Order Handling with a Layer Picking Robot & AS/RS Buffering
Project summary
MWES integrated an order kitting system for a cold storage facility that utilizes a layer-picking robot and an AS/RS buffer system.
The Challenge
Typically assembling large orders requires a substantial amount of floor space for workers to stage and organize each order pallet. This scenario is also prone to human error and inventory loss, which can hamper throughput and quality. Additionally, the high price of real estate forces most warehouses to need every square foot of the building for storage thus dedicating open floor space to a palletizing operation needs to be highly efficient. Ultimately the process converts single SKU inventory pallets into mixed SKU order pallets for shipping.
For these reasons, a firm that operates cold storage distribution centers required an order-kitting solution that was automated but it also had to operate within a small footprint. The firm also required a pallet racking storage solution for temporarily storing incomplete orders as they are being filled and the automation had to be compatible with their existing warehouse management system (WMS).
The Solution
The automation solution MWES presented to our customer centers around a fully automated layer-picking Fanuc robot that splits incoming pallets to fill orders and stores the in-process orders in an AS/RS buffer system. The system also is equipped with a second Fanuc robot dedicated to collecting and dispensing empty pallets and pallet support boards (PSB). The layer-picking robot is equipped with a custom layer gripping EOAT capable of picking multiple layers at a time that are up to 22 inches tall and as heavy as 550 lbs. The robot utilizes custom palletizing software to strategize an optimized build pattern to maximize pallet build quantities.
The system receives orders from the customer’s WMS and directs the operator to retrieve the required SKU inventory pallets from the warehouse. The operator then stages the pallets by the infeed conveyor and manually checks in each pallet with a scanner. The system directs the operator on the proper sequence to input the SKU inventory pallets. Once a pallet arrives at the layer-picking position, the 3D vision system scans it to determine its overall size and position and repositions it if necessary. The robot picks the required layer quantities from the inventory pallet and builds them on an order-filling pallet.
The order pallets that require more SKUs for completion are conveyed to the AS/RS buffer system for staging until the next SKU required for that pallet order is at the layer pick location. Pallets are retrieved from the buffer system asynchronously once the next SKU is ready so as to not hold up the layer-picking robot. This is repeated until the order pallet is complete.
Once completed order pallets are automatically stretch-wrapped and labeled for final shipment. The complete pallets are conveyed to the order pickup position where the system operator removes them by forklift. The system operator also picks up and returns the partial pallets from the infeed to the warehouse.
Impact to the Customer
The automation MWES integrated for our customer helped them reduce the operation’s footprint and labor count required to fill orders. The entire system fits inside a footprint of 45 x 20 feet and gives our customer a robot production rate of 120 layer picks per hour. The AS/RS buffer system can accommodate up to 56 GMA, CHEP or PECO 40×48 inch pallets each loaded as tall as 80 inches.
Midwest Engineered Systems has extensive experience integrating efficient AS/RS buffer systems and layer-picking robots. If you want to improve your warehousing and fulfillment throughput, we have the knowledge and experience to make the project a success.
Contact us to learn how Midwest Engineered Systems can automate even your most complex and challenging operations today.
Innovation Through Automation
Client Details
A nationwide order fulfillment firm that specializes in cold storage solutions.