The design services included the restructuring of the work floor to allow for the sequential movement of products from the kitchen to the shipping dock. The kitting process was also streamlined to match the overall throughput of the meals with the schedule of the courier services.
Following a customizable analysis flow chart [EDS PAGE], the results of the design study were summarized into a report that captured crucial engineering information that could be re-used for future projects.
Key Areas of System Design:
Overall control system: Our SIIMSPC-based control system would be designed to control the conveyor PLC, the pack stations PC and to manage separate PCs for each workstation, which comprise of bar code scanners, label printers and pack slip printers.
A-Frame set-up: SI’s pick-to-tote A-Frame was configurated for a throughput of 2,000 units per hour for the 30+ SKU set of unique meals and add-on products. This PTT (Pick to Tote) version of the A-Frame reduces the number of product touchpoints, which is essential when handling perishable products. The totes are conveyed straight to the packing station to be boxed for shipping.
Shipping Carton prep: To expedite the packing process, the box prep area was positioned as close to the freezer area as possible so that the first item that is put in the box would be gel packs.
Packing Stations: The packing station line includes a 3-tiered conveyor. The top tier delivers prepped boxes with frozen gel packs in them. The center tier delivers full order totes from the A-Frames to the packing stations. The bottom tier then delivers the completed boxes orders to end of the packing station line where they can then be gathered and palleted for shipping.
Conveyor Integration: The A-Frame dispenser lines and Packing Station lines are served and joined by a TGW conveyor system. Primary component of this system includes CRUZ belt Conveyor and IntelliROL Motorized Roller Conveyor.
Staffing deployment: Under the proposed automated layout, new roles were assigned to all warehouse associates to handle each of the key areas of design.