Overview
The Dematic Automated Case Pick System for Production is a system that provides order fulfillment of finished goods from a production operation. It also accommodates storage of raw materials and supplier components used for manufacturing. The system automatically builds and stores mixed case pallets in an automated storage and retrieval sub-system (AS/RS). It is also a goods-to-person piece and case picking system for outbound loads.
This system has two general applications for manufactured goods:
- Production and Distribution: The system supplies inventory to production where it is used to create finished goods. The system stores the finished goods. When an order is received, the system fulfills the order.
- Distribution Only: The system stores the finished goods. When an order is received, the system fulfills the order.
Benefits
- Process improvement, optimized piece and case picking
- Increase in throughput capacity
- Reduced system footprint
- Reduced time to process orders (service level agreement)
- Minimized amount of inventory on production floor
- Improved responsiveness
- Reduced damage to products
- Accommodates production and order fulfillment simultaneously
System description
The Dematic Automated Case Pick System for Production has a pre-engineered, standardized design configuration that ensures predictable performance. Here is the general order of how the system functions:
1. Inventory received and stored
Types of pallets received and stored in AS/RS:
- Pallets of components and assemblies
- Pallets of raw materials
- Pallets of finished goods
2. Production
Pallets of components and assemblies and/or pallets of raw materials conveyed from AS/RS to adjacent production facility. Finished goods created in production are palletized and conveyed to AS/RS for storage.
3. Order fulfillment
Finished goods pallets conveyed to goods-to-person workstations. Workers pick case from inventory pallets to build mixed case pallets for customers. Customer pallets of finished goods conveyed back to AS/RS for buffer staging prior to shipment.
4. Shipping
Customer pallets of finished goods conveyed to shipping area.
System management
The Dematic Warehouse Execution System (WES) software manages case and full-pallet picking as well as handling load move requests to and from the production floor. The Warehouse Management System (WMS) is responsible for inventory management, receiving, and put-away into the AS/RS.
The Dematic WES software can accept orders from the WMS in multiple ways, but typically as discrete orders. The Dematic WES software includes supervisor interface screens to provide a global view of transfer to/from production floor, order picking, order pick performance, system progress, order information, picks per operator, and total picks.
Warehouse Management System (Host)
- Order entry
- Inventory
Fulfillment orders
Status and completion
Dematic Warehouse Execution System
- Put-away strategies
- Order management and execution
- Order attributes, priority, changes
- Synchronize and optimize processes
- Direct case picking
- Scan barcode labels
- Balance workload
- Visibility and insight
Comparison
Dematic automated case picking systems are more accurate, require less labor to operate, and use less warehouse space than conventional case picking systems.
| Conventional Case Pick | Automated Case Pick — Production |
| Large system footprint | Smaller system footprint |
| Manual pallet storage and retrieval | Automated pallet storage and retrieval |
| Dedicated pick faces with case pick at rack storage | Eliminates dedicated pick faces and provides case picking at ergonomic workstation |
| Non-strategic case pick and production support | Eliminates pick paths |
| Long pick path | Automated pallet flow throughout system requires less labor |
| Less throughput capacity | Automation equipment (case sequencer, sorter, buffer, and storage) |
| Manual process prone to errors, inefficient, and slow | More throughput capacity |
| Limited visibility and insight into operations | Advanced workflow management and real-time control |