Order picking and fulfillment systems should increase productivity while providing innovative ways to reduce both costs of labor as well as total cost of investment and ownership.

The video examples below show some cutting edge ways to streamline operations. This is the same operation utilizing two different lines and segmenting the high and low volume items.

High SKU movers use full automation for order picking, totes are automatically filled and released to final pack and manifest.

On the slower moving SKUs it often makes more sense to manually pick these items, but still using optimal technology such as voice picking and touch devices to verify and pack orders.

When considering the multiple means to automate processes, it is best to consider the overall picture including:

1. Overall order volume
2. Line items per order
3. Quantity per line item
4. Product mix by size (paperclips or office desks?)
5. Hours of operation and number of shifts

All of these factors influence the type of system that will most efficiently handle the majority of the orders. If 5% of the order volume are very large and bulky items, it makes no sense to build automation around this scenario, however, it probably makes a lot of sense to build a system around the 85-95% of the volume.

Matching the right technology with the right application is key. The ROI should reflect factors in both labor and in order accuracy. There should be a clear reason “why” the project is a project and why it adds value to the operation.

Sometimes thinking outside of the box is a great thing. In the automation world it is also important to think INSIDE the box. It is always a great idea to automatically label, convey, sort, etc. the items and boxes used in fulfillment. However, automating things going into the box is also a great labor saving practice. In this example I am talking about inserting literature and promo materials via friction feed dispensers.

The only hands that really touch this entire process are loading flat corrugate into a case former, and a single operator who handles numerous non-standard items that vary from batch to batch which do not make much sense to automate at current volumes.

Once the box is formed, a label is printed and applied automatically, then items are dispensed into the open cases. The case is then taped and labeled with a preprinted label, then goes to a RFID reader where the actual products inside is read and verified against an order ID, and is weighed and manifested for shipping.

Inserting brochures and literature inside the box

Safe and Efficient Box Opening

A dangerous process most have ignored for years.

What happens when workers are handed razor sharp knives to cut open hundreds of pallets of boxes? Eventually someone gets cut, sometimes badly. Repetitive motion such as lifting and cutting boxes causes disabling injuries. Box opening remains one of the most common and dangerous operations in industry.

Most dangerous and high labor repetitive operations have been automated or eliminated in today’s modern factories and distribution centers. However, most order fulfillment, bulk material processing and reverse logistics operations still depend on manual labor to de-stack and open boxes; billions worldwide each year.

Many companies have long since implemented various safety oriented programs to address safety, but none remedy both safety in cutting boxes open and in lifting.

Stop box knife injures now! Cornerstone Automation Systems is the pioneer in box opening safety. ABOT™ (automatic box opening technology) is a fully programmable carton opening system capable of removing the top from cartons automatically. ABOT-ONE opens up to 600 cartons per hour, while ABOT-DUO opens up to 1000 cartons per hour. Speed will greatly depend on the size of box, cut depth, and other variables, which alter cut times.

The flexible design allows for automatic height and carton ID detection, enabling ABOT to adjust opening methodology by carton dimensions or optional barcode and RF tag scanning. State of the art sensors combined with CASI’s patented software and controls provide a most flexible and dynamic industry leading solution.

Advanced Applications

ABOT expanded capabilities include applications for automatic case extraction. ABOT ACE is a system designed to automatically index full cases or bags, cut tops, remove contents, and dispose of the carton and inner lining. CASI is the only company offering a standard system that performs all of these tasks with applications such as mixing ingredients, depalletising/repalletising cases, as well as other food and custom solutions.

ABOT ACE can empty contents into hoppers, bins, super sacks, and conveyors. ACE separates liners and disposes of corrugate and plastic separately and automatically.

Boxes may be opened by cutting tape seals, removing tops, and by cutting inner liners. ABOT ACE will remove the top then open the liner inside; allowing the contents to be poured from the case. ACE is flexible with programming to remove the liner with the contents then separating the liner from the contents.

ABOT ACE can pour many types of contents in a controlled flow at varying levels up to nine feet. This process automatically fills super sacks without need of conveyors or hoppers.
ABOT ACE has options for food grade rated and IP 67 wash down capability. The ABOT cutter is available in IP 65 and stainless construction.

About CASI
Cornerstone Automation Systems provides end-to-end fulfillment systems including receiving, putaway, order picking, and end of line processes for scanning, weigh in motion, print/apply, and shipping/manifest systems. Our modular approach allows maximum flexibility to integrate to current systems and processes or provide standalone systems to address a specific need. As your needs evolve, so does your system. CASI provides full in-house manufacturing and testing before a system is shipped so customers are able to see everything in operation before it is delivered and commissioned onsite.

Software is the heart of automation, and CASI has developed SolidSuite™; a suite of modules that provide unsurpassed performance and serve as the foundation of our industry leading solutions. Based on Microsoft SQL/.Net platform, it is designed, written and supported by CASI in-house, US, UK, and Australia based engineers. With hundreds of successful installations worldwide, SolidSuite offers features unmatched by our competition.

Frisco, TX, October 5, 2011, Cornerstone Automation Systems, LLC is pleased to announce its relocation to a greatly enhanced 86,000 sq. ft. facility in Frisco, TX.

The facility allows administration, engineering, inside sales, and manufacturing to work under the same roof. Efficiencies in manufacturing and integrating entire systems within the facility before shipping to customers have been greatly improved as scope and capacity of projects have increased. The new building allows adequate space to build multiple systems and fulfill CASI’s ongoing mission to provide fully functional systems before shipping.

About CASI:
Cornerstone Automation Systems has been in operation since 2002 providing highly cost effective software and hardware solutions for logistics and warehouse operations.
CASI’s highly talented staff is heavily experienced in designing and manufacturing cutting edge automation solutions for all types of businesses. CASI turnkey solutions include fulfillment systems, sortation, conveyor, automated shipping, and patented solutions such as automated box opening. Our SolidSuite software provides a modular approach and single point of control for all systems we sell and keeps integration seamless. The effectiveness of CASI’s designs and niche market solutions is evidenced by years of double and triple digit growth since inception.

1. Order Picking Process

Problem:

Many companies still rely on printing paper tickets to pick orders. Even at low volumes, this process ignores the number of steps taken to find the pick locations from one order to the next. Order accuracy also becomes an issue at the time of picking and through the packing process; requiring a manual audit for quality control.

Solution:

Device and software driven order picking.

By implementing one of several picking technologies such as RF scanners, voice picking, pick to belt, or pick to light, order picking time, accuracy, and number of employees required to perform these tasks is greatly improved. Most companies will see a 30% to 70% jump in picking efficiency alone once paper is removed from the process. Even companies with scanners now may consider voice or other features to add 15% to 30% increases to current productivity.

Other systems include automatic dispensing. These systems are designed typically for smaller goods such as small boxes, pharmaceutical or pill blister packs, or items such as CD’s and DVD’s. By dispensing the products on demand to a conveyor, the goods are transported and sorted to a packing area, thus removing labor and time to retrieve these items. High volume or fast moving SKUs are typical indicators, but many variations exist for every application that will dictate the solution.

2. Order Validation and Quality Control

Problem:

Most DC’s rely on manual QC processes to inspect orders. These processes are both time and labor intensive with very little payback.

Solution:

There are several solutions to address order validation. Here are two examples.

A) In many operations a checkweigh system will automatically scan, weigh, and compare actual weight with expected weight by using data tables. This process may be set up to automatically reject high value orders or where very small items exist to ensure maximum flexibility and customization.

B) In operations with static or batch items per carton or container, a vision system may be used to ‘look’ for inconsistencies in the carton. Color sensors or cameras are trained to see patterns or certain colors, which flag the system if there is inconsistency or an error. Vision systems are often fairly simple but may also be used in complex applications where multiple types of profiles are stored and viewed on the fly.

3. End of Line Shipping and Manifest

Problem:

Shipping and manifesting is one of the biggest areas associated with excessive touch labor occurs in the last 5 meters of the operation. The problem exists because people are performing QC tasks, packing, weighing, labeling, and data entry to ship the merchandise.

Solution:

An end of line shipping and manifest system allows either full automation or single person to feed a system that scans, weighs, labels, verifies, and ships packages. Options for sortation by carrier or to shipping lanes for palletizing or common carrier may be used to further the process and eliminate the need for manual intervention as to where packages need to go once they are ready for shipment.

A typical end of line shipping system will remove the touch labor or 2-4 workers depending on the volume of shipping.

The equipment for an end of line shipping system would include a system controller, a simple zoned conveyor, scanner(s) to lookup the order information, a checkweigher to record the shipping weight and/or validate the contents of the order, a printer applicator to label the package, a validation scanner to verify the label as readable and tie this scan to the package, and optional sorting equipment.  The software and controls would include an order interface to the host system, label file provided by a host or shipper such as UPS, FedEx, USPS, or other carrier.

About CASI

Cornerstone Automation Systems provides end-to-end fulfillment systems including receiving, putaway, order picking, and end of line processes for scanning, weigh in motion, print/apply, and shipping/manifest systems. Our modular approach allows maximum flexibility to integrate to current systems and processes or provide standalone systems to address a specific need. As your needs evolve, so does your system. CASI provides full in-house manufacturing and testing before a system is shipped so customers are able to see everything in operation before it is delivered and commissioned onsite.

Software is the heart of automation, and CASI has developed SolidSuite™; a suite of modules that provide unsurpassed performance and serve as the foundation of our industry leading solutions. Based on Microsoft SQL/.Net platform, it is designed, written and supported by CASI in-house, US, UK, and Australia based engineers. With hundreds of successful installations worldwide, SolidSuite offers features unmatched by our competition.

Prosper, TX, December  27, 2010, Cornerstone Automation Systems, Inc. was recently capitalized as Cornerstone Automation Systems, LLC.

The new team consists of investors from CIC II, LP and Michael Doke as equity partners, Thomas Karol, Gus Freshwater, and Kevin Beattie are operating partners for Cornerstone. Michael Cannonie has sold his interest to Cornerstone and will become a consultant to the business.

Cornerstone Automation Systems, LLC has announced the new executives as Gus Freshwater, CEO and Michael Doke, Executive Vice President. The new entity will focus on continued innovation, growth opportunities as well as customer satisfaction and service.

About CASI:
Cornerstone Automation Systems has been in operation since 2002 providing highly cost effective software and hardware solutions for logistics and warehouse operations.

CASI’s highly talented staff is heavily experienced in designing and manufacturing cutting edge automation solutions for all types of businesses. CASI turnkey solutions include fulfillment systems, sortation, conveyor, automatic shipping, and patented solutions such as automated box opening. Our SolidSuite software provides a modular approach and single point of control for all systems we sell and keeps integration seamless. The effectiveness of CASI’s designs and niche market solutions is evidenced by years of double and triple digit growth since inception.

Contact information:
Sean Robinson
214-263-7273
srobinson [at] cornerstoneautosys.com

Cornerstone designed the 4th generation standard PC based controller to replace the 1100AC2. The new CASI Core has some great features including solid state drive and Windows 7 OS. The optional CASI Core S model runs SQL Server and NEMA 4X washdown controller models are available.

See the new automation controller

It would seem strange to have “food” and “harsh environment” in the same sentence. However, when it comes to conveying food or other items that requires equipment to be washed, chemically sanitized, etc. the equipment itself must be able to withstand water, pressure, chemicals, etc.

The latest washdown conveyor from CASI is NEMA 4x rated; allowing the system to convey food or liquids as well and washed with water or cleaning agents.

CASI stainless steel conveyor uses all washdown components including frame, rollers, and belting material. Other NEMA 4X components with any conveyor system include touch screen PC controls, scanner/labeling housings, and checkweighers.

Call CASI for a quotation as each application may require different setup.

It seems that in designing a fulfillment system that optimizes putaway, picking, weighing, labeling, and sorting would solve nearly everything. There are many companies that manufacture or simply integrate systems based on third party products.

One challenge that can cause a lot of inefficiency in zone picking (pickers only pick to orders that come into their zone) is how to address items not in the flow rack. It is usually prohibitive to stock ‘everything’ or likely it is impossible to keep all things in all picking zones. Most companies opt to keep only the fast movers or top 80% of fast movers in their pick zones. What about the slower movers or items that are not in the flow rack zones?

Rather than send pickers out on a ‘per order’ basis when a slow mover is part of an order, there can be a temporary zone or zones set up that address all items not in the flow rack. A single picker can batch pick all orders at once that include item(s) not in the pick zones. Once items are picked, they are scanned to one of the temporary zones and the order is automatically released to the system once all items in that order are available for zone picking.

CASI has coined the term “Replenish to Order” or “RTO” as part the fulfillment process to eliminate costly time it takes to retrieve slow movers one order at a time. If you have a 500k Sq Ft warehouse, you can imagine how many trips back and forth are saved by having these items picked all at once.

Here is a case study that focuses on a fulfillment system using RTO.

It seems there is a machine or software solution out there for just about anything imaginable. In the material handling world this also rings true to the degree there is someone willing to buy such a solution or pay to have it custom built. One area that is often ignored even by some of the most advanced distribution facilities is the process of opening boxes for receiving and returns.

As trucks are offloaded, a typical bottleneck in the material flow is found with many people manually cutting boxes open. The results are quite expensive when looked at in terms of labor, turnover, injuries, and product damage.

An automatic case splitter is extremely useful for receiving applications.

1. A basic system will open 600 cases per hour, or advanced up to 1100 per hour
2. Systems lease for as little as $1000/month, which is less than 1/2 of a single employee burden
3. The cost of a single injury from a box knife can cost more than the machine that alleviates such injury

Given the constant need to streamline, amplify throughput, and improve safety, it is clear that an automatic case splitter can fill a void that exists in most operations, even the most automated facilities.