Holste Says: |
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| Industry experts know that oftentimes real payback can be found in thoroughly examining order processing, and smoothing out the peaks and valleys in receiving, inventory, picking, and shipping systems. |
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What Do You Say?
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For Example:
It’s common knowledge that “small” orders are playing an ever increasing role in the DC. Distributors that have multiple sales channels (B2B, B2C, catalog, Internet, e-commerce, etc.) report a large increase in the frequency of 1 or 2 line item orders. Likewise, manufacturers are being forced to downsize package sizes to accommodate demand for smaller quantity. This tends to increase the volume of small to very small (< 9″ lg.) cartons that have to be handled on conveyor and sorting systems.
The majority of powered roller conveyors installed in DC systems are equipped with 1.9″ diameter load carrying rollers spaced at 3″ centers. This works well when the smallest carton is 9″ long, or longer. Cartons shorter than 9″ can get stuck in the space between the rollers increasing the possibility of jams, frequent shut-downs, and product damage.
The good news is that a possible “fix” for this small carton handling problem may already be built-in.
This is because when conveyor side frames are manufactured, the axle holes for the load carrying rollers are punched at 1″ spacing. Therefore, if the conveyor ever needs to handle cartons less than 9″ in length, the load carrying rollers can be re-spaced at 2″centers. Of course, driving all those additional rollers may require an increase in conveyor horsepower. There may be some additional fine tuning required by the equipment provider, but, once those are completed the existing system will be able to handle a larger range of small cartons.
Material handling system expert, Bob Babel, VP Implementation Services, Forte (www.forte-industries.com) points out that another “fix-it” possibility is on systems that have mechanical sensors in the accumulation conveyor, that no longer activate reliably (especially on small, and/or light weight cartons) and can be a performance as well as a maintenance issue. Babel recommends replace them with photo eye sensors. Retrofit kits for this fix are available from most equipment suppliers.
More Embedded Capability
Uncovering embedded capability may be as simple as asking your system provider how to squeeze more capacity out of what you already have.
A good example can be found in the typical shipping sortation system. Most of these systems are capable of providing higher sorting rates than what was initially required. This is often done deliberately so as to provide for future growth. With a few simple equipment changes, like changing the ratio of the drive sprockets and re-calibrating the sorter tracking system (usually done automatically), higher speeds and sorting rates can be achieved. This type of incremental speed change can usually be accomplished without upgrading the drive unit.
Another example would be fine tuning controls to reduce gaps between cases at critical merge points and at the induction to the sorter, which will immediately increase throughput capacity.
You may also be surprised to find out that your current 1 or 2 level high picking module was originally designed to support a 2nd or 3rd level so as to accommodate additional growth in SKUs and picking volume. While you are in the picking module (if cartons are being picked from pallets) check the amount of clear space over the top of a full pallet load – because you may have sufficient space to add a shelf of carton flow lanes.
Note: The above practices are actually quite common in the Material Handling Industry among the top tier system providers. For an actual live DC system example – view a short video clip provided by Forte Industries http://www.forte-industries.com/client-stories/bdf-beiersdorf.aspx
Mr. Babel shared the following additional thoughts:
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