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FEATURE COVER STORY


10 SIGNS IT’S TIME TO rethink your intralogistics


Uncovering one or more of these symptoms might indicate it’s time to consider a new method for handling inventory, components, goods and/or spare parts inside your operation


I


ntralogistics - the methods used to handle, store, track, locate and manage


the inventory, parts, goods and items within the four walls of an operation - can have a significant impact on productivity. In facilities relying on traditional static shelving for storage of non-palletised items the inherent limitations of the storage method itself can hamper associates' ability to find the right item quickly and in its expected condition. Here are 10 signs your shelf- based intralogistics practices might be negatively impacting your operation.


EXCESSIVE REPLENISHMENT


If reserve inventory of fast- and medium-moving items is stored in static shelving time can be wasted waiting for replenishment of inventory.


EXTENSIVE PICK TRAVEL Often workers are walking many miles during a shift which translates into wasted time. In a manual operation where workers must travel to the items they frequently spend as much as 60-65% of their shifts simply walking.


WASTED SEARCH TIME Upon arrival at a picking destination a worker must visually search the shelves looking for the correct item and matching up part numbers, a process that can take several minutes or more.


PICK ERRORS Operators follow a paper pick list, travel to a location, find the item, check the list to determine the number of items required, pick the items, confirm the pick by marking the paper then deliver the items for packing. Each step is an opportunity for human error.


LOW THROUGHPUT In a manual operation pickers often fill one order at a time, translating into pick rates of approximately 50 lines per hour.


DAMAGED ITEMS


Goods stored on shelves, whether in or out of containers are exposed to dirt and dust common to warehousing and manufacturing operations. This shortens


6 NOVEMBER 2015 | FACTORY EQUIPMENT


Remstar are available as alternative solutions to improving a facility's intralogistics without requiring a major remodel. These high-density storage solutions significantly reduce the amount of square footage required to store inventory by up to 85%. Facilities with multiple floor levels or


their useful life and renders them unsuitable for sale or internal use.


MISSING INVENTORY In open shelving spread across hundreds or thousands of square feet items can simply get lost. It can be a challenge to know how many items are in stock and their precise location.


PILFERED PRODUCT Open shelving is unsecured storage allowing anyone who passes by the opportunity to pilfer.


WASTED STORAGE SPACE Traditional, static shelving not only requires a tremendous amount of floor space, it does not make use of empty overhead (or vertical) space.


IMPROPER ERGONOMICS Shelf-based storage forces workers to bend or stretch to reach inventory or even use ladders to access the highest items. All of these activities can increase the chances of injury. Self-contained automated storage and retrieval equipment options from Kardex


The Kardex Remstar Shuttle XP is an automated high-bay warehousing system with a modular design making it ideal for high density and flexible storage in a compact footprint


mezzanines can optimise replenishment of automated storage units by adding a second access opening at a different elevation. This allows one opening to be dedicated to replenishment and the other to picking. Speeding up picking maximises workers' available time for other revenue generating activities. Using batching picking to group together orders with common items allows for picks to be completed in a single rotation (or cycle) of the unit. Batch picking can increase throughput by as much as 200% - up to 600 lines per hour. Kardex Remstar`s automated storage and retrieval technologies operate on the ‘goods to person’ principle delivering a required item directly to the operator. This dramatically reduces travel time in addition to improved worker ergonomics. This eliminates the need to reach, bend or stretch for products stored at the top or bottom or static rack and shelving. Integrated with light-directed picking and


integrated message centers, these systems communicate the precise area within a carrier of the item to be picked, display the part number or description, pinpoint the exact location, direct picking and indicate the required quantity. These visual picking aids reduce processing errors and increase accuracy up to 99.9%. Consider automated storage and retrieval systems from Kardex Remstar to improve your intralogistics processes, increase accuracy, save floor space and increase productivity. Kardex Remstar is a leading provider of automated storage and retrieval systems for manufacturing, distribution, warehousing, offices and institutions.


Kardex Remstar T: +44 (844) 939 0800 E: contact.remstar.uk@kardex.com www.kardex-remstar.co.uk


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