Holste Says: Streamlining processes and taking full advantage of embedded equipment and system features should be the first steps in the quest to keep DC systems performing at their highest level. What Do You Say? Click Here to Send Us Your Comments Click Here to See Reader Feedback

Older conveying systems may not be capable of satisfying the diverse handling requirements of today’s multi-channel marketplace. Shippers therefore, may be considering replacing existing conveyors to increase handling and processing capability. However, it could be that some or all of the additional capabilities you now need already exist but have not been recognized. The following are examples of some of the “built-in” equipment and/or system features that may improve handling capability and capacity.

Bob Babel, VP Implementation Services at Forte www.forte-industries.com (recently acquired by Swisslog) 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 conveyor manufacturers. This modification could be done at the same time additional carrying rollers are added as described above.

Many shippers are experiencing higher case shipping volumes, which is once again the result of the higher order frequency of small packages. A good example can be found in the typical shipping sortation system. Many of these systems are capable of providing higher sorting rates than what was initially required. 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.

Another example where capacity can be increased would be to reduce gaps between cases at critical merge points and at the induction to the sorter, which will immediately increase throughput capacity. Control and software upgrades are readily available.

You may also be surprised to find out that your current 1 or 2 level high picking module may be capable of supporting a 2nd or 3rd level. 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.

The above modifications are actually quite common and should be considered before making a large expenditure for new equipment. For more info – 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:

“With thorough maintenance, the investment in a material handling system can perform for decades. The Beiersdorf DC (above video) is 18 years in operation and it runs as well as when they opened. I have been in many other facilities that in 5 years there are areas of the system that need replacing due to ‘fix-it-when-it-breaks’ mentality”.

“So often I visit sites where what appears to be a throughput issue is really a lack of understanding and coordination between areas in the DC. Most operations get a picking requirement and they concentrate on getting it all on the conveyor as quickly as possible. This often results in backups, jams, and other issues. Systems work best at a steady state, balancing the movement through the areas results in the continuous, high throughput the system was designed for. In many systems the personnel assigned to servicing the aftersort lines are too few for the staff assigned to picking. Aesop’s ‘Tortoise and the Hare’ fable applies to DCs”.

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. Streamlining processes and taking full advantage of embedded equipment and system features should be the first steps in the quest to keep DC systems performing at their highest level.

Final Thoughts

The bottom line is that by making a few equipment and system operational changes you can pick more SKUs, handle a larger range of carton sizes, and ship more volume – all with essentially the same, albeit “enhanced”, system.