Overview
The Dematic Case Pick System with Automatic Replenishment uses the pick-to-conveyor method to fulfill orders. Operators pick cases from pallets in a rack structure and place them onto a conveyor that flows to a sorter, which sorts the cases for outbound shipping. An automated storage and retrieval sub-system (AS/RS) replenishes inventory pallets to the rack structure. Pallet replenishment is accomplished using automated storage machines.
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 |