SSI Schaefer Optimizes Solar’s New Distribution Center
Posted by Travis Baker on Fri, Oct 07, 2011 @ 08:01 AM
With an integrated logistics concept, a new Miniload and connected Pick-to-Tote workstations, SSI Schaefer has significantly increased the capacity and performance in the distribution center of the Danish wholesaler Solar Danmark A/S. After the project the companies formed a strategic cooperation with Schaefer responsible for the design and equipment for Solar's future distribution center projects.
Sensor systems, ventilation systems, sanitary supplies and electrical items for machine engineering are just some of the items supplied by the central warehouse of Solar Danmark A/S in Vejen. The central location in the heart of Jutland, a sophisticated distribution operation and the high quality demanded by Solar have led to a continuous growth and a revenue of more than 340 million Euros in the last year.
“The increasing order volume and the requirements to satisfy demands of modern logistics limited the warehouse capacities and the order picking strategies“, explains Lars Kristensen, technical manager of the logistics system in Vejen. The expansion of the distribution center in Vejen began in early 2009. “We had to increase order picking performance, capacities and efficiency of the order creation to meet the increasing requirements of the market. “
SSI Schaefer was chosen as general contractor for this project. “Modern technology, a good cost/performance ratio as well as the market position and the world-wide presence were the decisive criteria", explains Kristensen. Increasing order volumes made it necessary to create a concept for efficient intra-logistics, resulting in the implementation of an automatic Miniload with connected order picking stations. In addition, Schaefer delivered and integrated the tote conveyor system, connected it to the existing system and installed a tailored warehouse management and control system with visualisation.
The expansion of the 45,000 square-meters distribution center has been in operation since the end of June 2010. Forty trucks arrive at the gate every day to transport the goods. 11,000 orders are commissioned in Vejen daily and are forwarded to the recipients.
“Solar-customers can contact us 24 hours a day, seven days a week. All orders which we receive before 6 p.m. are supplied on the next workday before 7 a.m., if this is geographically possible“, illustrates Kristensen. “Nevertheless the customers expect perfection in the order configuration - and we endeavour to meet this expectation. “
The new Miniload of SSI Schaefer is helping Solar meet their customer’s needs. The bulk of the small parts orders are compiled via the new automation system and the connected ergonomic picking stations - nearly a quarter of the order volume.
The technics wholesaler has 44,000 different items in stock in the old warehouse in Vejen with 32,000 totes available for storage. The capacity of the distribution center has doubled with the compact new system, which significantly increased with the new system. To accommodate the future growth of the company, the new system was designed so that a second, Miniload can be erected on the area previously occupied by older equipment.
At present the capacity of the new warehouse complex offers Solar sufficient range even for peak output. The compact system design with associated efficiency and the high-capacity components for largely automated processes enable the current advantages. Eight single-mast Storage and Retrieval Machines (SRM), Schaefer Miniload Cranes (SMC), with a speed of 23’ per second, and a lifting speed of 13’ per second, generate a throughput of 137 totes per hour each. Their telescopic load-handling device (LHD) offers double-deep storage of totes with a weight of up to 55 lbs. into the Miniload.
For the order creation, the item totes are retrieved in sequence by the SRMs and are sent via a short conveyor to four Pick-to-Tote picking stations. The direct connection to the Miniload offers, per station, a supply and removal buffer of up to 25 totes for retrieval and storage. This enables continuous supply and constant order picking.
Of the four Pick-to-Tote stations installed at Solar - one of them is used for the quality management. “Five order picking stations were originally intended", says Kristensen. “But the simulation clarified that four stations are sufficient to cope with the full load of the Miniload.”
Contrary to the conventional thinking the order picking stations in the new plant are not positioned crosswise, but lengthwise to the Miniload. This design offers a uniform arrangement of the material flows without deviations for the order picking. The benefit for the customer is an efficient supply to the picking stations in a compact area with a smaller conveyor system.
Schaefer designed the workstations for optimal ergonomics and operator ease, which means the picking at the "multi-functional Pick-to-Tote“ stations deliver a 10x increase in capacity compared to conventional strategies. They not only meet the strict occupational safety requirements in Denmark, but also the flexible design enables fatigue-proof and stress-free order picking. Individually adjustable control elements, as well as ergonomically positioned displays and indications direct the operator. The system checks the item amount and the correct allocation of the order and, if applicable, a fault removal routine is activated. This means that Solar can increase not only the picking rates, but also the picking accuracy.
Schaefer installed two separate loops on two levels for the tote supply and removal at the work stations. Each of them offers a high density with a capacity of up to 1,200 totes. The top loop transports the storage totes, the bottom loop the picked order totes. After retrieval from the Miniload the picking positions are supplied with storage totes via the supply section. Supported through a Pick-to-Light system, the goods can be directly picked into the available order totes with a performance of up to 1,000 picks per hour. “However, the high throughput was not decisive at the design", explains Kristensen. “We have to implement numerous additional tasks at the order picking; bags or small cardboard boxes have to be opened, for example. We currently operate every station with around 200 picks per hour. The performance capacity of the stations is already designed for future growth. Safety and efficiency of the processes was especially important for us”
The order totes are linked to two bottom loops so that the picker at the picking stations can pick from top to bottom following a sophisticated picking process; from one storage tote into seven order totes. The interaction of display details and integrated Pick-to-Light system makes for clear operator guidance. The display indicates the respective items and the item amount to the picker. An integrated light grid monitoring of the destination position avoids erroneous order picking. Removal and deposit of the items are confirmed per touch screen – generating at the same time a record in the WMS.
The warehouse management system ACX installed by SSI Schaefer controls both the order-related retrieval and also the order-optimized supply at the picking stations. With its functions and the control functions tailored to the processes at Solar it covers all tasks from warehouse management and inventory management, via processing of goods receiving and shipping, up to order picking and material flow control. The plant visualisation installed by SSI Schaefer offers integrated transparency of the processes and plant status in the Solar distribution center.
After the Pick-to-Tote stations, the goods totes are transported via the top loop back to the transfer conveyors into the Miniload. The completed order totes as well as empty totes are transported on the bottom loop to a transfer position at the installed conveyor system. This serves the packing stations installed in the old plant.
In the packing stations the order items are packed into delivery boxes, equipped with shipping documents, labelled and then forwarded to the goods shipping.
The separate tote management and the decentralisation of the material flows of goods and order totes optimizes the capacity and quality indexes of the entire plant. The integrated quality controls at the Pick-to-Tote stations deliver a high reliability at the order creation. “With 99.8% of faultless Solar-deliveries we are near the zero fault command variable in the order picking" says Kristensen proudly.
Just one year after completion the management of Solar are sure about their decision. “The plan has met our expectations in efficiency and sustainability", sums up Kristensen. “Moreover we can look back on an extremely harmonic course of the project at which SSI Schaefer has not only met all schedules, but even exceeded them. We were able to complete every project section almost one week earlier than scheduled.” The plant in Vejen is a reference plant both for Schaefer and also in the Solar concern. Solar A/S has formed a strategic cooperation with SSI Schaefer. As a partner SSI Schaefer is responsible for the design and equipment provision of the intra-logistics in future projects of Solar A/S.
Schaefer Systems International, Inc., the North American subsidiary of the SSI SCHAEFER group of companies, established headquarters in Charlotte, North Carolina, in 1989.
SCHAEFER’s automation integrates to any existing system earning us an international reputation as the global leader in the material-handling industry for returnable packaging, static racking, and highly complex, automated distribution systems. With over 70 years of experience and a 100% commitment to quality behind every SSI Schafer system, we focus on providing our clients with unconventional picking and storage solutions delivering best value