CASE STUDY: Automatic Returns Processing System

The Problem: Recent 3PL Expansion requires automation to reduce labor cost

A major third party logistics provider needed to expand their Reverse Logistics operation and wanted to reduce labor costs. They contracted with Cornerstone Automation Systems and Cisco-Eagle Material Handling of Dallas Texas to provide an automated material handling solution.

The Solution: Automatic Returns Processing and Sortation

CASI proposed an automatic returns processing solution that would interface to the customers red Prairie Warehouse Management System and automatically sort and process items as they traveled on the conveyor.

EQUIPEMENT LIST:

1. CASI 1100 Automation Center
2. SolidComm Red Prairie WMS Interface
3. SolidRoute Sortation Controls
4. SolidSuite System View Conveyor Maintenance Module
5. Microscan 820 fixed position barcode scanners

System Overview

As the cartons are unloaded from the trucks, they are automatically transported to an automatic box opener station that opens the master packs. These master packs are placed on the conveyor where they are transported to the Sortation System.

At each routing point, a fixed mount scanner scans the carton barcode and the returns processing system is updated with the carton position. Cartons are either sorted using a pusher sorter or allowed to go to the next station.

The SolidRoute system allows the users to change lane assignments, add or subtract lanes as the business changes. The SolidSuite System Manager module allows the customer to rapidly diagnose and correct exceptions that occur.

Benefits from the new efficiencies

The key benefits from installation of the automated parcel fulfillment system are as follows:

1. Reduced Labor Rate from automated return processing and sortation
2. Higher throughput
3. Better maintenance diagnostics
4. Flexibility to handle both peak and off season volume without temporary labor