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Automated distribution centre for heating specialist Rensa
26.07.2010
Rensa is one of the largest suppliers and wholesalers in the Netherlands and has a leading position on the heating and ventilation market
From the distribution centres in Doetinchem and Didam professional plumbers are supplied with the range of 35,000 products. Of these products some 16,000 articles can be delivered within 24 hours, and every day 3,400 to 4,000 products leave the warehouse.
The expected growth in the next ten years, prompted Rensa to invest in the modernization and automation of the distribution centre for small part in Didam. And for this reason, KNAPP had the following project definitions: increasing quality of performances and results through automation in the same building for small parts.
In order to meet the customer demands, KNAPP realized a Speeder-System for medium and slow-moving products as well as the Pick-to-Light system for fast-moving products. The installation of the Speeder-System makes it possible to manage a high number of medium and slow-moving products, achieve impressive storage and retrieval performances and significantly increase throughput. In order to handle repeated customer orders with a high number of order positions, 21 buffer locations were created in the Speeder pre-zone, allowing the operators to process several orders at one time. This makes for reduced waiting times and increased throughput. Through system adaptation to the product stockturn and no transit times, the picking performance was greatly increased. With the application of Pick-to-Light, the efficiency in paperless picking was greatly enhanced. These measures significantly increased the level of automation.
Goods-in
The goods are delivered on pallets with heavy-goods vehicles and the product data is registered in the WMS using the barcode. In the detrashing area, the products are sorted into containers and automatically stored at a suitable location in the Speeder-System. Due to the dynamic allocation of storage locations the logistics system is constantly optimized. Before the cartons are automatically set up at four stations and reach the conveyor, the WMS determines the necessary carton size according to amount and type of ordered items.
Super fast movers
Frequently ordered or oversized products are picked directly from the pallet using Pick-to-Light technology. The required quantity for picking is clearly marked by bright position indicators. The stockturn rate of these items can change due to large orders and such products are combined to special kits.
Fast movers
”Fastmovers” are picked from flow racks using Pick-to-Light. The Speeder-System provides replenishment to the flow racks, the operators take the required products from the front rack side according to the Pick-to-Light displays. As manual and automatic operations are performed independent of each other, optimum use of capacity is guaranteed around the clock.
Medium movers to slow movers
Medium-moving to slow-moving products are picked at two Speeder pre-zone work stations with 21 buffer locations. The relevant compartments in the container, the required quantity to be taken out and the target carton are indicated to the operators by the bright multi-function buttons of the Pick-to-Light panel above the storage container bays. To ensure optimal working conditions, the Speeder work stations are adjustable in height and the pick positions for the operating staff are inclined. The fact that the storage container bays slope gently downwards towards the work station not only means that the content of the containers is visible to the operator but also that the products can be picked easily.
Weight and height checks are carried out at the check stations in dispatch preparation. With the automatic application of a shipping label and insertion of invoice and delivery note, the cartons are prepared for dispatch and then closed by two carton lidding machines. The cartons ready for shipping are temporarily stored in static racks. All containers are then sorted according to route and supplied to the plumbing professionals by delivery vehicles.