PepsiCo - Automatisierte Palettieranlage für gemischte Kartons

Zielsetzung

PepsiCo was looking for a way to improve its end-to-end operations, starting from managing incoming inventory to efficient storage and dispatch to different distributors. The main aim was to increase storage and throughput capacity, optimise operations within a limited space, and set up a direct dispatch system to distributors.

To tackle this challenge, PepsiCo needed an automated mixed case palletizing solution with a large number of storage bins and pick faces for efficient case picking. The solution also had to allow for manual case picking to create mixed pallets. The innovative solution provided by Addverb not only met these requirements but also automated the manual case-picking process, leading to further improvements in operational efficiency.

Lösung

Addverb conducted an in-depth study by visiting manually operated sites and engaging extensively with stakeholders at all levels, from factory operators to senior leadership. Addverb’s solutions team collaborated closely with PepsiCo to design an innovative warehouse solution, incorporating crane-based Automated Storage and Retrieval Systems (ASRS), Mother-Child Shuttles, and Pick-by-Light technology. These systems were seamlessly integrated and powered by our advanced Warehouse Control System (WCS).

A standout feature of the solution was the modification of the Dense Racking System, creating custom aisles for the formation of Rainbow Pallets (mixed case palletizing). This allowed for dynamic allocation of pick faces, significantly improving throughput for both picking and put-away operations. The entire mixed case palletizing automated solution was implemented within a compact 36,000 sq. ft. facility.

Verbesserung der Schlüsselergebnisse (KPIs)

The solution provided by Addverb is one of the most unique mixed case palletizing solutions as it utilises the Mother-Child shuttle system not only for storage and retrieval but also for Rainbow-Pallet formation at the base of the same dense racking.

Die Niederregallager bestehen aus G+4 Ebenen mit 3.500 Palettenstellplätzen.

Der Hochregalbereich und der Tiefregalbereich waren über ein Zwischengeschoss miteinander verbunden.

2 Crane-basierte Regalbediengeräte wurden für den Hochregalbereich für langsam drehende SKUs installiert.

Auf der 'G'-Ebene übergab ein einziges Mutter-Shuttle an 6 einfachtiefe Mutter-Kind-Shuttle-Systeme zur Sortierung und Palettenbildung.

4 Mutter-Kind-Shuttle-Systeme wurden auf den oberen 4 Ebenen eingesetzt, die insgesamt 11 Mutter-Shuttles, 10 Kind-Shuttles und unterstützende Systeme umfassen.

Die doppelt und dreifach tiefen ASRS-Kräne können auf Hochregallager mit einer Höhe von bis zu 30 m und 6200 Palettenplätzen zugreifen.

Erreichte einen Systemdurchsatz von 300 Paletten/Stunde.