WAREHOUSING & MATERIALS HANDLING u ERIKS


person operating each cell. These vertical lifts are large, 12m high per unit with a capacity to hold up to 100 large trays – each tray measures 3.5m x 1.5m, and in some instances may be divided up into over 200 compartments, giving over 60,000 locations in the current design.


30% REDUCTION IN PICK TIMES Through the clever application of system and software design automated storage capacity for small parts has been increased by 500% and pick times have been reduced by 30%, resulting in a 110% increase in productivity. Owing to smooth Invar programming, totes


are optimally routed between picking cells in accordance to orders received from the WMS. As a tote approaches a vertical lift an


appropriate tray within the unit is called into sequence, to be presented to the picker as the tote arrives – perfectly synchronised to maximise performance. Near perfect order accuracy is achieved


through the use of barcode scanning at key points of the goods-in, put-away, picking and fulfilment processes, and weighing scales within the conveyor system help to verify pick accuracy. Also, pick-to-light technology is deployed across all of the vertical lifts to guide the operator to the exact location on a tray to pick from, speeding the process and enhancing pick accuracy.


AUTOMATED ‘SIMPLICITY’ Invar has designed the user interface with the handheld to be very simple. The handheld screen is coloured differently depending on the process you are completing. When you are directed to pick an item, the screen is coloured pink, if the screen is yellow, inventory is for storage. This allows us to mix the two tasks together giving even greater efficiency. The processing of orders for our customers has to be accurate, therefore we require each


Through the clever application of system and software design automated storage capacity for small parts has been increased by 500% and pick times have been reduced by 30%, resulting in a 110% increase in productivity.


item to be scanned to confirm it’s the right product before being placed into the tote. As well as barcode scanning, the storage lifts contain a pick-to-light system which highlights the storage compartment to pick from.


Then further checks are made before an order enters the packing area. We have collected all the weights and dimensions of our core range, so the total order can then be weight checked by the integrated weighing machine in the conveyor system. And, once these checks are completed, further checks are made by the packing department before an order leaves the FCE. Invar Group completed the installation and integration of the small-parts system in early June 2021, just six months after engaging with the project. And there is plenty of room for expansion. At present just 65% of the current facility is used and forward planning has allowed space for further storage – future proofing expansion of the business.


ECONOMIES OF SCALE By moving to a central distribution model, we have gained economies of scale, enabling us to use automation to great effect. And by reducing manual tasks and improving productivity around the whole operation, we can now deploy more people to checking the quality of incoming goods.


The initiative has also allowed ERIKS to create


a centre of excellence for quality control, bringing more customer services inhouse and centralising expertise, to provide services such as certificates of conformity, product marking or additional value-added services for customers. The efficiencies achieved through the FCE


provide significant benefits – in addition to the improvements made in customer service, through greater product availability, increased order accuracy and faster deliveries. Continuing its commitment to ERIKS


beyond installation, Invar Group provides a full maintenance and software support service to the business, ensuring reliable operational performance throughout the year.


34 January 2024 Irish Manufacturing www.irish-manufacturing.com


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