the sortation palooza - mwpvl€¦ · circulation sortation cross-belt sorter tilt tray sorter...
TRANSCRIPT
The Sortation Palooza
Track T5 Session #1
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Marc Wulfraat
▪ www.mwpvl.com
▪ 514-482-3572 x 100
▪ Dematic
▪ President
Bob Kregel
▪ V.P. Global Product Management
▪ MWPVL International
▪ (262) 860-6503
▪ www.dematic.us
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Abstract
3
Sortation systems have been acknowledged as "the heart of the
modern distribution center."
Fueled by the impatience of ecommerce customers, the eruption of
SKUs and the intertwined network resulting from omnichannel,
sorting goods inside the DC has gone from complex to perplexing.
In this comprehensive review, our sortation scholars will present a
multitude of contemporary sortation solutions in terms of function,
specifications and application. A deliverable from this class will be
a clear selection matrix to aid you in making design decisions that
you won't regret.
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Agenda
4
What is a sortation system and when is it needed?
What are the basic components of a sortation system?
What types of sortation systems are available?
What options exist?
What considerations are important when choosing a
sortation system?
Questions & Discussion
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Sortation Definition
5
Sortation is a process that orders items according to
specified criteria
It can serve as the heart
of an efficient
distribution center
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Sortation System Definition
6
Sortation can be a manual process, a semi-automated
process, or a fully-automated process
A sortation system identifies products and/or
packages (i.e. entities) and in turn transports, merges,
inducts, separates, sorts, routes and/or consolidates
these entities to specified destinations as per the
requirements of the distribution operation
Sortation
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When Do We Need Sortation Systems?
7
Sortation systems are typically deployed when
a distribution center has one or more of the
following characteristics:
- Batch picking: Multiple orders are grouped together and picked as a
single parent order to reduce travel time and afterwards the child
orders need to be sorted
- Multiple pick areas and/or material handling technologies are
picked independently and in parallel; and need to be merged prior
to packing
- Goods need to be moved between different areas, floors and
buildings
- Completed orders need to be sequenced prior to loading (e.g. by
carrier, by weight, by load/stop)
- Flow through distribution such as in the Retail Industry
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The Main Benefits of Sortation
8
Sortation systems allow companies to increase
throughput in a distribution center because
picking processes can be in parallel instead of
in serial
The enabler for high speed batch picking and
flow through operations which remove
significant labor cost from a DC operation
Highest levels of shipment accuracy can be
achieved
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Sortation System Design Considerations
9
Decision Criteria Design Data Requirements
Throughput Volume Requirements
& Speed
• Average and peak of sorts per minute
• Average and peak diverts per minute through
each destination point
Packaging format, size, shape,
diversity, and conveyability of
packages
• Type of packaging material, fragility, weight
distribution, flatness of entity
• Product orientation
• Product mix
Unit Load Characteristics • Length, width, height, weight of entity being
sorted
Operating Environment • Temperature, dust, oil, obstructions
Physical Site Constraints • Columns, clear height, doors
Accumulation & Recirculation
Requirements
• Buffer requirement leading up to sortation
• Recirculation after sortation discharge
Financial • System cost and ROI
Other Considerations • Ergonomics, noise, energy requirement,
maintenance, equipment interfaces
• Bar code label size, location & symbology
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Different Types of Sortation Systems
10
Sortation Type Available Technologies
Manual Put Wall / With Lights
Conveyor Systems Right angle transfer with bands or rollers
Conveyor with swing arm, pusher or deflector
Strip-Belt Sorter
Positive Belt Sorter
Swivel wheel sorter or pop-up wheel sorter
Linear Sortation Sliding Shoe with Angle Divert
Sliding Shoe with Parallel Divert
Sliding Shoe with Bi-Directional Divert
Circulation Sortation Cross-belt sorter
Tilt tray sorter
Bomb-bay sorter (1-tray, 2-tray, quad-tray)
Automation Shuttle system
Please note that there are other types of specialty and hybrid sortation systems not listed here that are excluded
due to time limitations for this presentation.
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Sortation System Component Diagram
11
Merge
Facilitates
Flow of Unit
Loads
Induction
Minimizes gaps
between loads and
maximizes the flow
onto the sorter
Sorter
Diverts items
to one or two
sides
Take-Away
Moves items
away from
the sorter
Controls
Tracks items
and ensures
accurate
flow
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Sortation System Components in Detail
12
Subsystem Options Description
Merge • Merge Options
- Single
- Dual
- Sawtooth
- Multilane
• Receives products/cartons from
various sources or areas
• Controls / regulates / funnels /
singulates the flow of cartons into a
single stream prior to sortation
Induction • Gap Options
- Brake belt or meter belt
- Blow through
- High rate gapping unit
• Gateway to sortation system
• Identifies carton and destination
• Gaps and spaces cartons to
optimize sortation system
Sortation • Tracking Options
- Relays, Programmable logic
controllers (PLC), Computers
- Diverter Options
- Manual, plow, pusher, pop-
up, slat-shoe, tilt- tray, etc.
• Tracks carton through to
downstream destination
• Activates diverter device
• Sorts cartons/packages into
different streams
Takeaway • Takeaway Options
- Conveyors
- Chutes, Spirals
- Drops
• Transport / takeaway cartons away
from sorter
• Feed downstream pack stations or
shipping stations
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Review of Different Types
of Sortation Systems
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Manual - Put Wall Sortation / With Lights
14
Operator scans incoming tote
license plate
Put to Light identifies the cubby
hole to sort product/quantity to
(30 – 75 cubby holes typically)
Confirm by pushing button on
light panel
Product removed from other
side of wall for packing
Typical Applications Pros / Cons / Considerations
Upstream batch piece picking process↑ Provides integrated order consolidation
and packing
Upstream goods to person automation ↑ System-directed manual process
Upstream pre-put picking process↑ Flexible, scalable, mobile (wheels), low
cost alternate to mechanized sortation
Small orders with few order lines (e.g. e-
commerce, catalogue, customer-direct)↓ Limited throughput volume rate
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Put Wall Video
15
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Conveyor with Right Angle Transfer
16
Powered roller conveyor with 90° bi-directional package
transfer to left or right
Pneumatic lift used to divert package
Standard diverter with pop-up straps has a lower
sortation rate of 25 - 30 cartons sorted per minute
High Speed diverter with pop-up rollers can sort up to 25
- 60 cartons per minute
Requires a flat-bottom entity such as a carton or tote
Typical Applications
Standard diverter handles minimum carton dimensions
of 6”W x 9”L with 2 – 110 LBs at 180 feet/min
High speed diverter handles minimum carton dimensions
of 9”W x 9”L with 2 – 110 LBs at 240 feet/min
Merge batch picked items to a highway lane
Divert / sort items/cartons to picking zones
Medium throughput sortation to shipping lanes
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Conveyor With Right Angle Transfer
17
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Conveyor with Swing Arm or Paddle or Push
Deflector
18
Powered roller conveyor with 45°-90°
package transfer to left or right
Pneumatic swing arm, pusher arm or
deflector arm used to divert package
Right angle Pusher can sort 25 – 50
cases/totes per minute
Swing arm diverters can sort 25 - 60
cases/totes / minute
Some applications can go higher
Typical Applications Pros / Cons / Considerations
Divert / Sort cartons or totes to conveyor
lanes for transfer to new pick zones or to
shipping lanes
↑ Medium cost, flexible and modular
diverter that can easily be relocated
within a conveyor system
Standard pusher handles minimum carton
dimensions of 4”W x 6”L x 2”H with 2 – 75
LBs at 250 feet/min
↓ Higher speed pusher diverters can have
a high impact on the product being
sorted
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Swing Arm, Paddle & Push Deflectors
19
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Conveyor Strip-Belt Sorter
20
Bi-directional right angle
transfers
Motorized pulley drive with
pneumatic transfer lift elevates
high strength belts
Designed to sort parcels up to
100 Lbs at speeds of 25 - 65
items/cartons/totes per minute
Often used to sort loose units or
totes
Typical Applications Pros / Cons / Considerations
Suitable for totes, trays and for rigid form
factor products like CDs, DVDs, returns
sortation
↑ Highly energy efficient
↑ High strength belt
↓ Product weight constraint
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Conveyor Strip-Belt Sorter
21
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Conveyor Positive Belt Sorter
22
Pneumatic lift mechanism causes
cartons to divert to left or right on a
30° angle
Powered belts face package flow for
diverting
One or two belts used depending on
width of conveyor to reduce minimum
gap requirements and maximize rate
25 - 60 cartons/totes sorted per
minute
Typical Applications Pros / Cons / Considerations
Generally applied to low throughput
applications
↑ Energy efficient
Divert / Sort cartons/totes to destination lanes ↓ Limited throughput volume rate
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Conveyor with Steerable Wheel Pop-Up Roller Wheel diverter
23
Pneumatic rotary actuator turns wheels
for diverting cartons 30° to left or right
Wheels rotate or pop up to divert
package
Steerable wheel diverter can sort 30 - 80
items per minute
Pop-up wheel diverter can sort 35 - 100
items per minute
Typical Applications Pros / Cons / Considerations
Steerable wheel handles min. carton
dimensions of 3”W x 9”L up to 24”w x 36”L
with 2 – 110 LBs at 315 feet/min
↑ Flexible and modular diverter that can
easily be relocated within a conveyor
system
Pop-up wheel handles minimum carton
dimensions of 6”W x 9”L up to 26”w x 36”L
with 4 – 100 LBs at 350 feet/min
↑ Range of throughput rates supported
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Steerable Wheel Sorter
24
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Linear Sliding Shoe Sorter Angle Divert
25
High-Rate Sorter
Aluminum slats (typ. 4”) with
sliding shoes
One sided, 30° sorting
100 – 280 cartons per minute
throughput capacity
Speed of up to 150 to 600+ ft/min
Typical Applications Pros / Cons / Considerations
Angled divert handles minimum carton
dimensions of 4”W x 6”L up to 41”w x
48”L with 2 – 100 LBs at 540 feet/min
↑ Possibility to eliminate chain drive, no
lubrication
↑ Electro-mechanical divert switch (no air)
↑ Automatic speed control for throughput
fluctuations saves energy & reduces wear
Applied for high throughput applications ↓ Higher cost system
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Linear Sliding Shoe Sorter Parallel Divert
26
Ultra High-Rate Sorter
Aluminum slats (typ. 4”) with
sliding shoes
One sided, 30° sorting
150 – 380 cartons per minute
throughput capacity
Speed range 150 – 600+
feet/min.
Typical Applications Pros / Cons / Considerations
Parallel diverting provides the highest sortation
rate & slowest transfer speed
Parallel divert handles minimum carton
dimensions of 4”W x 6”L up to 34”w x 60”L
with 2 – 154 LBs at 590 feet/min
↑ Possibility to eliminate chain drive, no
lubrication
↑ Automatic speed control for throughput
fluctuations saves energy & reduces
wear
↑ Smaller gap required between cartons
High throughput retail sortation applications ↓ Higher cost system
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Linear Sliding Shoe Bi-Directional Divert
27
Mid-Rate Sorter that requires low space
Aluminum slats (typ. 4”) with sliding
shoes
Two-sided, 30° angled sorting
100 - 280 cartons per minute throughput
capacity
Speed range 150 – 540 feet per minute
Typical Applications Pros / Cons / Considerations
Applied for medium/high throughput
applications as an alternative to pop up
wheel sorters
↑ Possibility to eliminate chain drive, no
lubrication
↑ Electro-mechanical divert switch (no air)
↑ Automatic speed control for throughput
fluctuations saves energy & reduces wear
Bi-directional divert handles minimum
carton dimensions of 3”W x 6”L up to 31”w
x 48”L with 0.2 – 110 LBs at 320 feet/min
↓ Higher cost system
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Sliding Shoe Sorter
28
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Circular Sortation – Cross Belt Sorter
29
High-speed bi-directional sorter
diverts items or cartons 90° left or
right
Divert points can be at close
intervals for space efficiency
Performs True Positive Active
sortation
Single, twin, double deck and quad
cell
Typical Applications Pros / Cons / Considerations
High speed throughput applications that can
handles minimum item dimensions of 3”W x
3”L x 0.1”H up to 24”w x 47”L with 0.2 – 110
LBs at 360 - 490 feet/min
↑ Flexible and modular diverter that can
easily be relocated within a conveyor
system
Diverts units or cartons to destination lanes ↑ Flexibility to sort a wide range of entities
of their shape, size and surface
characteristics
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Circular Sortation – Cross Belt Sorter
30
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Circular Sortation – Tilt-Tray
31
High-speed chain-driven 2-way sorter
used for a wide mix of unit or parcel
sortation
Wide choice of induction units and chute
designs
Flexibility to scale down throughput
speed to reduce product impact
Speed can range 400 – 500+ ft/min
Can sort 23,000 - 25,000+ pieces per hour
depending on design
Typical Applications Pros / Cons / Considerations
Applied where a diverse range of units or
parcels are sorted to destination chutes/lanes.
↑ High-accuracy, high-speed, low-noise
system that is scalable
↑ Modular by design – flexible to change
Commonly used to sort a wide range of
products including apparel, small items in poly
bags, mail envelopes, courier parcels, DVD’s,
CD’s and small to large corrugated boxes.
↑ Handles a diverse range of items and
parcels
↓ Can requires a larger footprint
depending on the design
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Circular Sortation – Tilt-Tray
32
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Circular Sortation – Bomb-Bay
33
Typical Applications Pros / Cons / Considerations
Often used to sort apparel / soft
goods, or small products that can fit
on a tray and that are not fragile.
↑ High-accuracy, high-speed sortation that can
scale to low throughput applications
↑ Less space requirement because chutes can be
directly below the sorter
↓ Efficiency constraints when 4 people induct at
one induction station
↓ Each wave release requires time to reset the
shipping cartons under the sorter
High-speed continuous loop sorter that is
typically an oval race track traveling at ~140 feet
per minute
8 operators can manually induct up to 40,000
pieces/hr at 2 ends of the loop
Also known as a split tray or quad tray sorter
because trays can be divided into 2 or 4 sub-
trays
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Circular Sortation – Bomb-Bay
34
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Automation – Shuttle System
35
Shuttle robots can be used as an alternative
to traditional sortation systems
Shuttles can stage totes or cartons selected
from one or many pick zones in the DC
Totes are staged and then released for
outbound deliveries in optimal sequence
Heaviest totes can always be on bottom of
pallet for ergonomic considerations
Typical Applications Pros / Cons / Considerations
Retail– merge and consolidate totes
from conventional pick areas and
release by store in aisle/weight
sequence
↑ High-accuracy sortation that can scale to high
throughput applications
↑ High storage density / low footprint
↑ High-flexibility solution
E-commerce home delivery for food
– sort by route and stop
↓ Higher thoughput requires more shuttles
therefore more cost
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Application Selection Guidelines
36
(8,000 to 40,000+)
(6,000 to 18,000)
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Sorter Selection Guide (Throughput)
37
(Cartons/
Hour)
(Cartons/
Min)
Right Angle
Transfer
(Bands)
Right Angle
Transfer
(Rollers)
Pusher
Diverter
Strip
Belt
Sorter
Positive
Belt
Sorter
Swivel
Wheel
Divert
Pop-Up
Wheel
Divert
Sliding Shoe
Bi-Directional
Divert
Sliding
Shoe Angle
Divert
Sliding Shoe
Parallel
Divert
Tilt Tray
Sorter
Cross Belt
Sorter
Bomb Bay
Sorter
25,000 - 40,000 420 - 670
18,000 - 25,000 300 - 420
15,000 - 18,000 250 - 300
12,000 - 15,000 200 - 250
10,200 - 12,000 170 - 200
8,400 - 10,200 140 - 170
6,600 - 8,400 110 - 140
4,800 - 6,600 80 - 110
3,600 - 4,800 60 - 80
2,700 - 3,600 45 - 60
2,100 - 2,700 35 - 45
1,500 - 2,100 25 - 35
900 - 1,500 15 - 25
0 - 900 0 - 15
Legend: Low Fit Med. Fit Optimal Fit Optimal Fit
Mid Rate
Sorter Selection Guide Based on Sortation Rates of a Standard 16" Carton
High RateLow Rate Throughput Rate
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Summary of Sortation Systems
38
Sortation
System
Throughput
Rate per Hour
Technology Typical
Rate
Max
Rate
Metric System Cost Flat Bottom
Required
Takeaway Options
Manual Put
Wall
Up to 700
Items/hour
Pick/Put to Light 7 12 Items per min. Low No Pack Station or
Powered conveyor
Right angle transfer diverter
with straps
25 30 Cartons/Totes per
min.
Low Yes Powered conveyor
Right angle transfer diverter
with rollers
25 60 Cartons/Totes per
min.
Low Yes Powered conveyor
Flat belt conveyor with swing
arm, pusher arm, or deflector
diverters
25 60 Items/Cartons/Totes
per min.
Low No All
Strip-Belt Sorter Diverter 25 65 Items/Cartons/Totes
per min.
Medium No All
Positive Belt Diverter 25 65 Cartons/Totes per
min.
Medium Yes All
Swivel/steerable wheel diverter 30 80 Cartons/Totes per
min.
Medium Yes All
Pop-up wheel diverter 35 100 Cartons/Totes per
min.
Medium Yes All
Bi-Directional Divert 100 280 Items/Crt per min High No All
Angle Divert 100 280 Items/Hour High No All
Parallel Divert 150 380 Items/Hour High No All
Cross-belt sorter 350 500 Feet/Minute High No Chute
Tilt tray 350 500 Feet/Minute High No Chute
Bomb-bay (1-tray, 2-tray, quad-
tray)
120 140 Feet/Minute High No Drop, Chute
Automation Shuttle System Customized High No Powered Conveyor
9,000 to 24,000
Items/hour
Conveyor
Diverter
Systems
Up to 7500
cartons or totes
per Hour
Circulation
Sortation 8,000 to 40,000+
Items/hour
Linear Sliding
Shoe
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Key Takeaways
Many sortation systems are available on the market and
we have only discussed the more common ones
Sortation system costs generally increase as
throughput rates increase
It is key to identify throughput rate requirements,
packaging format, weights, shapes, sizes of products,
cartons or totes to be sorted
There is an optimal sorter for each type of application
and the guidelines presented here provide a basic
starting point towards this objective
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Conference Cloud Additional Resources
40
Put Wall
- http://www.youtube.com/watch?feature=player_detailpage&v=NToQfX3NseQ
Linear Sorters
- http://www.youtube.com/watch?v=2TJ4NYHuXPI&feature=player_detailpage
Conveyor Sorters
- https://www.youtube.com/watch?v=PvLoU9D07s0
- http://www.youtube.com/watch?v=F-ZdQGtaItU&feature=player_detailpage
- http://www.youtube.com/watch?v=pSemAc9s7XQ&feature=player_detailpage
Cross Belt Sorters
- http://www.youtube.com/watch?v=HGkpXNQzZuQ&feature=player_detailpage
Tilt Tray Sorters
- http://www.youtube.com/watch?feature=player_detailpage&v=PM7dRuFmHI4
- http://www.youtube.com/watch?v=_RrU_AAqPtE&feature=player_detailpage
Steerable Wheel Sorters
- https://www.youtube.com/watch?v=PvLoU9D07s0
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Questions
41