Chain Case Cover
2010
An Enhancement To A Distribution Center For A Flexible Supply Chain
The Christopher & Banks 200,000 square foot distribution center had been able to support quick fulfillment to its stores, but the transportation expenses associated with their methods 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.
Faced with a paper picking system, an inefficient workflow and aging equipment, the company determined that if it is to continue supporting just in-time delivery and direct to consumer fulfillment operations, it was necessary to upgrade. Christopher & Banks hired a material handling consulting firm to assist, but the project was put on hold until a new supply chain and logistics manager, Mike Tripp, joined the team. Tripp joined the team with the know-how and experience to make a plan for a more productive, energy efficient, and ergonomically sound solution that met throughput and budget restrictions. There are also pick to light conveyor systems that use color codes to distinguish different types of materials from each other.
The company put the project up for competitive bids and Intelligrated won it in April 2009. The cost-effective proposal, offering productivity gains for less than half of the other proposals’ costs, was placed on a schedule for a fast paced completion by August 2009, before fall store deliveries started.
The retrofit of the Christopher & Banks facility is built for a new linear flow with a semi automated fulfillment process. Merchandise is inspected in receiving areas, quality checked and delivered via forklift to staging areas. Operators make use of RF-scanning to upload the data of new merchandise into the pick-to-light system, where the product is then placed into an ergonomically designed combination of shelf and conveyor support assemblies. Items are added to master cartons by distribution center workers as they move along an Intelligrated gravity conveyor. This semi automated fulfillment process represents an improvement over the legacy system, eliminating manual lifting and floor clutter and providing a safer, quieter solution that is quicker and more accurate.
When the orders are finished for individual stores, the cartons are moved onto a main take-away conveyor belt to a two-level Intelligrated motor driven roller, or 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. With this, order picking can go on independently of shipping activity. Cartons continue to a central merge and sorter where they are routed to one 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.
Other upgrades to the facility include a convenient overhead empty carton conveyor provided by Intelligrated. The facility produces up to 4 tons of empty corrugate every day, the reworked line for empty cartons directly routes corrugate into a container waiting outside to be sent for recycling.
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