CASE STUDY: Sort to Pack

The Problem: Order Picking and Fulfillment is Completely Manual Operation

CASI was asked to provide a turnkey system to address manual picking and fulfillment. The shipping and manifest line was also a manual process.

The Solution: Light Picking to Belt, Sort to Order, Inline Manifest

CASI provided a pick to belt system where operators pick to light, place items on a conveyor belt. The items then convey to a large sorter where they are sorted to each order. After items are packed, the full case conveys to a manifest system for automatic weighing, labeling, and sorted to proper carrier.

System Overview:

Lights and LED's are used to tell pickers location and quantity of items to pick. Each item picked is placed on the belt in single file.

One the item is picked, the operator presses a button to confirm the pick has been exectuted and picks the next items indicated.

Items are conveyed to the sorter. There are two levels of sortation, each sorter capable of ~75 pieces per minute for a total of ~150 per minute throughput.

Each book is scanned by Datalogic scan tunnels on each sorter level.

The CASI SortMaster 150 is a bi-directional continuous sorter; meaning when an item is sorted, the paddle does not need to reset to 'home' position.

Items sorted to individual lanes to be packed. Indicator lights let operators know how many items are required for each carton.

Full cases are conveyed to the ShipMaster 900, which consists of licence plate barcode scan, checkweigh, automatic print/apply of shipping label, and sort to proper carrier line.

The ShipMaster 900 reduces touch labor assosciated with manual manifesting and data entry. Cartons automatically receive a scan, weigth, shipping label, verification, and are then sorted.

Benefits from the new efficiencies

Benefits include drastic reductions in manual sortation, much more accurate picking and packing, and better throughput per order.

Videos and Product Data Sheets

Please fill out this simple form to view all CASI product sheets and videos. You will have access to all CASI downloads. The information provided will only be used to help us determine the best solution for your environment and meet your budget!