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Material Handling - Major Distribution Center - Project Summary

Project Objective

Major automation technology company built a state-of-the- art distribution center in 1995, and by 2003 had outgrown it. Changes in distribution patterns, technologies and the economy had led to growth in the number of SKUs and daily orders shipped. After wringing maximum storage space and pick faces out of the existing operation, Rockwell solicited nine bids for a new three- level pick module. The main objectives of this project involved de- sign of the new pick module, providing maximum flexibility for future configuration, providing rapid order throughput, and installation of the entire project with a minimum amount of impact on daily operations.

 

 

Project Scope

The scope of this project included complete design, supply and installation of the pick module. This included moving an existing rack system, building the pick module and all systems (lighting, 120v utilities, sprinklers, HVAC, carton flow, shelving, staircases, trash systems, emergency light- ing, etc.) Also included was the heart of the pick module - the conveyor system, The scope of the conveyor system included 8 pick zone modules with speeds up to 210 FPM, 32 motors, all programming, spiral conveyors for elevation changes, design and build of the control cabinet, program- ming, and cutting into and replacing a large section of the main existing conveyor trunk line to allow for new merge and diverts for totes and cartons.

 

 

Project Data

Distribution Center for Industrial Controls, Drives and Motors

Building Square Feet: 150,000
Approximate SKUs: 12,000
Pick Module Footprint: 36'X312'
Conveyor Speeds (FPM): 60 to 210
Total Pick Faces: 7,000+

 

Interlake Selective Rack System, Interlake Pick Module, Sylvan Deck Surface, Interlake SelectaFlo 2000 Carton Flow, Ermanco Conveyor (belt. lineshaft, accu- mulation, high-speed UBT transfers), Ryson Powered Spiral Conveyors, Mettler-Toledo Scales, AccuSort Scanners, Allen-Bradley Control Devices, CDI Control Cabinet and Remote I/O Subpanels, Republic Shelving