Storage/Staging: Software controls new robotic goods-to-person picking system

To serve the company’s growing number of customers, iHerb—a pure-play Internet retailer that distributes healthy and organic products to customers in more than 180 countries—invested in a second DC. The DC features modern materials handling technology and software that allow faster order shipping times for its customers.

The new distribution system contains a goods-to-person order picking system that holds a combined three million units in 10 aisles of compartmentalized totes. Robots within the system deliver totes to one of 20 operator stations where product is picked from to the shipping carton. The system also uses pick-to-light devices, two shoe sorters, and carton erectors to manage 35,000 SKUs.

A new warehouse control system (WCS) coordinates the automation, inventory and order routing. With iHerb’s homegrown warehouse management system (WMS) to manage inventory, it was up to the WCS to connect with the WMS to facilitate all communications between the two software systems. The WCS is also integrated with the automated storage and retrieval system. While managing and sequencing the robots in the system, it also provides the appropriate quantity, product, and product image on a touchscreen display at each operator station.

Combined, the new technologies created a nearly 100% pick accuracy, as well as daily reporting on throughput and metrics. The new DC can process an order in 15 minutes and is capable of processing more than 20,000 orders each day.

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