THE CHALLENGE

Saramax Apparel had started to outgrow the capacity of its Pick-to-Light tower and old conveyor system. It had served them well and earned Saramax the 2012 Walmart (DSDC) Supplier Award of Excellence. SKU quantity and volumes would be increasing and the current system did not have enough pick locations and a poor conveyor path to shipping which made it was unsuitable for higher volume. The rest of the warehouse was filled to capacity with high bay VNA racking and the shipping staging space was at a premium. The challenge was to provide a new multi zoned picking system with minimal impact to the current warehouse layout and reuse a lot of the existing shipping conveyor system. In addition the new system had to be expandable with a mezzanine level and the conveyor layout pre-engineered for the future. The new system required pick and pass capability between picking zones and also a fast track conveyor to the auditing area and shipping carousel loop. The new system had to be installed without taking down the existing operation. There was an aggressive schedule to have the entire new system running by mid-August 2012.

SDI analyzed the future SKU and case data and created several system layouts that would fit within the available space. There were a lot of very short distances for conveyor elevation changes, Egress concerns and pallet storage location being maintained.

THE SOLUTION

SDI provided several design options and worked with Saramax to fine tune it to best meet the requirements. A new 36 bay, 28 ft tall, picking module was provided. It was pre-engineered for 2nd level, so expansion in the future would be easy. The first floor has 648 locations with central takeaway conveyors and overhead empty carton removal integrated with the existing trash compacter system. Due to some very short distances for elevation changes and some complex paths between pick modules the latest MDR spiral inclines conveyors and accumulating belted MDR incline conveyors were utilized. The added benefits of an almost silent energy efficient conveyor system where greatly appreciated by Saramax and creates a very pleasant work atmosphere. The old conveyor system was very noisy. SDI purposely designed the system with MDR as it provides carton accumulation every 24” – 60”, even on inclines. These features where crucial to maximizing peak rates and minimizing carton flow back up.

The existing shipping race track carousel loop was relocated to make room for the new pick module and an additional case sealer was added with automatic sortation between available lines.

SDI consulting services analyzed the SKU and order details and provided new SKU to location mapping for the existing and new pick modules to balance work load evenly between pick zones. Keeping the highest movers on the first floor provides the easiest replenishment option.

The SDI Pick-to-Light system provides additional zone fine tuning and load analysis, complete with reporting of pick rates by employee or zone or other easily selectable criteria. The supervisory functions all being available on any browser enabled computer. A tiered security system provides user, supervisor or manager level access to features. The SDI Pick-to-Light is part of a suite of WCS products that also provide carton routing / sorting capabilities. Saramax utilizes the Smart Auditing functionality that keeps track of all picking transactions for each order. A range of selectable criteria can flag any order (carton) as having to divert to a Q/A Auditing area. SDI Dynatron WCS diverts order cartons as required to 6 auditing Thin Client workstations. Operators check orders for accuracy hand scanning items and repacking the order. Actual carton contents are uploaded to the host system.

The client server based architecture ensures that data critical redundant servers are in a safe environment controlled room, not out on the DC floor. Only the low level pick-light controllers are mounted in the pick aisles out of harm’s way.

THE SYSTEM

The new system provides Saramax with all the pick location required and order carton routing between pick modules. Pick rates are 800 – 1100 UPH and (pre Audit) order accuracy almost 100%.

Pre-engineering design features for the future will make expansion easy and cost effective. Lost pallet locations where minimized by adding overhead storage in the 28 foot high pick module racking.

Egress requirements were reviewed by SDI with the City of Sayreville and suitable cross-overs and exit doors provided.