAT Inter-Aisle Transfer (IAT) Shuttle system uses IAT on each level to route work to the correct aisle Reduces the sequencing requirement of traditional convey and sort systems to downstream process areas Smaller system footprint 21
Sortation - Inter-Aisle Transfer (IAT) 22
Advanced Automation 23
When to use Shuttle Sortation Replenish Flow Lanes Feed Picking Stations Automatic palletizing Weight - Heavy product on bottom - Light product on top Special handling needs 24
Making TOAST with a Shuttle System Make Technology and Operations Align Systematically Together A Shuttle system can All System Technologies help DC operations sequence, pick, buffer, and sort more efficiently and easily. 25
Key Takeaways Flexible - Numerous Applications Substantial Labor Savings Sequencing Enables New Capabilities Buffer - Balance and Coordinate Disparate Material Flows Sortation - Saves Conveyor Sortation - Enables Advanced Automation 26
Conference Cloud Additional Resources Material Handling Institute - Automated Storage Replenishment: The Next Big Target. Modern Materials Handling. "A Look at Multishuttle Goods to Person Automation." MWPVL. 27
Questions 28
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