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LogisticsIn 1999, after experiencing 14 years of phenomenal growth, we had exceeded the capacity of our existing order picking system. Our decision at this time was whether to buy a new facility or change the existing facility so that we could operate at peak efficiency and allow for future growth. Maybury Material Handling was asked to look at the existing system and provide insight as to what could be done to structure a more efficient facility. They redesigned the warehouse to receive at one dock and ship from another. This would allow for continuous product flow through the building and generate a more productive and time-efficient process.
Maybury designed a two-level pick module utilizing Interlake Material Handling's rack, conveyors, and carton and pallet flow units, integrated with a Maybury mezzanine, and Quantum Conveyor's automated induction and sortation systems. This module would provide state-of-the-art order picking, accumulation, sortation, and delivery to the loading dock, as well as automated verification of product shipped to our customers. Says Paul Marusek, Vice President of MIS, "This system will allow us to implement RF and other new technologies throughout the process as we move forward." A variety of equipment was integrated to provide efficient and productive storage and handling for each of our diverse product lines. The recently installed system accommodates more than 10,000 different items and is capable of handling a nightly cycle of more than 100,000 picks. Units picked range from individual healthcare items to full cases of beverages and paper cups. Candy is picked from carton and pallet flow racks into totes and transported on gravity and power roller conveyors; bulk goods are picked directly to a belt conveyor; and cigarettes are conveyed from pick locations to tax stamping machines and then to overhead accumulation lines. All conveyable products arrive at a common induction point, where a computer controlled sortation system picks them from the accumulation conveyors. Items are scanned for order verification and billing confirmation, then sorted to gravity conveyors to allow loading of up to four trucks at a time. When each of the 30 trucks per night arrive at the loading doors, the proper orders are released and conveyed directly into the truck. At this point, as they are stacked in the truck, the orders receive their first human handling since they were picked.
With its newly designed and installed system, we have been able to increase the volume of product movement through the facility, in terms of both number of items and number of picks per item. "The new system has already made a positive contribution to our productivity, and also provides an audit trail from each container we ship out of the building," commented Bill Fitzsimmons, Vice President and Chief Financial Officer. This has been accomplished in conjunction with a significant reduction of labor hours. The new design and equipment have provided the capacity we needed to remain in the current location as our business continues to grow.
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