Press releases

The SSI Schaefer Approach……Trends in Order-Picking and Warehouse Automation

‘Automation is leading the way in distribution today’

This is the message from the world’s largest storage and handling company, SSI Schaefer. Many of its customers are continually asking the same question – ‘why do we need integrated automated solutions?’

And the answer? ‘If you want faster reaction / cycle times, on-time delivery, same-day delivery, high picking accuracy, order fulfilment, manpower savings, store friendly picking, RFID, tracking, tracing, information transparency and visibility with a significant reduction in damaged stock then automation is the only way forward,’ says David Hibbett, Business Development Manager at SSI Schaefer.

Automation in distribution has matured in the past three years with new concepts, better technology and system integration compatibility. However, there are still many companies who consider automation to be non-beneficial but for all the wrong reasons.

Time and time again SSI Schaefer is faced with the same responses ‘it’s not economical’, ‘we’ve no resources or time’, or quite simply ‘we don’t need it’. Schaefer is urging companies to think ‘outside the box’ and to look at the range of proven concepts that are available and search for opportunities to handle today’s supply chain challenges.

Of course project requirements are paramount when considering switching from manual to automated with many pointers to consider, including; economic justification, reviewing overall business processes and validating cost implications, including manpower and cost per unit.

But ultimately when benchmarked, automation solutions are more cost beneficial than traditional solutions. Automation is proven to optimise the supply chain beyond the walls of the warehouse itself. New supply chain concepts require new technologies with different management skills.

Perhaps the most visual change to follow the implementation of an automated picking machine is the reduction in manpower. Manpower reduction is driven by several main design features:

 - Automation replaces staff for replenishment, handling and indirect staffing such as inventory control and cycle counting.

 - Uncoupling of work areas for receiving, replenishment, picking and shipping allows sustained, standard performance.

 - A workstation concept for receiving, replenishment and picking allows each individual operator to work independently (systems balanced and workload driven).

It is worth noting than an ergonomic environment can save a distributor as much as £8,000 per lost employee at the distribution centre level.

David Hibbett continues: “Technology to present the product to the picker is no longer the limiting factor to productivity. Ergonomic stations additionally offer accuracy at source and a significant reduction in injury rates.

“Ergonomics means ‘designed to minimise physical effort and discomfort, and hence maximise efficiency.’ This is what each and every one of Schaefer’s picking machines in designed to achieve.”

Schaefer’s ergonomic picking stations include higher picking rates per picker per hour, low error rate during picking and support to the picker by means of technological devices, such as radio frequency, hand-held scanners and light sensors just to name a few. Stations also feature short reaching times allowing optimal working height and limited reaching distance. Short distances are handled quickly thanks to goods-to-man, i.e. no distances to be covered and support for lifting heavy articles is given using mechanical lifting devices.

SSI Schaefer’s Ergonomic Picking Stations include:

Zone Picking Systems / Parelle Picking Systems – 200/300 picks per hour

Integrated Storage and Picking Systems – 250-350 picks per hour with automated storage and replenishment integrated

Pick to Tote Station – 500-1000 picks per hour with automated storage and replenishment integrated

Sequence Station – 500-750 picks per hour with automated storage and replenishment integrated

Pallet Case Picking - to Tote – 200-400 cases per hour with automated storage and replenishment integrated

Pallet Case & Tray Case Picking – to Pallet – 450-600 cases per hour with automated storage and replenishment integrated