Fixed path: Anheuser-Busch balances automation and manual picking
Staff -- Modern Materials Handling, 10/2/2009
It is better to be proactive than reactive. With that in mind, Anheuser-Busch overhauled its Southern California distribution center in anticipation of a 100% increase in stock keeping units. The solution—a mix of automated and human picking technologies—has so far resulted in rapid delivery times and better than 99.9% shipment accuracy.
To keep five million cases per year moving smoothly through its DC, Anheuser-Busch began with a central software application to control all materials handling, from receiving to the final loading of trucks. Advanced ship notice "one-scan" receiving, system-directed unloading, putaway, replenishment, loading and cycle counting, and real-time inventory tracking help take the guesswork out of product movement inside the center. First-in, first-out rotation ensures quality for the customer and prevents waste. Automated equipment monitoring minimizes downtime.
The system has a subsystem comprised of five automated storage and retrieval machines (AS/RS) servicing 18,360 selective case positions and achieving throughput rates of 1,200 cases in and 1,200 case out per hour. Each machine combines speed and computer-based controls to store and retrieve up to seven cases of same or different products simultaneously.
A highly engineered gantry robot is responsible for the initial layer-building of a rainbow pallet and is capable of stacking 200 layers per hour. A secondary robot supports the feeding of individual layers to the case singulator. This high-speed case singulation conveyor combines the technology of mat-top conveyor with servo controls to separate and orient each case prior to induction onto the case transport conveyor. The unique design of the robots allows them to pick single or multiple layers of all product types (bottles or cans) in a variety of package configurations.
Two ergonomic operator stations are used to finish pallets following the robotic layer-building process. The pallets are elevated inside of a squaring tube to a level that is waist-height for the operator, who is directed to add individual cases by a graphical layout display of each layer.
Since installed in 2007, the system has reduced direct labor and associated costs, transportation costs, and product damage costs. The center's order-fulfillment capacity and production have also been improved. In the first year of operation, the system easily handled a 100% increase in SKUs, and remains flexible enough to adapt to any influx of new SKUs.
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