Increase your DC’s efficiency

By Rudolf Hansl

Thousands of different products have to be handled in retail distribution centres, ranging from small chewing gum packages to voluminous and heavy detergent multi packs. Still many retail distribution centres are based on pallet storage and manual picking activities where each picking worker has to manipulate up to 15 tons daily in rather non-ergonomic operations.

The high requirements in throughput, logistics service, ergonomics, energy consumption and efficiency can best be solved by a tailor-made order fulfillment solution based on proven technology. Innovative distribution centre designs combine high performance modules for picking and warehouse automation with powerful software solutions. The resulting integrated systems provide highest distribution centre performance not only for perfect shop replenishment but for online retail operations too.

One of the most innovative systems is the recently introduced PerfectPick solution from TGW, which is a highly modular automated picking concept. In contrast to competing solutions it handles every SKU directly on the automated conveyor and storage equipment without the necessity of any additional load carrier. Therefore the material flow within the distribution centre is much simpler and the solution does not need any handling of empty load carriers. High reliability is guaranteed by the system's lean modules, which are based on standardized components. This modular concept enables the customers to choose among different levels of automation, depending on their individual processes and needs.

The PerfectPick solution not only is able to handle the very different product sizes and weights fully automatically, but it is highly cost effective too. Depending on the selected automation level and the intensity of usage, this solution pays off in 2 to 4 years.

An important function within integrated order fulfillment systems for retail distribution is to automatically configure and pack complete shop orders on pallets or roller containers. The configuration of the shipping load has to exactly meet the customer's requirements, e.g. by optimizing the stacking pattern to the unloading process within the individual shop's layout. And the solution should be applicable for the entire temperature range within the grocery retail product range, even in deep freeze applications.

During the design of a new distribution centre it is essential to keep two aspects in mind: The material flow should be designed as simple as possible and the solution has to be able to handle the greatest variety of retail SKUs. Both aspects should have major influence on the long term efficiency of our distribution centre operations.

Prior to installing an automated order fulfillment solution it is advised to test the critical processes not only in simulations but on real equipment with real products. In their technology centres the relevant systems integrators have the possibility to offer that service. In our technology centre we are hosting demonstration events, showing the abilities of our new solution. And we are offering to use it as test installation for our customers' real products too. Our customers are invited to bring their 'worst' products and test them throughout the entire PerfectPick process.

Biography

Rudolf Hansl is Managing Director of TGW Logistics Group, a leading provider of integrated logistics systems, specialized in high performance distribution centre automation and order fulfillment solutions.