Non-stop stationary
June 1st 2007 An overall increase in despatch productivity of 20 per cent
has been achieved by WH Smith at its Dunstable DC
following the introduction of an advanced automated
sortation system from SDI Greenstone
WH Smith has reduced costs,
increased order picking accuracy
and improved efficiency
throughout the site. The system has
specifically eliminated many powered pallet
truck movements and manual handling
operations to help promote better health
and safety within the site.
The two floored Dunstable warehouse
has been on the same site for over 26 years
and until recently had no automation. The
picking and despatch operations were
particularly labour intensive with order
picking managed using a combination of
trolleys, pallet trucks and totes. A goods lift
was used to transfer items between floors.
Greater productivity with better order
picking and assembly accuracy were
identified as key requirements. Automation
would help eliminate errors made, as
despatch staff would previously manually
sort consignments to stores by reading the
despatch label on the box/tote.
SDI proposed an automated sortation
system to link the principal sections of the
warehouse, including case picking, tote
picking, order assembly and despatch to
create a highly efficient picking
environment. The automation interfaces
with the warehouse management system to
ensure that order picking is synchronised
with delivery routes and schedules.
It was designed to accommodate up to
3000 cartons an hour, providing plenty of
capacity for current operations, seasonal
peaks and WH Smith's projected growth.
The warehouse currently operates roundthe-
clock five days a week and is busiest
during the summer 'back to school' and
Christmas periods. More than 4000 SKUs
are stocked in the distribution centre and up
to 2,000,000 units are shipped each week.
The most significant change in
operations has been in the case picking area
on the ground floor where cases are now
picked direct to belt in a single handling
movement. Items were previously picked
direct from their bin locations onto pallet
trucks. This area has experienced the
largest productivity gain in the warehouse
since the implementation of automation.
"We achieved a 100 per cent productivity
gain in this section," says Robin Ritchie. "In
other words, we can now pick twice as
much in the same time or the same amount
in half the time."
Another important benefit that was
especially noticeable in the case picking
area was the reduction of ferrying lift truck
movements. Now that case picks are moved
by the conveyor there is little need for trucks
to operate in the area, apart from
replenishment. This has reduced noise,
helped to eliminate a potential health and
safety hazard and allowed staff to undertake
different tasks. Lift trucks are now primarily
used to load transport vehicles. More articles from SDI Group UK Limited: | 
