Upgrades For A Extremely Versatile 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 urge to reduce transportation expenses by repacking items to increase the weight of the boxes. The need to repack a large percentage of the products strained the present capacity and aging equipment. The facility’s operations relied on an old and inflexible conveyor system where many chronic maintenance and operational challenges came from. material handling is also frequently used in the warehousing and packaging processes.
In the face of aging equipment, an inefficient work flow, and a paper picking system, the company thought that it needed an upgrade to continue supporting just in-time delivery and direct to consumer fulfillment operations. Christopher & Banks got assistance from a material handling consulting firm but the project was placed on hold until the team was joined by a new supply chain and logistics manager, Mike Tripp. Tripp came on board with the experience and knowledge to draw a plan for a more ergonomically sound, productive, and energy efficient solution that met budget and throughput constraints. There are also some interesting conveyor systems systems that use lighted colors that can be quickly recognized to distinguish various types of items 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 retrofitting of the facility for Christopher & Banks is made for a new linear flow with a fulfillment process that’s semi-automated. Receiving areas inspect the merchandise, check the quality and forklifts then deliver them to staging areas. Operators use RF-scanning to upload the information of the new merchandise into the pick-to-light system, where product is placed into ergonomically designed combination shelf and conveyor support assemblies. 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.
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. Sporting features like zero pressure accumulation and run on demand independent zones, the conveyor reduces power use and wear, removes product jams and lets the entire 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 lane, the cartons are automatically sealed, weighed, and labeled at a work station then conveyed to a trailer directly at the doors of the shipping dock.
A convenient overhead empty carton conveyor was given by Intelligrated as part of the upgrades to the facility. 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.
Lupe Fiasco – Break The Chain ft. Eric Turner and Sway (Lyrics)
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