CASE STUDY: Automated Shipping Solution

The Problem: Reduce Material Handling Labor Costs

A manufacturer of toys opened a west coast distribution center and needed to reduce DC labor costs. Automation of the material handling system was identified as a place to reduce cost.

The Solution: Automated Sortation, In Motion Scale and Conveyor System

CASI proposed an automated conveyor system that would transport the items through the pick module and to the shipping dock. An in motion scale and fixed position barcode scanners was used to check the weight of each item and ensure the case had the proper compliance labels. Ten lanes of shipping sortation routed each item to the correct dock door.

System Overview

The system begins with a custom interface to the Warehouse Management System to get the picks for the current wave being processed. Items convey through the pick modules and on to the shipping area.

Each carton stages in zero pressure accumulation before the in motion scale. A pick barcode on the front of the carton is read by the fixed mount barcode scanner as the carton moves onto the in motion scale.

As the item moves across the in motion scale, the UCC128 compliance label is read confirming that the carton is properly labeled for shipment to the retailer.

The SolidCheck software performs numerous QC checks to ensure the package is correctly picked and labeled before shipment.

Mispicked items or other exceptions are diverted to the left by the SortMaster 100 bidirectional divert. Last cartons need special paperwork and are diverted to the right.

After the QC process at the scale, the carton is tracked to the correct lane and diverted. Personnel then load the items onto the trucks using an extendable conveyor. An exceptions travel to gravity conveyor at the end of the sorter and are processed manually.

Benefits from the new efficiencies

The automatic shipping system lowers labor costs and allows the faster processing of orders. The system also allows peak volume to grow substantially without major system modification.

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