Logistics News

By Cliff Holste

November 2, 2011

Sortation Is Key To A Comprehensive Material Flow Solution

By Way of the Sorter - A Company’s Saleable Goods Flow to the Marketplace

Sortation is considered to be the heart of the order fulfillment process in logistics companies where it is deployed. These companies depend on their sortation system to rapidly and accurately consolidate random flows of products into discrete orders for shipping so that they can expedite delivery and maintain a high level of customer satisfaction. They are capitalizing on sortation technologies to meet their needs effectively and efficiently.

Logistics companies are not alone in their need for sortation. Automated sorting systems become increasingly essential in any environment where the product mix is complex. Retail, pharmaceutical, package delivery and mail have always required sortation. But, more recently manufacturers are also realizing the many benefits of automated sortation for their processing operations as smaller lot sizes with broader product lines are much more commonplace.

Holste Says: Automated sorting systems become increasingly essential in any environment where the product mix is complex. What Do You Say? Click Here to Send Us Your Comments Click Here to See Reader Feedback

Understanding The Basics For Deploying Sorting System Technology

Essentially, there are two basic approaches to developing a sorting system solution. You can view sortation as a process to add to operations, or as an essential component of an overall system solution specifically designed to meet your business objectives. The latter (which often requires a system planning audit) is the most comprehensive because it takes into consideration all possible product mixes from all production lines including factoring in future needs.

Deploying a sorting system typically involves a complex mix of equipment and subsystems that must interact with conveyors, product identification, product flow, and the sortation function itself.

Operational constraints requiring evaluation may include: product weight, case/package size, weight and handling characteristics, required throughput capacity (cases per minute), footprint and system configuration. A system planning audit when performed by a qualified consultant or industry expert, serves as the key to developing a customized sorting system solution.

Once the audit is completed and the business requirements have been documented, the next step is to determine what level of sortation from manual to full automation, is needed. Generally, the higher the need for speed and accuracy, the more automation is indicated. Automation should be considered when two or more of the following requirements exist:

• Throughput – 10,000 or more cases/units processed per day or shift
• Accuracy – 99% or greater
• Product damage – 1% or less
• Productivity – reduce incremental increases in headcount
• Resources – optimize capacity of existing facility and processes

*Induction: BSB = Brake Spacer Belt; BMB = Brake Meter Belt; BMB-HS = High-speed Brake Meter Belt

** Applications: 1 = Low speed distribution; 2 = Low speed in-plant processing; 3 = Case reorientation;

                            4 = Medium speed distribution; 5 = High speed retail, mail order, item/postal/parcel;

                            6 = high speed item/parcel, baggage

*** No limitations

The above three subsystems are essential elements of the automated sorting system solution. Their proper design and application is critical to the performance of the overall material flow system. They should be located in an area within the facility that will not be considered for expansion anytime in the foreseeable future.

As an example: Locating the sorter over the shipping dock doors is definitely worth considering as this space is seldom used efficiently. In facilities that have a clear height of 25 feet or more, installing the induction and sortation subsystems on a floor supported mezzanine takes advantage of the buildings cubic space while creating unobstructed floor space underneath for staging, as well as the efficient movement of personnel and mobile equipment.