Overview
The Dematic Automated Kitting Piece Pick System stores parts using Autonomous Mobile Robots (AMRs) and brings the parts to bin-to-picker workstations where operators consolidate them into kits that the system then delivers to production areas of a manufacturing facility. The AMRs store and retrieves totes in a double rack structure.
The primary application for the system is manufacturing and assembly operations of durable goods such as automotive, appliances, medical devices, agricultural machinery, aircraft, electronic devices, as well as industrial components.
Benefits
- Provides process improvement for production systems
- Minimizes/eliminates inventory shrinkage and loss
- Is scalable and expandable for future changes
- Provides real-time control, visibility, and insight of operations
System description
The Dematic Automated Kitting Piece Pick System has a pre-engineered, standardized design configuration that ensures predictable picking performance.
The system optimizes low to mid-rate flow inbound and outbound kitting operations. It is located adjacent to the manufacturing operation on the shop floor.
Parts inventory required for kit assembly is inducted into automated storage. The load container (typically a tote or small load carrier) and its contents are scanned and for accuracy to confirm piece count. An optional weigh check determines whether an over-weight condition exists.
When the system receives requests for kits, Storage AMRs retrieve the required load containers from storage and transfer then to Tote Transport AMRs, which bring them to the kitting workstations. Workers assemble the kits.
Pallet and Shelf Transport AMRs transport completed kits to the factory floor. Some kits may be returned to the automated storage sub-system for buffering until they are needed either on the factory floor or for outbound shipping.
System management
The Dematic Warehouse Execution System (WES) software controls and synchronizes workflows. The Dematic WES software also manages processes, inventory, labor, and material handling automation in real time.
The Dematic WES software determines and tracks parts inventory storage locations within the automated storage sub-system. The Manufacturing Execution System (MES) determines the appropriate materials for allocation.
Manufacturing Execution System (Host)
- Submit move requests
- Manage inventory
Kit orders
Status and completion
Dematic Warehouse Execution System
- Order management and execution
- Order attributes, priority, changes
- Synchronize and optimize processes
- Scan and weigh confirmation
- Manage process flow
- Visibility and insight
Comparison
The Dematic Assembly Kitting Piece Pick System is more accurate, requires less labor to operate, and uses less warehouse space than Non-Automated Kitting systems.
| Non-Automated Kitting | Automated Kitting |
| Manual process | Automated process |
| Manual put-away, manual retrieval | Automated put-away, automated retrieval |
| Traditional low-density shelving for storage | High-density storage for storage |
| Kit consolidation work often imbalanced | Kit consolidation work even/balanced |
| Manual storage and retrieval (reaching, bending, and lifting in and out of shelving) of kitted parts | Automated storage and retrieval of kitted parts |
| Manual functions prone to errors and inefficiency | Execution software synchronizes workflows for minimal errors and high efficiency |
| Limited throughput and capacity | Higher throughput and parts storage capacity |
| Vulnerable to inventory shrink/loss | Better asset protection for less potential for inventory shrink/loss |
| Limited real-time visibility and insight | Real-time visibility and insight |