CASE STUDY: Automated UCC-128 Compliance Labeling

The Problem

A major swimming suit distributor wanted to reduce labor and improve efficiency by installing an unattended compliance labeling and order sortation system.

The Automatic Compliance Labeling Solution

CASI supplied an automatic compliance labeling and case sortation solution utilizing SolidLabel for the automatic shipping labeling, SolidComm for the legacy host interface and SolidRoute for the shipping sortation software.

EQUIPEMENT LIST:

• CASI BudgetMaster 24 Volt Accumulation Conveyor
• CASI CD-160 Carton Cornering Device
• CASI 100A Scanner MUX
• CASI SortMaster 120 HD Case Sortation System
• CASI SolidSuite Modules – SolidComm, SolidLabel and SolidRoute.
• Datalogic DS6300 & DS2100N barcode scanners
• ID Technology 250 Printer Label Applicator

System Overview

Orders that are to be processed during the day are downloaded by the CASI SolidComm legacy host interface module. This data is used for UCC 128 Compliance Labeling and outbound sortation of the product.

Full Case Cartons are manually placed on the BudgetMaster 24 volt, zero pressure accumulation conveyor where they stage in zones before the labeling section.

The SKU barcode is read from the side of the carton by the sweep raster DS6300 barcode scanner. This data is sent to the SolidLabel system where a shipping label is prepared from the downloaded list.

Once the shipping labeling zone is empty, the carton is transported into the labeling zone where the CD 160 carton cornering device places it in a known position. The CD 160 includes a bladestop to square up the carton and a cylinder than pushes the carton to the rail. This ensures a highly controlled process that is repeatable and bulletproof.

Once the carton is in position and the label on pad sensor ensures the label is fully on the tamp pad. Once the label on pad sensor confirms the label is ready, it is applied to the box in a portrait format as required by the retailer. A label placement confirmation scanner reads the UCC 128 barcode on the label ensuring that the label is on the carton and is readable.

Once the Compliance Labeling operation is complete, the carton is then released and is transported to the sorting system. The SolidRoute software tracks the carton using a tachometer and update photo sensors until it reaches the assigned destination lane.

Once the carton reaches the assigned destination lane, it is sorted using the SortMaster 120 HD sorter onto a gravity conveyor spur when operators manually palletize the cartons. The SolidRoute system keeps statistics of the shipping sortation process and any 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 compliance labeling and sortation
2. Higher throughput – (more than 20 cartons per minute)
3. Reduced shipping errors
4. Flexibility to handle both peak and off season volume without temporary labor