Automation is Key, to Streamline CDW’s High-Volume Picking, Order Validation and Shipping Requirements

05/30/2006

Numina Group's One-Step Fulfillment System coupled with advanced material handling technologies and practices reduces processing time of orders at CDW's new North Las Vegas Distribution Center.

CDW Corporation is one of North America's leading providers of computer systems, technology and services for business, government, and the education markets. Their customer-centric philosophy of responding to customers needs with a sense of urgency is incorporated into all segments of CDW’s business operations and is demonstrated by a commitment to developing and applying the latest advancement in automation at their Distribution Centers.

"Speed, accuracy and reduced labor requirements are essential factors used in evaluating distribution process improvements. Automation is key to optimizing our operations to ensure quality, accurate and ensure next day deliveries for customer orders," stated Doug Eckrote, Senior Vice President of Operations. These objectives inspired the CDW Team in the development and design of its advanced distribution processes implemented at their new North Las Vegas Western Distribution Center, a 513,000-square-foot facility.

Numina Group, a Burr Ridge, IL-based system integrator and material handling automation provider, orchestrated the entire operation including intelligent carton routing, pick validation and the advanced automated labeling technology deployed throughout the facility. RDS combines real-time control and decision logic for the conveyor and sorting control and the other material handling automation requirements, while simultaneously communicating with ERP Systems such as SAP and Warehouse Management Systems (WMS).

Old Style Full-Case Pick Process
In the past, CDW used a “Pick to Label” process in which workers picked by discrete orders using pre-printed labels and packing slips to label cartons. Using hand scanners, they would scan the product number to verify the correct item pick, and additionally scan the serial number for customer warranty tracking purposes. Because the location of the serial number bar code could be on any side of the carton, the picker had to search multiple sides of a carton before locating it. Capturing the information and then hand applying the shipper label and the packing slip could take up to 45 to 60 seconds per carton.

"One minute per carton might seem fairly efficient in low volume distribution operations, but in a warehouse that ships thousands of full cases every day, that represents a major expenditure of labor," explains Dan Hanrahan, president of Numina Group.

Speeding Full Case Delivery
CDW turned to The Numina Group to jointly develop and integrate a paperless picking technology to improve case picking and labeling. The process developed by the CDW-Numina Team uses RF-directed batch picking to manage and direct full case pick-to-conveyor from several multi-level full case product storage modules. Numina provided its One-Step TM labeling system to automate case data capture and print and apply labeling of both packing slips and shipping labels. The systems consist of its Real-Time Distribution Software, RDS TRAK3 Controller, Panther Industries Print-Apply Applicators, and Vitronics Vision Scanning Tunnels. The five sided camera-based scanners are capable of capturing product and serial number barcode data as small as 5mil, from all sides of the cases regardless of orientation. For installation, Numina teamed with Matco Integrators who supplied the conveyor and mechanical installation.

CDW ‘s WMS Development Team developed a new order clustering and batch pick method that directs the pickers by RF terminal to batch-pick case quantities needed for several orders at one time. Cartons are picked to conveyor from several full case pick modules, they travel though the camera-based scan tunnel, where the system scans all sides of the case, and captures both the product ID and serial number barcodes. This barcode data is transmitted by the control system to the CDW Warehouse Management System (WMS). The WMS validates and assigns the pick to an order and transmits the labeling requirements and data for both the packing slip and shipper label back to the control system. Directly after the Scan Tunnel is an automated top apply labeling system consisting of dual Panther Industries servo-tamp print and apply label applicators used to print and apply a ship label or a combination packing slip and shipping label based on the WMS labeling rules.

"If an extra carton or a picking error occurs, the data from the scan tunnel is used to check and validate all case picks match current active orders," explains Hanrahan. "If the case is a miss pick, or a no-read condition occurs, the case will not be labeled and will be diverted as a 'not assigned pick' to an inspection-exception station for human disposition."

Integrating all of the full-case pick functions into a streamlined automated process provided reduced picking errors and labor while improving throughput and the capacity. "Essentially, we've reduced the pick labor by approximately 60 percent on full-case items," says Eckrote of CDW. "This has proven to be the right technology to increase throughput at our operation while improving productivity and enhancing accuracy."

Reducing Each Pick Order Fulfillment Time
CDW’s highest shipment volume is the “each pick” process in the split case pick area. To meet the demand of their increasing sales volume, an advanced pick-to-carton process with the ability to process 30,000 to 50,000 a day of split-case orders was developed. Improved order throughput, picking validation, and reduced labor drove the new design concept for the split-case order fulfillment process,” says Hanrahan. “CDW demands both fast picking and a means to validate what’s shipped to its customers. Picking was improved and order fulfillment time and labor reduced across the whole operation, including customer service labor costs, by eliminating sources of error and validating shipments.”The order driven process is orchestrated by Numina Group’s RDS Warehouse Execution and Control (WCS) System. The WCS manages empty carton delivery, labeling, as well as order pick routing through a bank of 36 pick zone route destinations. The system also incorporates Numina’s VPAK; vision pack audit technology to in-line image capture and weight-check carton pick contents.

RDS’s Zone Routing and Box Demand Module manages the split-case order process. This system receives customer order routing instructions from the WMS, and routes empty cartons (automatically built by a bank of five Auto-Carton Erectors) to the initial order pick zone. Each customer order is then automatically routed only to zones where picks are required, eliminating redundant handling labor and reducing order completion time. The carton route path is tracked, verified and recorded throughout the picking process.

As the cartons exit the picking area, they travel across an in-motion scale where the weight is validated against the WMS estimated order weight. If a carton passes, the weight is transmitted to the warehouse management system. While the carton is being weighed, Numina’s VPAKS Vision Pack & Audit System captures a digital image of the inside carton contents to visually validate each carton’s contents.
Following the inspection process, cartons are intelligently conveyed to the packing sorter. Pick-completed cartons are sorted to the automated sealing as well as special handling and inspection lanes. The validated and sealed cartons are then routed to a series of three print-and-apply labeling systems that automatically apply packing slips and shipping labels.

The new automation system incorporates order validation and print/apply technology for shipping labels and packing slips, along with a Mantissa Tilt-Tray Sorter to automatically sort cartons to the appropriate shipping lanes. Throughput, picking and shipping labor savings were improved throughout the operation.

For more information contact:

Dan Hanrahan
The Numina Group
10331 WERCH DRIVE,
WOODRIDGE, IL 60517
Phone: (630) 343-2600
Email: dhanrahan@numinagroup.com
Web site: www.numinagroup.com 

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