Completed WMS projects

KNAPP AG

NATURA Cajamar, São Paulo Brazil

Customers

NATURA, Cajamar

Completion

30.09.2005

Country

Brazil

Branch

  • Cosmetics

Description

Task description

In order to expand their position on the Latin American cosmetics market, Natura started optimizing its processes at the existing location in Cajamar so that with an ever-increasing range of products the daily deliveries can be handled more efficiently. The main task was installing a high-performance picking system on minimal space while centrally monitoring and operating both the entire area as well as individual processes.

The distribution centre

On two levels with a total floor space of approx. 10,000 sqm, a highly integrated manual picking warehouse was installed which made optimal use of the available space while adhering to the specified tight spatial conditions.

In a joint effort, KNAPP and Natura created a concept for the automated supply of flow rack channels. In the implementation of the project, the product turnover, the changing ABC structure and changing SKUs due to advertising campaigns and the low number of storage locations (limited height, small overstock area) presented a special challenge.

The manual picking area is served with a Pick-to-Light system, providing the highest possible processing speed with first-class picking quality. In addition to allowing greater flexibility in increasing or decreasing the number of storage locations and fitting new displays, Pick-to-Light is a system which is particularly suitable for frequent changes in the range of products due to advertising campaigns.

As fast-moving products tend to be larger and heavier than average products, fast-mover loops must be handled first. This ensures that these products are at the bottom of the dispatch carton. Complete carton units are placed on the conveyor system after applying the shipping labels at separate print stations and are then allocated to a specific order.

SORT & PACK
A separate SORT & PACK area was arranged to process online orders more efficiently. These very small orders are grouped to a batch order, diverted to three SORT & PACK stations after picking and repacked in small pack units. Cartons are then re-consolidated and invoices printed, folded, and inserted before each carton is sealed and directed to the dispatch sorting area.

Carton recycling
The picked products are delivered in cartons. Several carton erectors supply the cartons to the picking areas, and at the same time empty cartons from the manual picking stations are reused and returned to the order start points via the conveyor system.

This is made possible by a sophisticated volume calculation system: the software module Volumetrix ensures that customer orders are split and product parameters considered accordingly. Therefore various carton types can be filled to full capacity while being used over and over again. At the order start points, labels with a barcode are automatically generated and applied, with dispatch information included for as shipping label.

24/7 Hotline support
As Hotline contract customer, Natura enjoys highest priority in all questions of service, short response times in the diagnosis and resolution of issues as well as round-the-clock language support in the national language.

 

Logistics experts at work
With its new logistics system, Natura will profit particularly from the high flexibility regarding changes in the range of products and pricing and even a major increase of SKUs. Due to the expansion of the product catalogue and shorter delivery times, the company achieved a significant increase in turnover. The Natura project team itself brought an extensive logistics know how – this close cooperation gave rise to one of the most impressive distribution centres for cosmetics worldwide.
 

Key data:
- Total floor space approx. 10,000 sqm
- Number of articles (SKUs) approx. 1,200
- Order lines/day 600,000
- Items/day 765,000
- Orders/day 33,000
 

Natura Logistics, headquartered in Cajamar in the region São Paulo and with production facilities in all of South America, has become leading in cosmetics, perfumes and sanitary products over the past few years. The sales system is based on a large number of independent sales people who are supplied from the headquarters and are responsible for distribution to the end customer. Thus more than 5,500 cities are serviced in Brazil within an average of 2.5 days.

Contact person

Hannes Engelberger

Telephone: