Order picking system with automated miniload storage for TVH Forklift Parts
TVH Forklift Parts is Europe’s largest independent distributor of fork lift trucks and components. Vanderlande Industries was asked to supply the complete order picking system for its new warehouse in Belgium. The system has recently been extended with 4 QUICKSTORE miniloads. In the near future, 3 new ergonomic PICK@EASE workstations will be implemented, which enable a proven sustainable high operator performance.
In the facility, TVH stocks 450,000 SKUs from which it meets an average of 4,000 orders and 13,000 order lines per day. The system contains 6 QUICKSTORE miniloads with 52,000 storage locations. The miniloads store medium moving products. For order picking, totes are conveyed to special goods to man order picking workstations. Totes which are not picked empty are returned to the automated storage. On one side of the aisle the miniload supplies flow racks with faster moving products. Order lines for an order are picked in parallel through a zone picking system. Operators receive picking instructions via an RF terminal. Empty totes are taken from the tote loop and the required products are picked. Totes are put on the conveyor system and routed to the order consolidation area.
Eight miniloads are used as a order consolidation buffer. There are 1,100 positions for orders in progress. When an order is complete the packer at the end of the flowlanes takes the totes, packs the product and puts the empty totes (as stacks of max 4 totes) on the takeway conveyor.
Thanks to the high level of automation in order processing, order lead times have been shortened significantly and orders can now be based on actual customer demand. In addition, the new system has reduced manpower levels and improved picking accuracy.