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Presented by:
Barry Evans, Senior Vice President Sales
Brian Sullivan, Vice President National Sales
3 Dimensional
Conveying and
Sorting
Agenda
• WRH Global Americas – Introduction
• Using Gravity Sortation and Buffering Conveyor to Save
Space and Optimize Throughput
• Running Parallel Processes to Optimize the Value of
your System
• Closing Comments
WRH Global Americas – Introduction
• Global Leader in overhead carriage conveyor & rolling
friction continuous chain conveyor and sorter systems
• Founded 1957, Hinwil, Switzerland
• 2nd generation since 1997
• 1000 employees
• USD 350 Mio. revenue
• Profit is re-invested in R&D
• World wide, 20 fully owned subsidiaries
3 dimensional conveying solutions
• Barry Evans – Senior Vice President
• 30 Years with WRH Global
• System solutions
Flexible & Agile
5
6
A Case Study to maximize production flow through conveying technique at Soudal, Turnhout (Belgium)
7
Manufacturer of sealants,
PU-foams and adhesives for the building
industry
Family owned company (1966)
€ 565 m turnover ( 2014)
2200 employees
2011 Entrepreneur of the year in
Belgium
Worldwide presence in 110 countries
8
Turnover target 2020 : > € 1 bn
9
Story
January 2012: First meeting
April 2014: Installation of the first Skyfall buffersystem
September 2015: Decision for two new production lines
June 2016: Installation of the new lines
End of 2016 Installation of the second phase
10
Scheme : first line
Neu Buffer Skyfall
Filler (Schwerdtel) 200 cart./min
Transport empty cartridges
(Montech)
Depalettizer (Montech)
Case packer (Fischbach)
2 x 100 cart./min
11
Scheme : first line (April 2014)
Pick up station Buffer Delivery station
12
Scheme : new project 2016
2 new production lines equipped with Skyfall
Phase 2 : October 2016 Buffer
Switches
Centralised manual
feeding
72 73 Filler
(Schwerdtel)
Case Packer
(ETT)
Buffer
180 - 200 cart /min
Phase 1 : June 2016
13
Central feeding
Filling
Packaging
Skyfall conveyor
for empty cartridges
Skyfall conveyor
for filled cartridges
14
Layout : new project 2016
2 new production lines (72 and 73) equipped with Skyfall
50 m
42 m
72 73 2 ) Cartridges filler
3 ) Skyfall buffer
4 ) Case packer
5 ) Palletizer
1 ) Central feeding area
15
Scheme : new lines
17
• Skyfall Project
– Cockpit Automation – Dashboard
– Straubing, Germany
– No space on floor
– 2400 items per hour
– 4 components per trolley
– Skytrain is the buffer
– 2.4 kg (9.26 lb.) per part / 37 lbs.
per trolley
– Installation – May 2017
Antolin Straubing
(Previously Magna)
18
• Antolin Straubing Interiors
– Convey Cockpits from Pickup to
Dropoff
– Use Skytain as Dynamic Buffer
– Total System Length: 770 meters
(2526’)
– Maximum capacity of 2400 items
– Speed: 2 m/s or 40’ per minute
– Space Saving Verticle Lift
– Controlled Motion Transport
– Reduce Labor
– Reduce Handling & Associated
Damage
– Improve Efficiences
– Low Energy Requirement
– Quiet System
System Information
19
Skyfall Trolley System Layout
21
Stage Stores
Stage Stores, Inc. is a department store company specializing in retailing brand name apparel, accessories, cosmetics, footwear and housewares to small towns and communities throughout the United States. The corporate office is located in Houston, Texas.Stage Stores operates more than 855 stores in 40 states under the Bealls (no relation to the Bealls chain in Florida), Palais Royal, Peebles, Stage, and Goody's nameplates. The company operates stores mainly in small and mid-size towns and communities, primarily in Midwestern, Southeastern, and Mid-Atlantic states with a growing presence in the New England states. Stores are located in shopping malls and centers or in standalone areas.
Stage Stores
System designed for two waves of 1600 units each System speed 3200 uph 10 induction stations 24 packaging stations 6 primary buffers each with 510 pouch capacity 12 secondary sortation lanes each for 250 pouches Empty pouch buffer for 2500 pouches
Stage Stores
Running Parallel Processes to Optimize the Value of your System
• Brian Sullivan
• 30+ Years in Industry
• WRH Global Americas in 2016
• Intralogistics Emphasis
Running Parallel Processes to Optimize the Value of your System
• Many Projects:
– Distribution Center
182 / 715 meters – Scalable 1600 sq. meter footprint • 180 sort locations • Picking • Packing • Consolidating • Returns
Running Parallel Processes to Optimize the Value of your System
• Many Projects:
– Returns Handling
220 meters long 20 x 32 meter footprint • 42 sort locations • Induct • Upper Level Processing • Sort to Storage Location
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• GOAL: • Make Picking More
Efficient • Pick in Route Optimized
Batches for all Open Orders at Once
• Get away from picking Orders, one after the other, in sequence
• Better utilize Space: • Business Growth • Facilities
Consolidation
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• Incorporate two continuous chain technologies:
Denisort Deniway
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• 300,000 books per week • 7500 books per hour • Additional Traffic: 1500 books per hour: 1000 from storage 500 single returns 500 “special goods” / hour • 9500 items per hour 85% Max filling 10% Reserve • Means 12,300 Trays per
hour required
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
Four Product Areas: High Rank Store Pick From Pallet Pick From Shelf Special Products Induction Areas: High Rank Bulk Reserve Return Handling Small Incoming Shipments
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• Initiate induction in the Pick from Pallet
Storage Area when sort trays are empty after packing (on left)
• Note that escalations and de-escalations are made to optimize clearances.
• Single books from the Bulk Reserve use the system to fill Shelf Storage (on right)
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
Passing the Returns Area, returned singles are inducted (at right). Again escalating to allow forklift traffic, the system provides for elevated book induction. Incoming shipments are inducted from special storage area (on left)
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• Inductions from the “Pick from Pallet” area which flow over to the “Pick from Shelf” area along with returned books.
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• The “pick from Shelf” area where books are delivered from the sorter
• From here, books are also inducted and transported, along with books from other induction points, to the packaging area.
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• Picked orders are dispensed at packing.
• Empty trays advance to start the process over again.
• Packed cases are taken away on a Deniway continuous loop that runs through a binding station and diverts to four roller conveyors to feed trucks in bays
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
• Escalating return allows for material handling movement in open floor space
Running Parallel Processes to Optimize the Value of your System
Book Distribution Challenge
Benefits: • Change from Order Picking to Batch Picking optimizes
Staffing • Second facility can now consolidate business into main
operation • More business can run across the system • Floor space is freed up for additional activities • Maintenance requirements are minimized • Noise levels are reduced • Energy requirements are minimal
For More Information: [email protected]
website: www.wrh-global-americas.com
Or visit ProMat Booth N1007
Thank You for joining us today! Feel free to ask for more information on the solutions presented or
present us your own challenges with system engineering.
3 Dimensional Conveying & Sorting
Closing Comments