NOTE: The use of Scalable Order Fulfillment Solutions for...

© 2014 MHI®

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Sponsored by: Presented by:

Brian Keiger

Dr. Christian Wurll

Scalable Order

Fulfillment

Solutions for

Beverage

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01 Industry Overview

02 Flexible Scalable Solutions

Industry Overview

What Does Your Distribution System Look Like?

Scalable Order Fulfillment Solutions

Customer Business Model

Customer Pains

Customer Trends / Objectives


Full & Mixed pallets

(includes RDPs)

Homogeneous pallets

from the production

(extensively

automated)

Standard Pallet

Trailers – Not Bay

Trucks

Receiving

Storage

Replenishment Full layer / case

picking

QC

Palletizing Stretch wrap

Consolidate

Ship


Rapidly Changing Consumer Demands

− SKU Proliferation

− Smaller Shipments with More Frequent Deliveries Dynamic Warehouse

Rising Cost Pressures

Growing Consumer Concerns Over Food Safety Risks and Increasing

Regulatory Requirements

Poor Visibility and Traceability Across Shipping and Production

Poor Picking Accuracy Added Costs and Unsatisfied Clients

Double- and Triple-handling of Product

Shrinking and Aging Work Force

Land-locked Warehouse Space

Rising Energy and Fuel Costs


Significant investment in in growth (new product development, pricing strategies,

geographic expansion)

Significant improvement in operation processes and related technology

Significant cost reduction initiatives

Mergers and acquisitions

Entrance into new markets

Significant changes in business model

Significant changes to financial processes and related technology

Social media (Facebook, Twitter, Pinterest, etc.)

Mobile/online consumer engagement

Flexible & Scalable

Solutions

Warehousing and Distribution

A Warehouse & Distribution Center needs three things:

─ Get the products to the palletizer in the correct sequence efficiently

─ Palletize products for a single customer order

─ Sequence the order loads properly onto the outbound trucks

Delivering Proper Case Sequencing

─ Grenzebach and its partners have focused on

finding the best way to get the correct

sequence of cases picked and to the

palletizer in a way that:

─ Minimizes Investment

─ Minimizes Labor

─ Maximizes Future Flexibility

─ Is Scalable fro Different Sized Facilities

On time, every time to the palletizer

Three Primary Modules

─ Cascade Layer Picking with Associated

Residual Buffer

─ Order Release Module

─ Zone Picking from Pallets and/or Flow

Channels

Simple, Flexible, Scalable

Cascade Layer

Picking with Residual

Buffer


─ Cascade operator picks layers as required to supply

product to the express lane as needed. The express

lane product travels directly to the final merge and

then on to palletizing.

─ Cascade unit(s) typically used to supply product to

the Automatic Case Buffer / Dispenser.

─ A wireless display is mounted to each fork truck and

displays all layer picking requirements.

─ The case descrambling and singulation conveyor

separates cases from the Cascade units into single

file.

─ SKUs in the Layer pick area are assigned to

Automatic Case Buffer / Dispenser. Less than layer

quantities will come from this area.

─ Forklift Display Units are typically provided (Cascade

/ Full Pallet Replenishment Forklifts)

Layer Picking and Descrambling

Layer Picking and Descrambling


─ Layers are depalletized, singulated and sent directly to the palletizing cells; any

left over from the layer, not part of the order, are sent to the automatic case

buffer / dispenser

─ The automatic case buffer / dispenser consists of multiple case lanes

─ The automatic case buffer / dispenser can be mounted to the floor mezzanine.

The lanes are typically 18” – 24” above the fixed floor / mezzanine

─ Each lane is used for storage of the overflow product that is not used from

layers picked for the express lane

─ Product is automatically dispensed if the lane has the correct quantity to meet

the requirements of on order

─ The lanes are 24 LVDC powered lanes

─ Lane assignment is not dependent on product weight or size

─ The output of the automatic case buffer / dispenser flows to a merge point

where it is verified by a height checker

Case Buffering & Automatic Case Dispensing

Case Buffering & Automatic Case Dispensing

Order Release Module

(ORM)


Order Release Module (ORM)

Urethane Belts on Powered Rollers

provide more surface friction with cases

for superior control of automatic case

release

Load Level sensor and light indicators for

picker visual aid

Pick monitor with scrolling requirements

for guidance

Access lane between every set of ORM

Lanes for maintenance


Product Sensors S2

Stack Light for Zone

Reload Status

Zone Pick Screen

Product Sensor S1

Order Release Module (ORM)

Each Zone is made up of 3 or 4 conveyor

lanes with one Stack Light for Reloading

Status and one Zone Pick Screen for

picking priority.

On each conveyor are two sets of

sensors. When all sensors in every zone

are made, the green light will illuminate. If

any lane in the group gets below the first

sensor (S1), the white light is illuminated.

If any lane in the group gets below the

second sensor (S2), the red light is

illuminated.

The Zone Pick Screen will scroll the pick

priority but the lights will allow the

operator to know more accurately where

to go visually. When the cases are loaded

and sensors made the screen with

eliminate that pick.

If the picker is walking to fill the next pick

and sees a white light, he can place a few

cases on, depending on the urgency of

his next pick, making him more efficient.


─ Operator picks cases off of bulk

pallets and fills up conveyors to

be released automatically by

the system as needed

Automatic Case Release

Zone Picking Module

(PTZ)


─ Zone Picking Method eliminates the need for a “Pick-

to-Light” or “Voice Picking System”.

─ A count zone is provided in the powered take away

conveyor for each pallet pick position and each carton

flow bay.

─ The count zone activates when the PLC is expecting

product to be picked from the adjacent pick location.

The operator will see the rollers turning in the pick

zone. Note that the DC MDR conveyor is normally not

running unless product is traveling down the

conveyor.

─ Overhead monitors or wrist modules are provided to

indicate the location and quantity to be picked. These

devices display the current pick requirement, location

and quantity.

─ The count is decremented as the operator places

product on the pick zone and the product crosses the

count photo eye.

Zone Picking Modules


─ If the operator miscounts and then attempts

to place a case in any other pick zone, the

conveyor will stop and the overhead monitor

will indicate there was a pick error. The

operator will then use the HMI work station

provided to resolve the error.

─ A full line photo-eye will be provided. When

the full line condition occurs for the pick line,

the overhead monitor will display that the

system is full and the count zone will not

operate until the full line condition is cleared.

─ The Pick module and the High Volume Pallet

Pick lines all utilize the Zone Picking System.



─ Multiple levels typically contain pallet pick.

The operator picks directly from the pallet to

the conveyor

─ Two-deep gravity pallet conveyor is provided

for mid-volume SKUs

─ The bottom level of the Pick Module typically

contains a combination of pallet pick faces

and low-volume carton flow rack

─ A separate floor level case zone picking area

usually contains an area for seasonal SKUs;

additional pick zones can be added without

increasing footprint

─ Each level has a height verification check at

the end of the pick line


Zone Picking Module

Case Flow Rack

Multiple Bays – Floor Level

(Configurable)

Pick-to-Zone

Levels 2 & 3

Lift Gate(s)

Zone Picking Module

Mixed Row Palletizing

Mixed Row Palletizing (MXRP)

MXRP Cell with Row Gripping Functionality: • Cases feed from customer conveyor(s)

• Empty pallet conveyed into position

• Robot arm builds pallet per customer stack pattern

requirements

• Operator /Forklift take-away of completed pallets

Cell Capacity: • 1000 – 1200 CPH (with Row Gripping)


MXRP Cell with Row Gripping

Case In-Feed with

Row Grouping

Empty Pallet

In-Feed

Full Pallet

Out-Feed

Target

Palletizing

Position

MXCP Robot

with Gripper



Payload weight up to 310 lbs

Gripper weight 365 lbs

Min [L x W x H] 4” x 4” x 4”

Max [L x W x H] 24” x 16” x 16.5”

Multiple SKUs can be handled at one time

Gripper is configurable for row grouping



Calculation of “ideal” pallets based on parameters

derived from various rule groups, like

– Start with Full Layers

– Consider Stacking Rules

– Create Mixed Layers based on Package Type Class

– Usage of known pallet pattern templates for mixed layers

– Calculation of “really” mixed layers for top layers

Visualization

Plausibility Check for customer data (product, layer,

pallet)


Example Pallet Configurations

48” x 40” 36” x 36” 42” x 18”


Example Pallet Configurations

What Does Your Distribution System Look Like?

For More Information:

Speaker #1 email: [email protected]

Grenzebach-INOS Automation Software, Inc.

Website: www.grenzebach.com

Speaker #2 email: [email protected]

Grenzebach Automation GmbH

Website: www.grenzebach.com

Or visit MODEX 2014 Booth 7913

NOTE: This ending slide is OPTIONAL. Items that can be included are your

speaker’s email address/home page, the Exhibiting Member Company’s name,

home page and Booth Number.

mailto:[email protected]

http://www.grenzebach.com/

mailto:[email protected]

http://www.materialhandlingtech.com/

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