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© 2014 MHI®
Copyright claimed as to audiovisual works of seminar sessions and
sound recordings of seminar sessions. All rights reserved.
Sponsored by: Presented by:
Brian Keiger
Dr. Christian Wurll
Scalable Order
Fulfillment
Solutions for
Beverage
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01 Industry Overview
02 Flexible Scalable Solutions
Industry Overview
What Does Your Distribution System Look Like?
Scalable Order Fulfillment Solutions
Customer Business Model
Customer Pains
Customer Trends / Objectives
Scalable Order Fulfillment Solutions
Full & Mixed pallets
(includes RDPs)
Homogeneous pallets
from the production
(extensively
automated)
Standard Pallet
Trailers – Not Bay
Trucks
Receiving
Storage
Replenishment Full layer / case
picking
QC
Palletizing Stretch wrap
Consolidate
Ship
Scalable Order Fulfillment Solutions
Rapidly Changing Consumer Demands
− SKU Proliferation
− Smaller Shipments with More Frequent Deliveries Dynamic Warehouse
Rising Cost Pressures
Growing Consumer Concerns Over Food Safety Risks and Increasing
Regulatory Requirements
Poor Visibility and Traceability Across Shipping and Production
Poor Picking Accuracy Added Costs and Unsatisfied Clients
Double- and Triple-handling of Product
Shrinking and Aging Work Force
Land-locked Warehouse Space
Rising Energy and Fuel Costs
Scalable Order Fulfillment Solutions
Significant investment in in growth (new product development, pricing strategies,
geographic expansion)
Significant improvement in operation processes and related technology
Significant cost reduction initiatives
Mergers and acquisitions
Entrance into new markets
Significant changes in business model
Significant changes to financial processes and related technology
Social media (Facebook, Twitter, Pinterest, etc.)
Mobile/online consumer engagement
Flexible & Scalable
Solutions
Warehousing and Distribution
A Warehouse & Distribution Center needs three things:
─ Get the products to the palletizer in the correct sequence efficiently
─ Palletize products for a single customer order
─ Sequence the order loads properly onto the outbound trucks
Delivering Proper Case Sequencing
─ Grenzebach and its partners have focused on
finding the best way to get the correct
sequence of cases picked and to the
palletizer in a way that:
─ Minimizes Investment
─ Minimizes Labor
─ Maximizes Future Flexibility
─ Is Scalable fro Different Sized Facilities
On time, every time to the palletizer
Three Primary Modules
─ Cascade Layer Picking with Associated
Residual Buffer
─ Order Release Module
─ Zone Picking from Pallets and/or Flow
Channels
Simple, Flexible, Scalable
Cascade Layer
Picking with Residual
Buffer
Scalable Order Fulfillment Solutions
─ Cascade operator picks layers as required to supply
product to the express lane as needed. The express
lane product travels directly to the final merge and
then on to palletizing.
─ Cascade unit(s) typically used to supply product to
the Automatic Case Buffer / Dispenser.
─ A wireless display is mounted to each fork truck and
displays all layer picking requirements.
─ The case descrambling and singulation conveyor
separates cases from the Cascade units into single
file.
─ SKUs in the Layer pick area are assigned to
Automatic Case Buffer / Dispenser. Less than layer
quantities will come from this area.
─ Forklift Display Units are typically provided (Cascade
/ Full Pallet Replenishment Forklifts)
Layer Picking and Descrambling
Layer Picking and Descrambling
Layer Picking and Descrambling
Scalable Order Fulfillment Solutions
─ Layers are depalletized, singulated and sent directly to the palletizing cells; any
left over from the layer, not part of the order, are sent to the automatic case
buffer / dispenser
─ The automatic case buffer / dispenser consists of multiple case lanes
─ The automatic case buffer / dispenser can be mounted to the floor mezzanine.
The lanes are typically 18” – 24” above the fixed floor / mezzanine
─ Each lane is used for storage of the overflow product that is not used from
layers picked for the express lane
─ Product is automatically dispensed if the lane has the correct quantity to meet
the requirements of on order
─ The lanes are 24 LVDC powered lanes
─ Lane assignment is not dependent on product weight or size
─ The output of the automatic case buffer / dispenser flows to a merge point
where it is verified by a height checker
Case Buffering & Automatic Case Dispensing
Case Buffering & Automatic Case Dispensing
Case Buffering & Automatic Case Dispensing
Order Release Module
(ORM)
Order Release Module
Order Release Module (ORM)
Urethane Belts on Powered Rollers
provide more surface friction with cases
for superior control of automatic case
release
Load Level sensor and light indicators for
picker visual aid
Pick monitor with scrolling requirements
for guidance
Access lane between every set of ORM
Lanes for maintenance
Order Release Module
Product Sensors S2
Stack Light for Zone
Reload Status
Zone Pick Screen
Product Sensor S1
Order Release Module (ORM)
Each Zone is made up of 3 or 4 conveyor
lanes with one Stack Light for Reloading
Status and one Zone Pick Screen for
picking priority.
On each conveyor are two sets of
sensors. When all sensors in every zone
are made, the green light will illuminate. If
any lane in the group gets below the first
sensor (S1), the white light is illuminated.
If any lane in the group gets below the
second sensor (S2), the red light is
illuminated.
The Zone Pick Screen will scroll the pick
priority but the lights will allow the
operator to know more accurately where
to go visually. When the cases are loaded
and sensors made the screen with
eliminate that pick.
If the picker is walking to fill the next pick
and sees a white light, he can place a few
cases on, depending on the urgency of
his next pick, making him more efficient.
Order Release Module
─ Operator picks cases off of bulk
pallets and fills up conveyors to
be released automatically by
the system as needed
Automatic Case Release
Order Release Module
Zone Picking Module
(PTZ)
Scalable Order Fulfillment Solutions
─ Zone Picking Method eliminates the need for a “Pick-
to-Light” or “Voice Picking System”.
─ A count zone is provided in the powered take away
conveyor for each pallet pick position and each carton
flow bay.
─ The count zone activates when the PLC is expecting
product to be picked from the adjacent pick location.
The operator will see the rollers turning in the pick
zone. Note that the DC MDR conveyor is normally not
running unless product is traveling down the
conveyor.
─ Overhead monitors or wrist modules are provided to
indicate the location and quantity to be picked. These
devices display the current pick requirement, location
and quantity.
─ The count is decremented as the operator places
product on the pick zone and the product crosses the
count photo eye.
Zone Picking Modules
Scalable Order Fulfillment Solutions
─ If the operator miscounts and then attempts
to place a case in any other pick zone, the
conveyor will stop and the overhead monitor
will indicate there was a pick error. The
operator will then use the HMI work station
provided to resolve the error.
─ A full line photo-eye will be provided. When
the full line condition occurs for the pick line,
the overhead monitor will display that the
system is full and the count zone will not
operate until the full line condition is cleared.
─ The Pick module and the High Volume Pallet
Pick lines all utilize the Zone Picking System.
Zone Picking Modules
Scalable Order Fulfillment Solutions
─ Multiple levels typically contain pallet pick.
The operator picks directly from the pallet to
the conveyor
─ Two-deep gravity pallet conveyor is provided
for mid-volume SKUs
─ The bottom level of the Pick Module typically
contains a combination of pallet pick faces
and low-volume carton flow rack
─ A separate floor level case zone picking area
usually contains an area for seasonal SKUs;
additional pick zones can be added without
increasing footprint
─ Each level has a height verification check at
the end of the pick line
Zone Picking Modules
Zone Picking Module
Case Flow Rack
Multiple Bays – Floor Level
(Configurable)
Pick-to-Zone
Levels 2 & 3
Lift Gate(s)
Zone Picking Module
Zone Picking Module
Mixed Row Palletizing
Mixed Row Palletizing (MXRP)
MXRP Cell with Row Gripping Functionality: • Cases feed from customer conveyor(s)
• Empty pallet conveyed into position
• Robot arm builds pallet per customer stack pattern
requirements
• Operator /Forklift take-away of completed pallets
Cell Capacity: • 1000 – 1200 CPH (with Row Gripping)
Mixed Row Palletizing (MXRP)
MXRP Cell with Row Gripping
Case In-Feed with
Row Grouping
Empty Pallet
In-Feed
Full Pallet
Out-Feed
Target
Palletizing
Position
MXCP Robot
with Gripper
Mixed Row Palletizing (MXRP)
MXRP Cell with Row Gripping
Payload weight up to 310 lbs
Gripper weight 365 lbs
Min [L x W x H] 4” x 4” x 4”
Max [L x W x H] 24” x 16” x 16.5”
Multiple SKUs can be handled at one time
Gripper is configurable for row grouping
Mixed Row Palletizing (MXRP)
MXRP Cell with Row Gripping
Calculation of “ideal” pallets based on parameters
derived from various rule groups, like
– Start with Full Layers
– Consider Stacking Rules
– Create Mixed Layers based on Package Type Class
– Usage of known pallet pattern templates for mixed layers
– Calculation of “really” mixed layers for top layers
Visualization
Plausibility Check for customer data (product, layer,
pallet)
Mixed Row Palletizing (MXRP)
Example Pallet Configurations
48” x 40” 36” x 36” 42” x 18”
Mixed Row Palletizing (MXRP)
Example Pallet Configurations
What Does Your Distribution System Look Like?
For More Information:
Speaker #1 email: brian.keiger@grenzebach.com
Grenzebach-INOS Automation Software, Inc.
Website: www.grenzebach.com
Speaker #2 email: christian.wurll@grenzebach.com
Grenzebach Automation GmbH
Website: www.grenzebach.com
Or visit MODEX 2014 Booth 7913
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