HUL : Centro de distribución automatizado

Objetivo

Hindustan Unilever aimed to shift from a distributor model to an automated distribution center that directly serves retailers. However, their distribution center could only handle cases while retailers ordered eaches. To reduce operational costs, they sought to automate the warehouse to break cases into eaches and send them directly to retailers.

El proyecto se enfrentaba a retos debidos a una amplia gama de productos con distintos requisitos de almacenamiento y manipulación, como bebidas, artículos de cuidado personal y alimentos envasados con una vida útil corta, lo que provocaba la obsolescencia del inventario. Era necesario un sistema sólido de gestión de inventarios.

The goal of the automated distribution center was to implement individual item picking in the automated distribution center model to fulfil approximately 4,000 to 5,500 customer orders daily, consisting of 18,000 to 25,000 cases comprising 800,000 individual items. The system had to handle up to 1.1 million individual items during peak demand days. The goal was to ensure accurate and timely delivery of orders, including overnight fulfilment, while minimizing manpower intervention to maximize operational efficiency and accuracy.

Solución aplicada

Addverb implemented an automated distribution center solution for their warehouse in Chennai, utilising technologies such as Carton Shuttle, Pick-to-Light, Box-It, and Warehouse Control System.

Six months of data analysis helped categorise the SKUs into A, B, and C classes, with a different storage mechanism proposed for each class to optimise storage and dispatch efficiency. This enabled them to fulfil orders for 28,000 Kirana stores in Chennai within 24 hours without a minimum order size requirement, improving their service levels.

The solution enabled pickers to achieve a rate of 9,500 picks per hour, ten times more productive than conventional paper-based picking. Fast picking and packing, dynamic load balancing, order scheduling, and finished goods scheduling reduced overall turnaround time for order fulfilment. The complete solution helped them save major costs, eliminated dependency on distribution centres, and reduced dependency on labour.

Mejora de los resultados clave (KPI)

The automation distribution center solution involved changing the model and handling a wide range of SKUs to supply retailers directly and quickly. The system had to be robust to fulfil demands overnight accurately and efficiently to save major operational and manpower costs.

Categorización de las SKU en clase A, B y C para un almacenamiento y una preparación de pedidos eficaces

Picking mercancía a persona que lleva las referencias a los preparadores para atender 8 pedidos de clientes al mismo tiempo, por puesto de picking para referencias de clase C.

Sistema Pick-to-Light asistido por cinta transportadora para picking de clase A y B que permite una cadencia de picking de 6.500 y 3.500 unidades por persona y hora, respectivamente.

Esta solución única ha permitido multiplicar por 10 el índice de preparación de pedidos, alcanzando las 9500 recogidas por hora, lo que facilita la preparación de pedidos en 24 horas.

Entrega de pedidos en 28000 tiendas en 24 horas sin requisito de pedido mínimo

Capacidad para atender unos 5.000 pedidos de clientes al día, lo que supone entre 8 y 11 lakhs cada uno durante los días punta.

Dimensionamiento, sistemas de pesaje y cámaras de alta calidad para captar las discrepancias, lo que permite realizar controles de calidad sin errores.

Proceso de secuenciación seguido de la carga de cajas según el destino en el camión para optimizar la planificación de rutas y ahorrar tiempo y costes.