Efficient small parts picking

Published on: October 19, 2015 / Update from: April 24, 2021 - Author: Konrad Wolfenstein

[In collaboration with Kardex Remstar – ADVERTISING]

Nowadays, warehouse logistics companies in many industries are faced with the challenge of a constantly growing product range. It is important to guarantee fast, complete and reliable delivery or provision at all times. This is often made more difficult by the simultaneously increasing process complexity, which is caused by

• Range extensions
• Forced to be permanently available
• increasingly smaller batch sizes and
• higher requirements for safety and ergonomics in the workplace

is marked.

Choosing the right storage system

It is now up to the logistics experts to optimize the available storage capacities and processes in order to meet the increased requirements. In general, a change in intralogistics market requirements towards greater flexibility, greater variety of items and shorter access times can be seen. In addition, the type of goods stored is increasingly shifting towards smaller formats.

Existing storage systems often do not or only partially meet the complex requirements. The biggest disadvantage of conventional rack warehouses is the relatively long travel times and distances that the staff has to manage. In terms of picking accuracy, they are inferior to automated systems, which now do the work with almost 100% precision. However, the problem that often arises is that storing the goods in containers or boxes of different dimensions is not possible or is only possible with restrictions.

For small items with low volume, AKL are often the first choice. These are mostly aimed at extensive ranges with 4,000 or more containers, achieving picking performance of up to 200 picks per hour. But what about companies that need a smaller system with shorter storage and retrieval times for their small-scale inventories?

The circle of potential customers is large, as an offer like this is aimed at a wide range of user profiles: from supplying a production line with a wide variety of items to a buffer warehouse for assembly to picking in the distribution warehouse.

The next generation

In order to achieve high process efficiency in the warehouse, these companies need a system that best meets the following criteria:

• high picking performance and precision
• Easy integration into existing conveyor technology and WMS software
• Energy efficiency
• ergonomic design of workplaces
• Storage of different containers and boxes
• Accommodation of different heights of stored goods

The intralogistics provider Kardex Remstar has targeted customers with exactly these requirements with a newly developed provisioning system called Kardex Remstar LR 35.

Higher productivity – lower costs

With its product category called Vertical Buffer Module, Kardex Remstar is implementing a new brand line for medium-sized, quick-picking and flexible storage lifts. It can be assumed that in addition to the 35 kilo unit, further versions will be added to the portfolio in the medium term.

The main features of the device are performance improvements in the following areas:

Speed: It allows up to 250 double plays (storage and staging) per unit per hour. The system can handle up to 500 picks per hour, which makes it extremely fast compared to other devices.

Precision: The included software including the control element based on touchpad technology allows almost zero-error precision in picking performance. The order picker is supported by pick-to-light systems, which show him the items to be picked in detail, thereby further increasing accuracy.

Energy efficiency: The design of the Vertical Buffer Module is designed to save energy. The central transport arm inside the device is used in such a way that conserves consumption, so that only a third of the energy is used compared to comparable systems (AKL, walking beam systems).

Flexibility: Users can be flexible when it comes to the type of payload, as the devices can store containers, boxes or trays of different shapes. Up to four different heights of stored goods are possible and the operating openings can be installed anywhere. In addition, the devices can be combined with each other so that the overall solution can, if necessary, match the storage performance of AKL with ten thousand or more containers stored.

Compatibility: The open concept of the device allows for easy connection to existing logistics systems. Be it conveyor technology to be integrated using an assembly line or the automatic transfer of items to autonomously operating transport robots such as those from Servus Intralogistics : the Vertical Buffer Module can be coordinated with existing intralogistics in a variety of ways. Due to its modular design, the system can be optimally adapted to existing building heights and widths.

Deployment of personnel: Since an order picker can operate up to two devices in parallel, the use of the system reduces the need for personnel. This frees up capacity that can be used efficiently in other areas of warehouse logistics.

Ergonomics: The “goods to person” principle used in picking results in significant improvements for employees in terms of both travel times and ergonomics. In addition, the parts are delivered to an ergonomic operating opening that is lowered by 20 degrees, which makes the picking process even easier. Safe operation of the device is guaranteed by access protection using an automatically opening sliding door.

Software: The warehouse management software enables easy integration into the WMS/MFR software already used in the company. In addition, software-supported picking strategies for efficient provision and picking, such as batch picking or multi-user picking, are included in the scope of delivery.

Overall, the Vertical Buffer Module is an efficient solution for storing and providing small-volume items. With its high picking performance of up to 500 order items per hour with low energy consumption and its flexibility, it is suitable for a wide range of applications: be it as a small-scale replacement, to supply a production line, as a buffer or distribution warehouse.