The objectives of the automation project for the DC can be broken down into three major parts i.e., implementing a Pick-to-Light system, a Print and Apply system, and a Case sorting module. They wanted to optimise the material flow and streamline the sorting process for break-pack items (items that had to be picked by opening the case), as well as to achieve the throughput requirements. By implementing the Pick-to-Light system, the DC could automate demand handling from both shelving and racking and sort units to crates for stores. Another ask was for a smart conveyor system to transport crates to weight, print and apply stations where handling labels could be applied. Through automation, they wanted to perform store-wise sorting and streamline cases and crates to pallets for ease of loading and delivery. This would help them save major operational and logistics costs to cater to a wider market.
The comprehensive approach to optimising the material flow through the warehouse and streamlining the sorting process for break-pack items was involved in the solution. The right SKU mix was identified and a process utilising batch picking and Put-To-Light (Rapido) based sortation was developed in close collaboration with the customer. Multiple put walls enabled with Pick-to-Lights were designed, and dynamically allocated to different categories like Food and Non-Food. To simplify operations, a network of smart conveyors was established to transport crates, reducing picker travel time. The solution also included dynamic mapping of the store for sorting operations, with zoning and sub-zoning created to allow for greater flexibility. Features like ease of integration, multi-coloured lights, and easy installation were provided by Pick-to-Lights, making it a comprehensive solution for optimising warehouse operations. To conclude, our configured warehouse control system ensured accuracy and provided real-time data for the smooth management of all tasks.
The comprehensive solution developed, which involved utilising batch picking and Pick-to-Light sortation, and establishing a network of smart conveyors, saved significant operational and logistics costs and time while streamlining sorting processes.
Included installation of more than 300 Pick-to-Light units, enabling efficient order picking by the picker
Installation of over 300 metres of smart conveyor network, both accumulation and non-accumulation conveyors
Supplied all automation in-house built equipment required for the project in just 8 weeks, decreasing productivity loss
Quick FSD finalisation and configuration through a close collaboration led to the installation of a robust Warehouse Execution System.
Our extensive product portfolio helps us design customised solutions for varying industry requirements.
Changing the storage paradigm from square feet to cubic feet
One of the fastest, intuitive, and versatile Person-to-Goods technology
Complex sorting, now simpler and swifter
Versatile solution for storage and retrieval of crates, cartons, and totes