Warehousing

Even after 17 years and several retrofits, the cosmetic maker's AS/R and AGV systems help it stay ahead of customer demands.

By Staff -- Modern Materials Handling, 4/1/1998

HK Systems, Milwaukee, Wisc.

A continuous improvement program of upgrades and retrofits has enabled Revlon Corp.'s Phoenix Site DC to keep its automated materials handling system, first installed in 1980, stay ahead of business demands and fulfill its mission successfully.

Consolidation of three outside warehouses and an anticipated boost in handling efficiency were primary reasons for installing the multi-million dollar system originally, but flexibility to marketplace changes also was a factor.

Advanced even by today's standards, the system receives and puts away raw materials in a 7-aisle AS/RS or a 2-aisle mini-load system. A fleet of 14 automatic guided vehicles (AGVs) then picks and delivers orders to a staging area or pick station adjacent to the factory. The AS/RS also stores up to 7000 pallets of finished stock, and replenishes the Phoenix Site DC.

Even in the face of constantly changing requirements, the system has outperformed initial expectations in several areas, including an over 200% increase in throughput capacity. Order delivery time to the production lines has been reduced from days to hours.

Revlon's Phoenix director of receiving and stores, Mike X. Shamrell, credit's the company's constant focus on continuous improvement, including several major software, controls, and equipment upgrades, for the system's success. In fact, Revlon launched its first modernization effort during the first year of the system's operation at the Phoenix location.

The number of P&D stands on the factory floor was cut from eight to one. Operators no longer travel up and down a 350 ft aisle unloading pallets.

Over the years, Revlon has undertaken a number of upgrades, many in order to address the trend toward smaller lot sizes and more frequent delivery of orders. Replacing the manual (P&D) stand with 3 indexing conveyors in 1983 boosted full pallet out capacity by 20%.

Ten years later, output was further increased by adding 3 AGVs, 4 partial pick stands, 3 line return conveyors, 3 raw material P&D stands, and 1 full pallet out conveyor.

An AS/RS software enhancement in 1994 gave the unit load cranes the ability to retrieve another load while a load is waiting to be picked up by an AGV. A similar software enhancement allows the AGVs to look for work while at stops on the main guidepath. Through the years, simulation software has played a key role in helping Revlon validate proposed design changes to the system.

Despite the tre-mendous gains in system performance to date, Revlon does not intend to stop progressing, an attitude that has served the company well in the past.