In the fast-paced world of logistics and warehousing, optimizing space and enhancing the efficiency of storage and retrieval systems is crucial. A carton shuttle solution offers a highly automated and efficient method to manage inventory. However, several key factors must be considered before implementation to ensure the system is a perfect fit for your operations. This blog will guide you through the essential pre-requisites to evaluate before adopting a carton shuttle solution
What is a Carton Shuttle?
Carton Shuttle is an innovative automated storage and retrieval system designed for cartons, crates, and totes. This system features shuttle-based storage with vertical lifts and specialized racking, allowing for efficient high-throughput operations.
The double-deep storage capability enhances productivity and maximizes storage density in distribution centers. The Carton Shuttle maximizes space utilization, accelerates order fulfillment, and improves inventory management, resulting in streamlined and optimized warehouse operations.
Prerequisites for Implementing Carton Shuttle
In Goods-to-person systems like carton shuttle shelving, orders are stored, picked, and retrieved in a hodgepodge before being delivered to the customer. This system has contributed to increasing the overall throughput of picking, allowing businesses to meet their customer demands through improved order accuracy. However, to successfully deploy these systems, a few critical calculations such as process throughput, space capacity, product profile, operating plan, etc along with the technical requirements such as those mentioned below need to be done carefully.
Business Needs Assessment
Define operational goals: throughput, accuracy, and cost reduction. Analyze product volume, variety, and peak demand periods.
Space and Layout Analysis
Evaluate the current warehouse layout and available space. Consider height utilization and identify any physical constraints.
Inventory Management
Profile inventory by size, weight, and turnover rate. Determine specific storage requirements for different products.
Technology Integration
Ensure compatibility with the existing Warehouse Management System (WMS). Identify necessary software and hardware upgrades for integration.
Financial Planning
Calculate initial investment and ongoing operational costs. Estimate the potential return on investment (ROI) and payback period.
Scalability and Flexibility
Assess the system’s ability to scale with business growth. Ensure the system can adapt to changes in product lines and storage needs.
An Analysis before implementation
A thorough analysis and inspection of the warehouse, and an understanding of the current throughput and operation is required before even proposing the carton shuttle solution. It also requires a detailed report on the existing process with the average time of order fulfillment and concluding how the implementation of carton shuttles can improve productivity and hence remove process bottlenecks like delayed orders or improper inventory control.
How to compare & calculate carton shuttles productivity?
The throughput calculation considers the current SKU pace, average units fulfilled per order, and provides the expected process accuracy to be achieved by deploying these automatic systems. Interestingly, these systems are capable of picking orders of say 300 picks per hour whereas the traditional manual order picking may bid for the utmost 100 picks per hour per operator.
Also, these systems provide the flexibility to increase the throughput by adding more of such systems into the fulfillment center which then conflicts with the operating space available. So, space capacity is another such scrutiny that needs to be addressed before implementing the system. To get higher throughputs, increasing the height of the aisles to the maximum permissible height,i.e, 100 feet can harm the overall accuracy of the order fulfillment.
Learn more about automation by exploring our other blogs!
Key Technical Requirements for Carton Shuttle Solution Installation
1. Track Installation: Lay tracks with aligned electrical busbars and ensure a steady power supply of 230 VAC, 50Hz, single-phase. Position barcode labels accurately for reliable distance measurements and positioning.
2. Safety Features: Install limit switches and external caging with automated, magnetic coil-based door locks for aisles containing shuttles.
3. Network Integration: Ensure that network interfaces are installed, and set up network access points (APs) at critical locations to integrate with warehouse management systems (WMS) and warehouse control systems (WCS).
These steps, along with a focus on safety examinations, are crucial for a successful implementation.
Conclusion
To implement a carton shuttle solution, consider inventory type, assess warehouse space, design an efficient layout, invest in IT infrastructure, align with throughput needs, train staff, implement safety measures, and consider total cost.
An advance and scalable carton shuttle system enable accelerated picking, order sequencing and order fulfillment, driving the storage efficiency through the ceiling. With Addverb, being the first largest manufactures of carton shuttle in India, we bring a diverse and wide industry exposure in implementing a carton shuttle system.
FAQ
What type of inventory is suitable for a carton shuttle solution?
Carton shuttle systems are ideal for operations handling medium to high volumes of small to medium-sized items.
What are the space requirements for installing a carton shuttle system?
Adequate vertical and horizontal space is necessary to accommodate the shuttle tracks, storage racks, and picking stations.
What technological infrastructure is needed?
A robust IT infrastructure is required, including warehouse management software (WMS), control systems for the shuttles, and reliable network connectivity to ensure seamless operation.
How does the system integrate with existing warehouse operations?
The shuttle system should seamlessly integrate with existing material handling processes, inventory systems, and order fulfillment workflows to ensure a cohesive operation.
What is the total cost of ownership?
Consider the initial investment, ongoing maintenance costs, and potential savings from improved efficiency when evaluating the total cost of ownership of a carton shuttle solution.
