By Bringing goods to man, instead of man to goods, through a combination of ClassicMat™ and EffiMat®, a manufacturing and distribution customer gained a 514% higher throughput efficiency which resulted in 69% fewer resources spend on picking.
Designing the best solution
Prior to the project, the customers achieved 55 picks per hour per operator, which is considered good within manual picking. The hourly picks were optimized through great WMS software, which analyzed the picking and showed the operator how to pick efficiently.
But in order to realize growth, the company had to find new ways of improving their throughput with two primary drivers: Increase throughput with minimum resources spend and do it without taking up more space than the current setup.
Initially the customer was looking at traditional VLM’s but in order to achieve the throughput, it was quickly realized that it would require too many VLM’s, as the speed of picking per unit was not high enough to reach the required throughput.
Focus on the 80% that requires labor.
Together with the customer, EffiMat went through an ABC profiling and a thoroughly walkthrough of the internal processes to define the actual requirements.
The analysis showed that by combining ClassicMat™ and EffiMat®, the customer could reach the required throughput while optimizing space. The setup was designed in the way that the EffiMat® storage robots would handle 80 % of all picks in order to achieve maximal throughput efficiency, while the ClassicMat™ VLMs were adding up M2 which it is designed for.
Value
Releasing space for growth
Prior to the project, the customer was picking from manual racking and shelves, but by removing the manual shelves, which rarely gives a good utilization of space, the customer released 74 % space.
The primary focus was to utilize the full height of the building, which also eliminated long walking distances for the operators. Additionally, the aisles between the manual shelves took up a lot of space.
With the new ClassicMat™ and EffiMat® solution there has been created a dense area with all the units for a much faster pick and pack process improving the overall working dynamic significantly.
The added values
Through the analysis, it was found that the company in average were picking 5 order lines per order. This meant that by implementing the EffiMat® storage robots, every cycle would be able to close an order due to the patented Box Mover Technology which makes it possible to deliver 5 unique order lines for every cycle, no matter the position of the boxes in the tower.
Even if some of the slower moving items is placed in the ClassicMat™ VLMs, the full order will be picked in the same cycle.
As a result, it has created a highly optimized working dynamic, allowing the operators to be much more efficient in their working process, and the same amount of people will be able to handle 5 times more orders compared to before the project was implemented.
For more info or a specific inquiry
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