Saramax - SDI Systems

case study
Saramax
Sayreville, New Jersey
SPEED
ACCURACY
SPACE EFFICIENCY
205
Saramax
Key Highlights
The SDI Solution for Saramax
ENHANCED OPERATION The solution
has increased operational efficiency,
added capacity, performance, visibility
and control.
Saram
THE CHALLENGE­
Saramax Apparel had started to outgrow
the capacity of its Pick-to-Light tower
and old conveyor system. It had served
them well and earned Saramax the 2012
Walmart (DSDC) Supplier Award of Excellence. SKU quantity and volumes would
be increasing and the current system did
not have enough pick locations and a poor
conveyor path to shipping which made
it was unsuitable for higher volume. The
rest of the warehouse was filled to capacity with high bay VNA racking and the
shipping staging space was at a premium.
The challenge was to provide a new multi
zoned picking system with minimal impact
to the current warehouse layout and reuse
a lot of the existing shipping conveyor
system. In addition the new system had to
be expandable with a mezzanine level and
the conveyor layout pre-engineered for the
future. The new system required pick and
pass capability between picking zones and
also a fast track conveyor to the auditing
area and shipping carousel loop. The new
system had to be installed without taking
down the existing operation. There was an
aggressive schedule to have the entire new
system running by mid-August 2012.
SDI analyzed the future SKU and case
data and created several system layouts
that would fit within the available space.
There were a lot of very short distances
for conveyor elevation changes, Egress
concerns and pallet storage location being
maintained.
THE SOLUTION
SDI provided several design options and
worked with Saramax to fine tune it to best
meet the requirements. A new 36 bay, 28
ft tall, picking module was provided. It was
pre-engineered for 2nd level, so expansion
in the future would be easy. The first floor
has 648 locations with central takeaway
conveyors and overhead empty carton
removal integrated with the existing trash
compacter system. Due to some very short
distances for elevation changes and some
complex paths between pick modules the
latest MDR spiral inclines conveyors and accumulating belted MDR incline conveyors
were utilized. The added benefits of an
almost silent energy efficient conveyor sys-
tem where greatly appreciated by Saramax
and creates a very pleasant work atmosphere. The old conveyor system was very
noisy. SDI purposely designed the system
with MDR as it provides carton accumulation every 24” – 60”, even on inclines. These
features where crucial to maximizing peak
rates and minimizing carton flow back up.
The existing shipping race track carousel
loop was relocated to make room for the
new pick module and an additional case
sealer was added with automatic sortation
between available lines.
SDI consulting services analyzed the SKU
and order details and provided new SKU to
location mapping for the existing and new
pick modules to balance work load evenly
between pick zones. Keeping the highest
movers on the first floor provides the easiest replenishment option.
case study
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The SDI Pick-to-Light system provides additional zone fine tuning and load analysis,
complete with reporting of pick rates by
employee or zone or other easily selectable
criteria. The supervisory functions all being
available on any browser enabled computer.
A tiered security system provides user, supervisor or manager level access to features.
The SDI Pick-to-Light is part of a suite of
WCS products that also provide carton routing / sorting capabilities. Saramax utilizes
the Smart Auditing functionality that keeps
track of all picking transactions for each
order. A range of selectable criteria can flag
any order (carton) as having to divert to a
Q/A Auditing area. SDI Dynatron WCS diverts order cartons as required to 6 auditing
Thin Client workstations. Operators check
orders for accuracy hand scanning items
and repacking the order. Actual carton
contents are uploaded to the host system.
The client server based architecture
ensures that data critical redundant servers
are in a safe environment controlled room,
not out on the DC floor. Only the low level
pick-light controllers are mounted in the
pick aisles out of harm’s way.
THE SYSTEM
The new system provides Saramax with all
the pick location required and order carton
routing between pick modules. Pick rates
are 800 – 1100 UPH and (pre Audit) order
accuracy almost 100%.
Pre-engineering design features for the
future will make expansion easy and cost
effective. Lost pallet locations where minimized by adding overhead storage in the
28 foot high pick module racking.
Egress requirements were reviewed by
SDI with the City of Sayreville and suitable
cross-overs and exit doors provided.
ABOUT SARAMAX
ABOUT SDI
Saramax Apparel is a whole sale supplier and manufacturer of intimate
SDI is an innovative provider of
systems and solutions to the retail,
wholesale, fulfillment and ecommerce industries for all aspects
of distribution center materials
handling.
wear for Walmart, JCP and others.
As both consultants and systems
integrators, the company provides
clients with a total logistics solution
package which includes materials
handling consulting, as well as design, engineering, fabrication, installation and integration services.
TEL: 818.890.6002 FAX: 818.890.2858
SDI.SYSTEMS
13000 PIERCE STREET, PACOIMA, CA 91331