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10 Years and No Downtime for High Density Automated Storage and Retrieval System
In 1997, a famous ice cream company initially installed a 5,000 pallet position Automated Storage and Retrieval System (AS/RS) with eight storage levels and pick tunnel operations. The 2 aisle system has a combination of seven- and five- deep storage lanes containing one crane each capable of handling approximately 70 pallets per hour. Five years later, the system expanded. The manufacturer realized a 40% increase in storage density, 30% reduction in energy costs, and 50% drop in labor among other benefits. This AS/RS has not had a single down day in over 10 years!
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Automated Storage and Retrieval System Increases Storage Density 40%
To meet demand for high throughput, a leader in the private label bottled water industry installed an Automated Storage and Retrieval System (AS/RS) and Warehouse Management System (WMS), which increased their storage density 40%. In a few short months, a marked improvement in safety has already been noticed due to fewer forklifts being used. Their WMS manages all product movements resulting in less waste and product lost.
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Vertical Lift Modules Regain Floor Space and Increase Productivity
By replacing pallet rack with five Vertical Lift Modules (VLMs), a hardware manufacturer regained 5,000 square feet of floor space and increased productivity by 22%. The VLMs eliminated the need for building expansion, improved worker ergonomics and helped meet their lean manufacturing initiatives, which provided their customers with shorter lead times.
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Automated Order Fulfillment Increases Distribution Center Productivity by 80%
The use of automated storage and retrieval systems (AS/RS) ensures that this medical device distribution center’s order fulfillment process is efficient and accurate. With horizontal carousels and vertical lift modules (VLMs) running on inventory management software, surgical kit and medical device orders enjoy same day turnaround. Automation increased productivity by 80%.
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High Density Storage Reduces Energy Consumption
When this dairy manufacturer decided it was time to consolidate distribution from 14 manufacturing facilities into one national distribution center, it produced a state-of-the-art facility that could accommodate aggressive growth. This distribution center continues to set the benchmark within the chilled dairy market.
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Direct Mail & Direct Response Company Slashes Cycle Time
Faced with rising variable costs and looming capacity restraints, a leading direct mail and direct response company built a new 470,000 sq. ft. facility around several core manufacturing processes: digital transfer printing technology, printing coupon signatures instead of individual coupons, and wrapping the envelopes around the coupons rather than inserting them. Automating the material flow between each of these processes and the buffer storage areas with an automated storage and retrieval system slashed cycle time.
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Home Furnishings Retailer Adds AS/RS with Flexibility to Handle Euro and Custom Pallets
With a new automated storage and retrieval system (AS/RS), this home furnishings distributor has the capability to store over 81,000 pallets. Sizes include Euro (800 x 1200 mm) and customized (800 x 200 mm) pallets. The storage and retrieval machines handle 30 pallets per hour. This provides an overall system throughput in excess of 400 pallets per hour in and out. Along with lift trucks, bar coding and a visualization software package, The entire system provides an extremely efficient and controlled operation.
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Meat Producer Achieves Prime Results with Improved Software, System
This global beef processing leader processes over 4,650 heads of cattle and produces more than 3.4 million lbs. of beef in 600,000 sq. ft. of space daily. However, an out-of-date ASRS and order management software limited the company's ability to meet customer needs. Learn how this site now has 100% order control, visibility and traceability of boxes with their new system.
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Vertical Carousel System Maximizes Floor Space
Substantial growth presented challenges to this manufacturer of fixed point and portable gas detection systems. Rather than build a new facility, automation in their existing plant maximized space, inventory and productivity with the installation of vertical carousels. Mobile carts consumed 300 square feet of floor space. The vertical carousel system reduced that space to just 67 square feet. Production setup time was reduced from 4 hours to 20 minutes. Within a short time, 11 individual vertical units are now in operation in this manufacturing facility.
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Push Carts and Static Shelving Eliminated with Automated Vertical Carousel Technology
A subsidiary of a worldwide manufacturer of dental products was building a 30,000 square foot warehouse/distribution facility in western NY state. The company had run out of space at their previous facility, which hampered distribution. With the help of 6 vertical carousels working in conjunction with a sophisticated materials handling system, the system is fully integrated from order entry through order picking and shipping.
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Industrial Engine Distributor Revs Up Facility with Vertical Lift Module System
The installation of vertical lift modules helped this distributor of industrial engines consolidate space. The company warehouses 5,000 different parts that accommodate approximately 380 different engine configurations. Warehousing personnel now just walk a span of 27 feet in front of the vertical lift modules (VLM) versus covering 8,000 square feet under the old batch processing system. The VLMs have consolidated space, increased efficiency and enhanced ergonomics.
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Grocery Leader Goes to the Express Lane for Product Distribution
Learn how one of the nation's leading grocery store chains newest facility is organized complete with wireless real-time inventory control terminals with computerized tracking, laptops, label printers on forklifts and voice-activated selection. The integration of voice-directed "put" coupled with the buffering of product in an AS/RS moved this grocer through the express lane!
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Upgraded Technology Eliminates Headaches for Lab
In the highly competitive pharmaceutical industry, production excellence is prescribed for health care companies. So when an obsolete and unreliable sterilization system caused concerns, this Virginia Lab decided to upgrade technology via automated systems with remote control vehicles and operator screens, eliminating high downtime and low reliability thereby creating 100% real-time tracing and control.
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Blast Freezer Technology Zeroes in on Reducing Costs, Space and Time
The challenge for one of the country's top 3PL refrigerated services company was to design, build and install a product material flow system in a blast freezer environment with extreme conditions. Traditional mechanical systems would be severely challenged. See how automated storage and retrieval technology provided answers!
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"Where's the Beef" no Longer an Issue for Meat Processor!
What gives this major beef processor self-sufficiency in its operation? Find out in this case study how modernization increased reliability, flexibility and productivity in the most cost-effective manner.
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Increased Efficiency is Just What the Doctor Ordered
A distributor of medical and health-related supplies utilized pallet rack and a stationary shelving system for storage; they needed a new system to increase productivity and decrease labor costs. An order processing system was designed and integrated, which consisted of 4 horizontal carousels, an ergonomic workstation, 2 vertical light trees, a sortation light bar at each picking “pod,” and interface software, which increased efficiency, throughput and inventory/distribution control.
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Book & Multimedia Retailer Uses Vertical Carousels to Consolidate Store Orders
A global book and multimedia retailer was looking for a way to increase efficiencies and make better use of floor space in its distribution centers. A new store order consolidation system was developed, which includes two dozen vertical carousels. The system provides the ability to handle a greater number of orders in a more efficient manner, better use of space and improved ergonomics.
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Aerospace Company Expands Manufacturing with Automated Storage and Retrieval System
The new facility houses a system designed to handle more than 270 dual cycles per hour and 2,500 order lines per day using three S/R machines and a front end conveyor system. Their overall system transaction time was reduced by 24%.
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Food Service Provider Utilizes AS/RS for Product Storage and Picking Replenishment for its New Distribution Center
This major food service provider utilizes an AS/RS for the inbound side of their new distribution center. The outbound side is a pick to belt conveyor system from pick tunnels in the rack. The system supports shipments of over 100, 000 cases per day.
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Beef Processor Adds AS/RS That Significantly Reduces Cost per Case Handled
Learn how this beef processor’s new AS/RS provides high performance that increases the throughput per aisle. The company is able to sort, store and ship cartons of beef with every carton tracked in real time!
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