Overview
The Dematic Work-in-Process Buffer System for Staging Pallets Between Processes features an automated storage and retrieval sub-system (AS/RS) and conveyor sub-system to balance variations in flow between production processes or accommodate a curing time requirement for work-in-process (WIP) materials. Dematic Warehouse Execution System (WES) software synchronizes workflows with real-time controls and manages product sequencing, product location tracking, and precise timing of release.
The system is ideal for operations that strategically stage inventory on the factory floor to accommodate variations in production or demand. Other applications include operations that need to allow for a certain amount of inventory to accumulate between workstations so that an interruption in just-in-time flow does not stop production.
Typical users include manufacturers of durable goods such as automobiles, trucks, automotive components, appliances, medical devices, construction machinery, agricultural machinery, and electronics.
Benefits
- Process improvement
- More WIP buffer capacity in a smaller space
- More responsive access to WIP materials
- Controlled access to WIP inventory (improves accuracy)
- Visibility and insight of operations
System description
The Dematic Work-in-Process Buffer System for Staging Pallets Between Processes has a pre-engineered, standardized design configuration that ensures predictable performance. Here is the general order of how the system functions:
- WIP materials from a production process are transferred to an AS/RS that serves as an automated storage buffer.
Load container may be a unit load such as a pallet, a skid, a tub, or a large component such as a vehicle in the process of being assembled. - When the system requests the release of a load container, the AS/RS retrieves it from storage.
- AGVs or AMRs transport the WIP materials to a second production process.
System management
The Dematic Warehouse Execution System (WES) software controls and synchronizes workflows. The Dematic WES software manages processes, inventory, labor, and material handling automation in real time.
The Dematic WES software determines and tracks parts in the buffer storage locations for WIP materials within the automated storage sub-system. When the WES receives transport orders, the Manufacturing Execution System (MES) determines the appropriate materials for allocation.
Manufacturing Execution System (Host)
- Submit move requests
- Manage inventory
WIP move orders
Status and completion
Dematic Warehouse Execution System
- Task management and execution
- Task attributes, priority, changes
- Synchronize and optimize processes
- Put away location management
- Retrieval management
- Visibility and insight
Comparison
Dematic automated work-in-process buffer systems are more accurate, require less labor to operate, and use less warehouse space than non-automated work-in-process buffer systems.
| Non-Automated WIP Buffer System | Automated WIP Buffer System |
| Manually operated | Automated system |
| Manual put-away, manual retrieval | Automated put-away and retrieval |
| Conventional low-density racking for staging | High density, small footprint WIP staging |
| Employees set pace for all tasks | Dematic WES software provides even, continuous workflow |
| Does not synchronize with MES on the assembly plan | Synchronizes with MES on the assembly plan |
| Manual functions prone to errors, inefficient, slow | Dematic WES software optimizes workflows |
| Variations in response time for load move requests | Predictable response time for load movement requests |
| Limited visibility, status, and insight | Real-time visibility, status, and insight |