Case Study

Meat Processing Industry Supplier

The Situation

We worked very closely with the customer over their two-year project timeline to make sure each and every need they had was met. In collaboration with a team of strategic partners, we were able to introduce new technologies that integrated with the customer’s current warehouse management system (WMS) software to provide a complete, automated warehouse systems solution that addressed each of their needs and challenges.

Our client’s goal was to maximize productivity to be able to handle increased business volume, without needing to increase labor. They also needed to accommodate substantial growth, at an average of 10% over a ten-year period. With this new facility being a main hub, there would be different types of orders coming in, ranging from small single item orders to full truckloads. Shrink wrap items being sold needed to be under temperature control, or else those items would shrink before usage. Large and irregular shaped items needed to be combined with small items upon shipment. The size and shape of the items was not the only factor that went into facility design. There are small cube, high value items that needed to have access control. Incorporating industry best practices in order to avoid double handling items was a key requirement.

Customer Goals

Improve

business growth an average of 10% over a ten-year period

100%

visual Quality Assurance (QA) process required

Optimize

facility to accommodate a variety of orders in a temperature-controlled environment

Where Storage Solutions Came In

Inventory is housed in various storage mediums and pick zones within the facility based on the type of item being stored & how that item is picked. A WCS software solution handles order distribution to the different picking zones & provides controls for automated equipment to route totes to zones where picks are needed.

Integration was done with the customer’s existing WMS software, which manages the inventory levels. Storage mediums range from Vertical Lift Machines (VLMs) for very small cube items that are picked individually up to 2-deep pushback pallet rack for very large items that are picked as full cases.

Zone routing principles are used so that pickers only see orders that require a pick in their zone to maximize operational efficiency and pick rates for individual associates. The WCS software releases orders in waves to balance workload throughout all pick zones within the facility.

The Results

Vertical Lift Module

3 VLMs
Store small cube broken case items & high value small cube items that need secure storage
Integrated with pick to light batching table that allows up to 8 orders to be batch picked at a time out of all 3 machines by a single picker
Achieves 120+ line items picked per hour by a single picker
WCS software distributes orders intelligently throughout the operation
Orders that don’t require a pick from VLM area will be inducted in furthest downstream area where there is a pick required
Order flow through the facility starts here
Once the VLM picks are completed, the tote is set on the powered conveyor to be routed to the subsequent zones where picks are required

Split Case/Full Case Divert

All totes are scanned
Totes for orders requiring Broken Case and Full Case picks are diverted using a single bi-directional conveyor divert for both zones (as shown in video)
Once a broken case item is picked, the tote is dropped back on the powered takeaway conveyor still in front of the scanner at the divert point and scanned again
If there is also a pick required in the Full Case zone, the tote will be diverted there as well

Broken Case Picking

Totes for orders requiring Broken Case picks are diverted
Order picker forklifts with special attachments allow multiple orders to be picked at once
WCS software batches orders to minimize travel distance and maximize order picking efficiency
Broken case items are picked from all levels of hand stack and selective pallet rack
Once a broken case item is picked, the tote is dropped back on the power takeaway conveyor still in front of the scanner at the divert point

Full Case Picking

Full case orders without broken case or VLM items on them are initiated in the full case picking area
Order picker forklifts are used to pick full case items from all levels of selective and 2-deep pushback pallet rack
Pickers carry mobile printers and print shipping labels at the time of the pick and place them on the boxes
Once full case items are picked and labeled, they are placed back on the powered conveyor
Full case boxes bypass all QA & packing function and go straight to loading
WCS software identifies orders with multiple quantities of full case items with certain characteristics that require them to be taken to a consolidation area and packed together prior to shipping

Non-Conveyable Section

Storage area right next to shipping for irregularly shaped, non-conveyable items such as mops, dollies, trash cans, etc.
The WCS software ensures non-conveyable items are picked and loaded on the same shipping trailer as the rest of the order

QA, Single & Multiple Tote Packing & Shipping/Manifesting

Initial scanner checks to see if item is a tote or a box
Boxes are sent straight to shipping
Totes are diverted off the loop where they reach the QA area
The WCS software provides order details on a display to allow the QA associate to verify all items for the order are present and correct
Correctly completed orders are placed back onto the powered conveyor
Orders with incorrect or missing items are pushed across to a “hospital” lane for corrections
3 packing stations are located on the outside of the loop for single tote orders
If an order takes multiple totes, they are diverted to the inner section of the packing loop
5 packing stations are located on the inside of the loop for multiple tote orders
A gravity flanker conveyor is used as a work table by the packers and QA associates
If a tote for a multiple tote order is not pulled off at the packing stations, there is a recirculation function
Item will hit a divert at the bottom and recirculate to the top of the loop area
Shipping and Manifesting station is where packing lists are inserted and labels are placed on the box

Final Thoughts

At Storage Solutions, our team comes from decades of experience. That experience, combined with our network of strategic partners, allowed us to develop a solution to get this client running at optimal efficiency in their new facility, while also sticking to their timeline and budget. Every facility is unique, and each client has their own specific needs to meet. Our team will work with you to address those needs and make sure we cater a solution to fit your challenges.

We made the absolute right decision selecting Storage Solutions as the project integrator and supplier for our newly built primary warehouse. Storage Solutions partnered with us every step of the way, from the initial design concept to the first week of Go Live in the new facility. The Storage Solutions team brought expertise and a host of world class hardware suppliers and engineering partners that helped design and build our racking, conveyor, automation and software which led to significant productivity gains just days after start up. I would recommend to give Storage Solutions strong consideration for your next warehousing project.

Senior Director of Operations