Making smart automation decisions in today's fast-paced distribution center (DC) environments requires careful evaluation of all variables, with pick densities, peak/average volumes, number of SKUs, conveyability of product, accessibility to labor and ROI among the deciding factors. Often, the number of orders that need to be fulfilled per day dictates the degree of automation required.
Regardless of your DC's specific requirements and throughput rates, the right sortation automation solution helps enable the process efficiencies needed to meet rising service level agreements. From receiving and put-away to picking and packing, sortation technology plays a role in nearly every aspect of DC operations.
In Intelligrated's next On The Move webinar, titled "Sort it out! Making smart sortation automation decisions," Satyen Pathak, senior product manager, will discuss the full range of sortation automation solutions that are available for modern DC operations. He will cover various options, from manual methods well-matched for lower throughput rates to advanced sortation technologies designed to accommodate up to 150,000 orders per day.
This informative webinar will take place on Thursday, January 26 at 2 p.m. EST / 11 a.m. PST. Attendees will learn:
- Which areas of the DC are the top candidates for sortation automation
- Which automation method is best suited for low, medium and high throughput rates
- How to scale a sortation automation solution to your specific requirements
Framing the discussion around increasing throughput rates, Satyen will begin with an explanation of sortation and conveyance solutions used to manage up to 10,000 orders per day. Belted conveyors provide a cost-effective means for transporting items over a significant distance while ensuring good product control. Modular sweeper sorters can be installed above the conveyor to enable the sortation of large quantities of smaller products. Software-driven cart picking solutions are ideal for entry-level automation systems that can be scaled to grow with DC operations and ramped up for peak order periods. Put-walls also enable directed putting and packing efficiencies capable of meeting lower throughput rates.
Satyen will then explain how zone routing - with pick-and-pass and sortation - can achieve throughput rates of up to 50,000 orders per day. By integrating pick-to-light, RF or voice-directed pick modules with intelligent conveying and sortation systems, zone routing automatically routes product to the best available picking station. Push tray sorters - which can sort a combination of disparately sized products - can efficiently increase capacity within a small footprint. A variety of sortation technologies can be used for shipping, cross-docking, line balancing, defect rejection and order consolidation.
For throughput levels up to 150,000 orders per day, Satyen will demonstrate how major e-commerce retailers are utilizing tilt-tray and cross-belt sortation solutions to sort up to 25,000 items per hour. These systems utilize manual, automatic and semi-automatic induction methods and rely on advanced software to oversee supply and demand order consolidation.
Regardless of your objectives for seeking a sortation automation system, this webinar will help you evaluate the best system to suit your specific selection criteria. Register now to join Satyen Pathak on Thursday, January 26 at 2 p.m. EST / 11 a.m. PST.
Halloween has haunted, Thanksgiving is over and the madness of Black Friday has passed. Now the race is on to finish the holiday season strong as major carriers continue their efforts to get gifts under the tree by the time stockings are hung by the chimney with care.
But impressing the in-laws with those last-minute monogrammed stocking stuffers depends on more than retailers providing a seamless shopping experience and shippers driving Santa's sleigh. Products need to make their way out of storage, run through value-added services and consolidation before heading out to shipping.
All year round, Intelligrated makes it possible to deliver on fulfillment promises with efficient labor, processes and automated equipment that ensure consistent throughput and accuracy, from picking and replenishment to conveyor and sortation.
Holiday season means peak order volumes
According to the National Retail Federation, holiday sales increased to $626.1 billion last year, including nine percent growth in online and other non-store sales. This increase in e-commerce demand applies extra pressure on distribution operations to route, pack, personalize and consolidate orders in time for shipping cut-off times.
These multi-step processes place a premium on fast, accurate sortation. Just like Santa's reindeer operate on a tight schedule, retailers cannot afford unplanned downtime or delays. Keeping operations moving swiftly requires precise diverts to direct orders to the right chutes and avoid jams, re-circulations or other errors that can stretch order cycle times and occupy system capacity.
Innovative sortation technology maximizes accuracy, throughput
Maximizing the precision of diverts from cross-belt sortation equipment depends on the size of the item and its exact location on the sortation surface. Traditional technology assumes, sometimes incorrectly, that an item is located in the center of a cross-belt and discharges at the center of the chute based on those conditions. However, Intelligrated's patented dynamic discharge compensation (DDC) technology is designed to more accurately handle the diverse product mix associated with e-commerce and holiday fulfillment, from golf clubs and footballs to apparel and shoes. DDC uses an overhead vision system to detect the exact size and location of an item, and adjust the discharge based on those criteria, enabling more precise diverts and 99.9 percent accuracy levels.
Though Intelligrated does not drive Santa's sleigh, his workshops are in good hands. The equipment, software and expert support keep gifts flowing from the North Pole to the right place at the right time. Happy holidays from Intelligrated!
It’s an exciting time of year in Chicago. Thanks to the World Series, Wrigley Field has taken over as the city’s epicenter in the north, but the Near South Side is primed to take center stage next week as McCormick Place hosts PACK EXPO International 2016.
From Nov. 6-9, attendees from more than 130 countries will find the latest solutions designed for today’s most influential challenges facing packaging and processing operations: constantly changing consumer demands, pressure to do more with less, labor challenges and advances in technology. At booth S-3666 in the south hall, Intelligrated will highlight high-throughput automation solutions, seamless integration capabilities and lifecycle support services.
The in-booth, live demonstration will feature the company’s new Alvey® 891i palletizer and a robotic depalletizing cell, integrated with vertical reciprocating conveyor and motor driven roller (MDR) conveyor. The solutions on display are ideal for food, beverage and consumer packaged goods operations with reduced or eliminated secondary packaging. This requires equipment capable of handling everything from display cases and polywrapped bundles to paper-board overwrap packs and more.
The Alvey 891i palletizer provides exceptional versatility and maintainability, thanks to an updated user-friendly design. Ideal for both single and multi-line operations, this high-level, row-forming palletizer manages intricate stacking patterns and handles packaged food, beverage, converted paper and personal care products. The 891i also includes enhanced features for improved safety, ease of use and maintenance.
Intelligrated is recognized by the Robotic Industries Association as a certified robot integrator, and offers end-of-arm tooling designed and built in-house to handle a variety of applications and product types. This flexibility allows for quick product changeovers, frequent packaging changes and can handle single cases, rows or layers.
The vertical reciprocating conveyor offers a simple, cost effective solution to move cartons and totes in a compact footprint. The scalable solution offers user-configurable input and discharge heights, and industry leading speed to match each operation’s unique requirements.
Representatives from Intelligrated Lifecycle Support Services will offer advice to maximize return on material handling investments and keep critical systems running smoothly. Mechanical and risk assessments form the backbone of proactive lifecycle management and offer proven solutions to improve safety, system longevity and efficiency.
Stop by Intelligrated booth S-3666 to see the automation solutions that leading manufacturers depend on to exceed expectations for reliability, throughput and flexibility.
To schedule a meeting at the show, email email@example.com. Multilingual booth support in Spanish and French will be available.
Intelligrated, now part of Honeywell, invites you to also visit their booth in Upper Lakeside Center, E-7441, for workflow productivity solutions that optimize manufacturing and warehouse operations, and embedded sensors and controls that help keep teams safe and productive.
I look forward to seeing you at PACK EXPO International 2016!
Think of conveyor as the streets and canals of the distribution center. Automated conveyor solutions are the essential infrastruture required to keep orders flowing to the right place at the right time. From pallet transport conveyor to case, tote and polybag varieties, each component - even down to conveyor parts and accessories - plays a critical role to meet operational requirements.
And just as city streets must accommodate motorcycles, cars, trucks, pedestrians and bicycles, every industry must accommodate more variety thanks to SKU proliferation. Big box retailers are expected to sell every brand of every product, from toothpaste to refrigerators. Every food and beverage distributor must offer year-round variety, seasonal specialites and health-conscious options. But besides product, packaging makes a difference, too. With the advent of dimensional weight pricing, most conveyor and transmission solutions must handle packaging types like polybags and bubble mailers that represent a significant departure from the rigid corrugate cases for which they were originally designed.
This places a premium on flexible conveyor solutions capable of fueling a facility's high-speed sorting procedure reliably and efficienctly. This means picking the right technology - conveyor belts and parts - matched to the requirements of the application.
And just like avoiding road closures and construction detours keeps traffic flowing, minimizing unplanned downtime and ensuring system availability is critical. This means a preventive maintenance program to head off issues before they happen and quick-response, 24X7 support in the event of an outage. Working with an OEM lifecycle management group and a computerized maintenance management system provides data-driven decisions and the necessary level of detail - even covering how to aggregate conveyor parts.
To learn more about advanced conveyor applications, read the Intelligrated blog, Understanding accumulation technology choices leads to better solutions for operations or contact a representative.
Alfred Sloan pioneered the concept of market segmentation in the automotive industry back in 1924, directing General Motors to produce "a car for every purse and purpose." This strategy is built on the notion that an extra layer of specificity - rather than a one-size-fits-all approach - best addresses the nuanced demands of each customer. Its staying power is a testament to the importance and relevance of this strategy in virtually any industry.
But when considering how to design a material handling system, every purse and purpose gives way to different industry challenges, from e-commerce and retail to food and beverage. Material handling automation must be based on these specific operational requirements and applications.
Today's material handling solutions must combine the right mix of automation, software and labor to meet benchmarks for throughput, accuracy and other performance criteria. Material handling consultants who take an in-depth approach dial up the right components, with appropriate modifications to ensure peak performance based on environmental, product and performance specifications.
Here are two customization examples from the recent history of material handling:
E-commerce: Goodbye cartons, hello polybags
Material handling conveyors are mission critical components of virtually every automated system in every industry. But with the advent of dimensional weight pricing in 2015, e-commerce retailers are challenging the capabilities of conveyor and sortation equipment to transition from traditional rigid cartons to smaller and more malleable shipping containers such as bubble mailers and polybags.
Despite the packaging changes, operations still need material handling equipment to quickly and efficiently move product and keep their businesses running. To accommodate packaging changes, system suppliers can provide new material handling technologies designed or modified to handle the flow of bubble mailers and polybags from pack-out operations to shipping in e-commerce applications.
Food: Palletizing performance tailored to operational demands
Food distributors are faced with the challenge of supplying multiple products to buyers around the world. The challenge is to serve the need for different products, packaging, pallets and layer patterns while still maximizing profitability and operational efficiency.
Customized material handling guidelines and equipment modifications enable automated systems to handle these variable requirements, thus enabling distributors to effectively leverage scale to minimize cost for end users. Solutions can also streamline compliance with food safety and traceability initiatives, with some systems incorporating barcode scanners to ensure the right cases make it onto the right pallets.
Material handling and logistics continues to adapt
From new packaging to product traceability initiatives, material handling systems continue to evolve to accommodate macroeconomic forces and the requirements of individual operations. This flexibility can enable operations to break new ground with new, innovative applications and greater levels of system performance and longevity. Follow Intelligrated on Twitter, Facebook and LinkedIn, and attend a material handling expo to find what's next.