Horizontal Carousel System
description
Transcript of Horizontal Carousel System
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Horizontal Carousel System
• “Good” carousel stock is typically a subset of the SKUs that have medium velocity
• They are called for often enough to make automatic retrieval sensible, but not demanded so often that the system slows down through too frequent replenishment
• The accepted rule of thumb requires that an 8 to 10 day supply of a given SKU should be able to fit within 10 cubic feet of a carousel bin space
• An 8 to 10 day supply only requires replenishment of a more manageable 8 to 10% percent per day
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Warehousing and Distribution Operating Costs
• Order fulfillment is the highest priority for productivity improvements
• 63% of all operating costs are attributed to order picking
• Order fulfillment has become more difficult to manage due to the large numbers of SKUs handled
• Smaller quantities are delivered more often
• Greater emphasis on quality, customer service, picking accuracy, improved product handling and tighter inventory control
• Distribution applications need to pick faster with fewer errors at a lower cost
Of the 63% Spent picking the product, Walking consumes 38%
38%16%
6% 3%
Walking
Extraction
Searching
Other Activities
Warehouse Operating Costs
63%18%
13%6%
PickingShippingOthersReceive
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Storage Media Selection
• In the process of designing an order fulfillment system, one of the first considerations to make, is what storage media is appropriate
• This decision is based on SKU (Stock Keeping Unit/part number) velocity
• SKUs with a very high velocity are better handled in A-Frame or Flow Rack
• On the other end of the velocity scale, the very slow movers are better stored on Static Shelving or Racking Racking
Shelving
A-Frame
Flow Rack
Vertical Storage Device
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The Machine
• Series of Shelving Sections/bins Rotating on Closed Loop Oval Track
• Bins Either Suspended From Top or Supported on Bottom by Wheels
• Bins Vary in Width, Height and Depth
• Actuated by Footswitch, Keyboard or Computer Control
• Classified As ‘PARTS TO PICKER’ As Opposed to ‘PICKER TO PARTS’
• Eliminates Walking and Searching
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History of Horizontal Carousels
• The concept of the horizontal carousel originated with White almost 50 years ago
• Dry Cleaning establishments needed to have garments delivered to the front of the store so that they could service a customer without leaving the front counter
• In the early 1960s White began to manufacture carousels for light weight industrial applications
• Since the early 1970s, White developed and patented heavy duty bottom drive carousels, Twin Bin and pallet carousels, robotic inserter/extractors, as well as other types of carousels
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The Pod Concept (cont.)
• The pod allows an operator to work with several carousels simultaneously
• Typical pod is two to four carousels
• All equipment within the pod work zone would be under software control
• The premise of the Pod is that as the operator is picking from one carousel, the software is pre-positioning the other carousels for the next item to be picked
• Operator is being directed by lights for picks and puts
• Product moves in a continuous flow, eliminating operator wait time
• Multiple orders are picked in a single batch
• Very high throughput is achieved
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The Pod Concept (cont.)
Picker to Parts
Up To 100 Lines Per HourParts to Picker
Up To 800 Lines Per Hour
Movie Clip
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Parallel Picking
Video Clip
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Pick and Pass
Video Clip
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One Touch Distribution
• A new approach to picking and sorting orders utilizing carousels and tilt tray or cross belt sorters
• Depending on SKU velocity, carousels, flow rack or shelving can be incorporated into the system
• Eliminates moving and tracking orders from storage zone to storage zone
• Orders are consolidated into packing chutes
• Size of the sorter system is fully scalable and expandable
• Based on activity, the number of operators can be either increased or decreased
Video Clip
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Carousel Automated Storage & Retrieval Systems (CAS/RS)
• System automatically stores and retrieves cartons, totes and other types of containers
• Links stacks of carousels to inbound and outbound conveyors
• Handles multiple size containers within the same system
• Designed to run 7/24/365
Movie Clip
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Other Horizontal Carousel Applications
Put Systems
• At the put pod, the carousels bring orders to the product rather than the other way around
• Many orders can be active simultaneously in the relatively small area occupied by the carousels
Movie Clip
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Progressive Assembly
• Passing Kits From 1 Assembly Workstation to the Next
• Easily Modified For Virtually Any Product Configuration
Other Horizontal Carousel Applications (cont.)
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New Horizontal Carousel Applications
Cart Carousel
Video Clip
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Full Case Picking
• Up To 400 Lines Per Hour
• 99.99% Pick Accuracy
• Batch Picking
Other Horizontal Carousel Applications (cont.)