CASE STUDY: Book Receiving System

The Problem: Used Books Need to be Received, Sorted, Shipped, and to Putaway

An online distributor of books receivedused books constantly and needs to putaway and fulfill orders at the same time. The challenge is to handle incoming books that are already an order as well as label/receive new titles to putaway, and sort according to a complex set of business rules.

The Solution: Turnkey Fulfillment System Using Sort to Pack

The CASI solution includes 24V conveyor system with Datalogic Matrix 400 scanners ,checkweigher, automatic labeler, verification scanner, and multiple SortMaster 150 sorters to pack stations and putaway locations.

System Overview

Received books are received and manually placed on the conveyor by multiple operators. There is no need for the operator to space (gap) products as the system performs this task automatically.

Matrix 400 scanners read a UPC or EAN code of each item. A lookup using SolidComm interfaces the host system to determine if the product is already part of the inventory and/or if there is an order for the book.

Each book is automatically gapped and weighed after the barcode tunnel.

Checkweigh Manager assigns actual product weight to each book as it passes through the checkweigher and writes this data back to host and manifest for existing orders. Weight is used to identify books that do not have a barcode.

Books with no barcode receive a barcode label to identify and sort accordingly. Random labeling occurs at 60 pieces per minute. A Datalogic 4800 scanner follows to scan and track each item before the sorter.

Books are automatically sorted using the SortMaster 150 sorter. No air drops for pneumatics are needed as the system is all electric using standard 24V DC components.

Popular books are sorted where packers consolidate into inventoy containers.

Gaylords are used to sort books for bulk resell.

Books which received a new label waterfall and convey to manual stations for processing.

SolidRoute is used to setup sortation lanes and rules. These rules may be adjusted in real time as necessary. Optional reporting features such as dashboards and web reporting are available.

Benefits from the new efficiencies

The benefits of the system include reduced labor costs and increased accuracy for the returns operation.