Snack Food Manufacturing Distribution Center, Location: Southern U.S.
A manufacturing shipping buffer that ensures accurate, on-time orders
This Fortune 50 client required a manufacturing shipping buffer that would enable the company to ensure accurate, on-time orders, sequenced loading for multi-drop direct-store-delivery, and support of pick-to-belt operations. Because of ACTIV’s high-density characteristics, the existing building required minimal expansion to achieve the client’s goals. The ACTIV System in this application runs 24 hours per day. It is a two-module system¾ levels are 3 and 4 high.
Storage, Sortation, and Full Pallet Staging
This module acts as a storage buffer for the manufactured product. Unit loads are sorted and flow through to staging lanes at the dock end of the system, which pre-stages over 40 full trailer load orders in required sequence.
In operation, forklifts move palletized finished goods from manufacturing to the ACTIV input point where bar-coding technology scans the unit loads into the ACTIV System. A conveyor system transports the loads to ACTIV’s VTLs, which in turn moves the loads between levels. ACTIV’s Path Management Software calculates the optimum path for each load and the system’s basic components (VTLs, DLTs, and CATs) work in unison to move the load through the system in the most efficient manner to service order requirements.
Staging takes place within the ACTIV footprint. Orders are arranged in reverse trailer order in a “staging slot.” For this application, the staging slots consist of three staging lanes arranged vertically. For loading, the trailers are directed to the dock nearest the location of the staged order.
The forklift operator uses a RF terminal on the forklift to sign onto the applicable staging slot. As each load is brought off a staging lane, the ACTIV System updates automatically. For positive verification of an order, the forklift operator scans a bar code that corresponds to the dock door to which the load is delivered. This information is then provided to the client’s Warehouse Management System (WMS).
Pick Face System
The pick faces in this module are two and three deep. Fast-moving products are assigned dedicated pick faces; medium movers are assigned a single-deep position with backup pick faces located on the opposite side of the distribution transfer; and slow-moving items are located in a fast access area and pulled for picking as needed. The WMS electronically communicates SKU assignments to the ACTIV System, which in turn controls pick face replenishment.
The client is able to utilize first-in/first out (FIFO) for product movement. ACTIV’s software selects, routes, and tracks the product’s location at all points within the system. The system then selects the most efficient path for routing each unit load from its initial placement into the ACTIV to its load position on the pick face or trailer.
Since unit staging takes place within the system footprint, trailers arriving at their pre-designated loading docks receive the loads in a timely manner. Shorter delivery cycles, competitive transportation pricing, and increased order accuracy combine to help this client meet and exceed the expectations of its customers.
Manufacturing Cross Dock
To enable internal cross docking or cross docking from manufacturing to staging, each level within ACTIV has its own express lane. (Express lanes are open lanes that are dedicated to transporting product from one end of the system to the other.) In addition catwalks and platforms are utilized throughout the system to permit access to ACTIV’s controls and drives, which are located outside the rack structure area.