CASE STUDY: Inline UPS Shipping System

The Problem: Inefficient UPS Shipping Operation

CASI was asked to design an inline UPS shipping system to replace the labor of manual packers to ship and manifest orders.

The CASI Solution: Inline UPS Shipping and Manfiest System

CASI provided a ShipMaster 900 system with end of line sortation for various UPS service levels such as Next Day Air, Ground, and Second Day Air. System includes order scanning, weighing, labeling, UPS interface ,customer host interface, and sortation.

Turnkey System Overview:

Orders are picked in the warehouse and conveyed to pack stations. Each order is verified against the pick ticket and packed into boxes. A license plate barcode is applied so order data may be processed automatically by CASI system.

Packed orders are conveyed to the void fill station where operators fill the boxes, fold the flaps, and push through the automatic taper. The taper indexes the boxes onto the zero pressure accumulation (ZPA) conveyor to enter the ShipMaster 900 system.

The carton is scanned by a Datalogic DS6300. The order data is looked up via SolidComm host interface software. The carton is then weighed on a CASI 951 checkweigher and the actual weight is matched up to the order. This data is passed to the host in preparation for applying a shipping label. Customers have the option to send a label from the host system or have CASI receive from UPS directly.

A blade stop pauses the carton for a moment and guarantees the shipping label is applied in the correct place. The shipping label is verified by a second Datalogic DS6300 and manifested back to UPS and written to the host with order, weight, tracking number, and verified readable label.

Exceptions such as no order found, labels out, etc. are diverted for manual QC. The remaining lanes are used for various UPS service types.

Benefits from the new efficiencies

The benefits from the new system include reduced touch labor associated with manual manifesting. Additional benefits include higher throughpu and easy adjustment to peaks and seasonality without the need to hire and train temps.

Most operations shipping more than 1,000 orders per day will realize a 6 month to 1 year ROI depending on operational flow. Contact CASI to learn more about end of line shipping systems as well as turnkey fulfillment from receiving, putaway, picking, and much more.

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