Upgrades For A Flexible Supply Chain’s Distribution Center
The 200,000 square foot distribution center of Christopher & Banks had been supporting quick fulfillment to its branches, but their methods’ transportation expenses were cost prohibitive. Additionally, there was a strong desire to reduce transportation costs by repacking items to increase box weight. The drive to repackage a large portion of the products put a strain on the aging equipment and the existing capacity. The facility was dependent on an old and inflexible conveyor system that was also where operational challenges and lots of chronic maintenance came from. Conveyor and material handling are also utilized frequently in airports and freight handling businesses.
With the combined difficulties of an inefficient workflow, a paper picking system, and aging equipment, the company decided that in order to continue supporting just in-time delivery and direct to consumer fulfillment operations, upgrades were necessary. Christopher & Banks hired the services of a material handling consulting firm, but they put the project on hold until Mike Tripp, the new manager for supply chain and logistics joined the team. Tripp joined with the experience and know-how to make a plan for a more energy efficient, productive, and ergonomically sound solution that satisfied throughput and budget constraints. There are also pick to light conveyor systems that use color codes to distinguish different types of materials from each other.
The project was put up for bids and the contract was won by Intelligrated in April 2009. The proposal was cost-effective; it proposed productivity gains for less than 50% of the cost of the other proposals, they put it on a fast paced schedule for completion on August 2009, prior to fall stores deliveries.
The retrofit of the Christopher & Banks facility is built for a new linear flow with a semi automated fulfillment process. Merchandise is inspected and the quality is checked in receiving areas, then delivered by forklift to staging areas. The operators utilize RF-scanning to upload all the new merchandise information into the pick-to-light system, where the product is put into an ergonomically-made combination conveyor and shelf support assembly. In the distribution center, workers add items to master cartons asthey move along the Intelligrated gravity conveyor. The semi-automated fulfillment process signifies an improvement over the legacy system, removing manual lifting and clutter on the floor, providing a quieter, safer solution that is faster and more accurate.
Once the orders are complete in individual stores, cartons are moved onto a central take away belt conveyor towards a two-level Intelligrated motor driven roller (MDR) conveyor collection line. Features like run on demand independent zones and zero pressure accumulation, the conveyor lessens wear and power use, gets rid of product jams and allows for the whole length of the conveyor to be filled. This lets orders be picked up to go on independently of shipping activity. Cartons move to a cental merge and sorter and then get routed to a any of three shipping lanes. On each of the shipping lanes, cartons are sealed automatically, weighed, labeled at a work station, and then conveyed directly into a trailer by the shipping dock doors.
Intelligrated provided a convenient overhead empty carton conveyor which was part of the facility’s upgrades. The facility makes up to four tons of empty corrugate daily, the reworked line for empty cartons directly moves the corrugate into a waiting container outside that is then sent to be recycled.
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