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.
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.
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.
로우 베이 스토리지 시스템은 3,500개의 팔레트 보관 위치가 있는 G+4 레벨로 구성되었습니다.
하이 베이 영역과 로우 베이 영역은 메자닌을 통해 서로 연결되었습니다.
2 Crane- 느리게 움직이는 SKU를 위해 하이 베이 영역에 ASRS를 설치했습니다.
'G' 레벨에서는 분류 및 팔레트 형성을 위해 단일 모체 셔틀이 6개의 단일 깊이 모체 셔틀 시스템으로 이동했습니다.
총 11대의 마더 셔틀, 10대의 차일드 셔틀 및 지원 시스템으로 구성된 4개의 마더-차일드 셔틀 시스템이 상층부 4층에 배치되었습니다.
더블 및 트리플 딥 ASRS 크레인은 6200개의 팔레트 위치로 최대 30m의 높은 베이 영역에 접근할 수 있습니다.
시간당 300개의 팔레트 처리량을 달성했습니다.
광범위한 제품 포트폴리오를 통해 다양한 산업 요구 사항에 맞는 맞춤형 솔루션을 설계할 수 있습니다.
