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3-Aisle Mini Load AS/RS Improves Upon Manual Pre-Shipping Buffering Process
In a medical client distribution center, custom kits containing surgery instruments and implantable parts are assembled and shipped daily. Before automating the pre-shipping buffering process, the client was challenged to meeting shipment deadlines due to the amount of labor involved in manually picking items from conventional racking and in delivering kits to the correct customer. In the company’s new facility, a three-aisle mini load AS/RS holds assembled and ready-to-ship kits.
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An 11-Story 100’ Tall Rack- Supported AS/RS Building Yields Many Benefits
America’s largest cookware company and the world’s second largest cookware manufacturing operation wanted to enhance the speed and efficiency of shipping a growing range of product to retail customers in the U.S., while maintaining control of operational costs. The company hired Daifuku America Corporation to tackle the challenges.
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State-of-the-art distribution center is a tribute to engineering and new technologies in warehousing
Retrotech Inc. was commissioned by a Fortune 50 consumer goods manufacturer to develop one of the world’s largest automated distribution centers using state-of-the-art technology. Retrotech employed a unique super high-density dynamic storage technology that buffers, sorts and pre-stages palletized unit loads. The system operates 24 hours per day and stages over 160 orders. It manages 109,000 pallet positions in one warehouse.
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Designing for Efficiency & Growth in 33’ High Warehouse Using AS/RS & WMS
A famous brand Greek yogurt producer has installed an Automated Storage and Retrieval System (AS/RS) with Warehouse Management Software (WMS) at their plant in Johnstown, NY. The single aisle AS/RS handles storage and order picking in the 35°F cooler warehouse. Originally designed to store 1600 pallets, the AS/RS was recently expanded to 4100 pallet positions.
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Two-Aisle Mini Load AS/RS Improves Inventory Control & Access to Spare Parts
A mining, smelting and refining company needed to improve the efficiency of its small spare parts operations. The company’s spare parts, including electronic components and heavy machine parts, were located at 20 sites and over many acres. To improve the process, the company added a hybrid system using automated and conventional material handling solutions. The mini load AS/RS holds a variety of parts stored in 3,312 rack locations.
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Single Aisle AS/RS Replaces Manual Picking Operation
A single aisle AS/RS ensures efficient, cost effective and secure product handling for a wholesale hardware company providing products such as bathroom fixtures, drawer slides, knobs, hooks, wall plates and more to home improvement stores in the US. The benefits included expanded warehouse capacity, a decrease in labor for value-added activities, secured expensive inventory and improved throughput.
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Automation Provides Assembly Expansion While Adding Part Capacity
The installation of VLMs allow a company to reclaim approximately 1,600 square feet of floor space which could then be used for production, rather than storage. The VLMs also automatically locate and retrieve stored items with the push of a button, eliminating the time previously spent walking and searching through shelving. By installing automated storage and retrieval systems and software, this company has not only been able to create additional assembly area, they have been able to manage their parts inventory more efficiently.
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Customized Automation Maximizes Storage and Controls Flow
As a leading US newspaper searched for ways to maximize storage in their new warehouse, they needed a solution “made to fit” with their tight conveyor line requirements. They realized their current plant was too small to accommodate the higher volume of free standing inserts (FSIs), and the use of more modern technologies would improve their processing efficiencies, maximize storage and reduce costs, especially labor savings. The solution included a high density AS/RS, with 5 pallet deep storage on each side of a center aisle to provide higher throughput rates. The desire to maximum up-time was addressed by placing two Storage /Retrieval Machines (SRMs) in the same aisle.
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Running Out of Freezer Storage Space? Look Up for High Density Automated Storage!
After celebrating over 100 years of producing ice cream, this Alabama firm was running out of warehouse space. In order to keep up with growth, their key distribution center needed to enlarge and streamline their operations. Its 3,000 pallet position, freezer (-30° F) warehouse was quickly running out of room. Because it was a two-story facility, the firm knew they would need to go up to gain more storage space. To streamline production and storage facility an Automated Storage and Retrieval System (AS/RS) consisting of two Storage/Retrieval Machines (SRM) operating in one aisle was installed. The system is 9 levels high and stores more than 7,000 pallets in only 14,000 sq.ft. of space.
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Fragrance Distributor Uses Horizontal Carousels to Speed Order Processing Time
Handling 4,900 SKUs and shipping over 3,000 orders per day, distribution methods for a major fragrance company had changed from full-case shipping to retail distribution centers to split-case picking of individual orders for shipment either directly to stores or to retailer distribution centers. A one workstation consisting of two 65-ft long horizontal carousels to handle the slow moving items was installed. Slow movers are picked by one person from one zone and orders ship within 24-48 hours.
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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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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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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 Performance Picking System Eliminates Replenishment Labor
A high performance picking system (HPPS), an intelligent combination of mechanics and software, met project requirements for a redesigned central warehouse and distribution center of a European cutlery supplier. The pick-to-light system, storage and retrieval machines allow for the quick, efficient and ergonomic replenishment of stock. The HPPS eliminated labor and automatically re-slotted slow moving SKUs.
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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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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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