Getting products to consumers as quickly as possible is essential to maintaining high customer satisfaction, efficient resupply and increased profits. But manual picking fulfillment procedures is slow, cumbersome and inefficient.
Automating simple picking processes is one of the best way to streamline the supply chain for businesses such as pharmacies, discount stores and other line-level retail operations, according to a new white paper, “5 Ways to Increase Profits with Simple Picking Automation,” issued by Kardex Remstar, a leading manufacturer of storage and retrieval systems based in Westbrook, Maine.
Using automated picking machinery such as a vertical lift module, a vertical carousel, or a horizontal carousel can reduce labor costs, expand operations without adding more labor, reduce picking costs, take up less floor space, help eliminate or reduce worker absenteeism and injuries, and lower the incidence of mispicks, according to Tim Archer, sales trainer for Kardex Remstar.
Archer presented the paper at last month’s Modex materials handling trade expo, which was held at the World Convention Center in Atlanta, Georgia.
A vertical lift module, for example, is an enclosed system of vertically arranged trays that are controlled by a computer. As specific products are required, the module automatically delivers them to an ergonomically-engineered work station where an warehouse employee can collect them. This type of efficiency can help reduce labor by reducing the number of employees that are required to fulfill the same task while maintaining the or even improving current productivity levels.
If the same number of employees are used, then the vertical lift module and other simple automated picking devices can help increase throughput, Archer said.
One company that currently is using automated picking devices is Jo-Ann Fabrics. At its Toronto distribution center, the decorative fabrics wholesaler and retailer uses four shuttle vertical lift modules as well as integrated software to handle the more than 1,100 different products that move through the facility to the company’s North American stores.
After the equipment was installed, orders were fulfilled in half the time and only one worker was required, according to Archer. Plus, the pick time was reduced by 70%, from an average of 10 minutes to just 3 minutes.
Ken Hovesen Krasa, Jo-Ann Fabric’s vice president, said the system has helped the company achieve successful results.
“The shuttle VLMs allowed us to expand our hardware line without adding labor and maintain our 3 pm order cutoff time,” Krasa said.
Another benefit of automated picking devices is the ability to reclaim floor space for other uses. Because VLMs and other devices take up so little room, as much as 85% of a facility’s valuable floor space can be freed up, according to Archer.
This can allow for floor to ceiling utilization, eliminated wasted aisle space, and maximum unit density. The result is increased manufacturing capacity, expanded quality control and other benefits.
Plasser — a Chesapeake, Virginia, company that makes machines for tamping and other industrial applications — eight VLMs were used to improve productivity. The result? The company recovered 70% of the floor space at its facility.
Daniel Boone, Plasser’s quality manager, said the company was thrilled with the savings.
“A mandated floor space reduction for a production expansion turned out to improve the overall efficiency of the stockroom,” Boone said. “It’s a win!”