Overview
The Dematic Automated Kitting Piece Pick System stores parts in automated storage and releases them to goods-to-person workstations where operators consolidate them into kits that the system then delivers to production areas of a manufacturing facility. The system’s automated storage also serves as a buffer between receiving parts and final production.
The system can be configured with automated storage technologies that best meet the requirements of the operation, including Dematic Multishuttle®, Dematic Miniload, and AutoStore™.
The system can be configured with transport technologies that best meet the requirements of the operation, including Autonomous Mobile Robots (AMRs), Automated Guided Vehicles (AGVs), and conveyor.
The system is a pre-assembly support sub-system for manufacturing and assembly operations. Typical durable good applications include automotive, appliances, medical devices, agricultural machinery, aircraft, electronic devices, as well as industrial components.
Benefits
- Process improvement for production system
- Increased kitting throughput rates
- More inventory storage capacity in a smaller footprint
- Provides increased accuracy, controlled access, and scan verification
- Minimizes or eliminates inventory shrinkage and loss
- Improved worker ergonomics
- Real-time control, visibility, and insight of operations
- Scalable and expandable for future changes
System description
The Dematic Automated Kitting Piece Pick System has a pre-engineered, standardized design configuration that stores parts for kitting, consolidates parts into a kit and delivers kits to assembly workstations.
The system optimizes the kitting process and provides the capacity to accommodate mid to high-rate flow inbound and outbound. The system is located within the factory floor environment of manufacturing operations.
Operators induct inventory required for product assembly into automated storage. The system scans and weighs (optional) inventory containers (typically totes) and their contents for accuracy to confirm piece count in the tote. The weigh check can also indicate whether an “over-weight” condition exists.
When the system receives a request for release of a specific kit of parts for assembly, the automated storage sub-system retrieves inventory totes and transports them via conveyor to the kitting workstations. The system uses the goods-to-person method — parts needed for kitting come to operators at the kitting workstations. In some system configurations, autonomous mobile robots (AMRs) or automated guided vehicles (AGVs) transport parts between automated storage and the kitting workstations.
System management
The Dematic Warehouse Execution System (WES) software is the scalable logistics platform that controls and synchronizes workflows. The Dematic WES dynamically manages processes, inventory, labor, and material handling automation in real time.
The Dematic WES determines and tracks parts inventory storage locations within the automated storage sub-system. When the WES receives transport orders, the Manufacturing Execution System (host) determines the appropriate parts for allocation.
Manufacturing Execution System (Host)
- Sumit move request
- 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 inbound and outboud 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, workers exposed to harsh conditions | Automated process |
| Traditional low-density shelving for storage | Put-away and retrieval automated |
| Imbalance in pick rates | High-density storage, small footprint |
| Reaching, bending, and lifting materials in and out of shelving | Kit consolidation work managed evenly/balanced |
| Manual functions prone to errors, inefficient, slow | Automated storage and retrieval of kitting parts |
| Limited throughput and capacity | Execution software synchronizes workflows |
| Vulnerable to inventory shrink/loss | More throughput and parts storage capacity |
| Limited real time visibility and insight | Less potential for inventory shrink, better asset protection |