Overnight order delivery and ATU's recycling program

David Maloney -- Modern Materials Handling, 3/1/2004

Besides being Germany's premier auto parts stores, ATU also performs auto repairs. Often needed parts are not on hand in each shop's inventory for all makes and models of cars rbought in for service. To facilitate the repair as quickly as possible, these typically slow-moving parts are picked at the distribution center and and shipped overnight to the shop.

The large and small parts picking modules each have an area adjacent to the main pick zones on Level Two of the buidling that is dedicated to processing these picks that will be processed within 24-hours. Product cages are delivered automatically to the large parts area where four order cages are staged to gather the 24-hour orders. Each represents a compass direction that will segregate them for delivery - North, South, East and West.

Pick-to-light is used here, with lights indicating the products that need to be picked and which of the four staged cages should receive the items. These large picks are already in product cartons that are suitable for shipping, so all that is required is a shipping label.

Adjacent printers issue the label, which is applied manually before the carton is deposited into the order cage. These cages of mixed SKUs comprising orders are then conveyed to shipping, where individual cartons will be delivered by overnight carriers.

Orders placed for 24-hour delivery of small parts are picked in a similar manner to regular store replenishment orders. These, however, must first go to a packaging station where items are removed from the totes and placed into cartons suitable for parcel delivery.

RECYCLING AND RETURNS

In keeping with strict environmental standards, products used in the repair shops must be recycled. ATU has set up a building adjacentto the distribution center for recycling of these items.

Products from the stores are returned on empty trucks after deliveries are made. Old tires are reused in retreads or shredded and recycled. Containers and corrugated packaging materials are also gathered for recycling.

Returned merchandise from the stores is also processed here. Damaged goods are returned to suppliers or recycled, while products for resell are returned to the distribution center for restocking via a conveyor bridge that links the two buildings.