CASE STUDY: Returns Sorting

The Problem: Reduce Labor in Returns Processing and Sortation

A major manufacturer of cell phones wanted to reduce labor in their distribution center operations by implementing an automatic returns processing and sortation system. An interface is required to the customer’s legacy ERP using the IMEI number on the cell phone.

One of the main challenges in the system was the fact that the barcodes on the phones were extremely small and not designed to be read by automation. The sides of the phone often will shadow the barcode and create a no read situation.

The Solution: Automatic Returns Sortation System with automatic tote in feed and take away

The CASI solution consisted of a 30 lane returns processing sorter with 30 lanes of automatic tote replenishment. An interface to the legacy host was established using SolidComm host interface software. SolidRoute routing and sortation software was used to control the sortation system.

System Overview

The system starts with the phones being singulated and justified to one side for easier scanning.

The phones are scanned by a Datalogic Matrix 2000 scanning array in order to get a high read rate on the difficult to scan barcodes.

After the cartons are scanned, the phones are tracked down the slider bed conveyor using SolidRoute and diverted to the proper lane.

Once the phones are sorted, they travel through a chute to a pre-staged tote where they are collected.

These totes are automatically staged using a tote in feed conveyor and secondary sortation system.

A barcode on the totes is read and recorded by the system before the totes are sorted into position.

Benefits from the new efficiencies

The benefits from the system include faster processing and reduced labor in the returns processing operation.