Controlling complex operations

A large multi-channel retailer needed to automate and extend its operations. The objectives were to provide next day national delivery to all customers and to improve reporting on and visibility of warehouse operations performance. The solution needed to manage high volume everyday business and cope with peaks generated by regular promotions.

Conveyor Networks used its upgraded WCS software product, Interface Manager (IM2014) to control a complex automation solution incorporating picking, packing, label design and print for manual and auto label functions. IM2014 is a suite of intelligent software products able to control automated and manual warehouse functions. In this instance IM2014 was an integral part of the outbound operation handling all automated and manual pack requests and print functions for both packslip and label.

Conveyor Networks developed the software solution which can handle an order pool of over 100,000 orders which are tagged as to whether they will be processed:

• Manually.

• As a multi quantity.

• As a bagged order.

• As an original carton bulk order.

• As a mixed carton over ship label (OSL) order

The key benefits of IM2014 are that client IT input is at a minimum and that all functions are controlled by a single point of contact. Moreover IM2014 has a library of protocol convertors to enable direct communications with a wide range of automation solutions including:

• Label print and apply.

• Weighing.

• Conveyor transport systems.

• Operator touch screens.

• Handheld mobile devices.

• Sortation machines.

• Auto bag or wrap machines.

• Laser printers – PCL, ZPL, PDF, IDOL and more.

Where an auto bagging solution is in place, the pack slip data is delivered in real time by IM2014 to a laser print and apply where pack slips are conveyed in synchronisation with the product. Product and slip are merged and presented to a bagging machine. Conveyor Networks scan both SKU and pack slip to ensure integrity. Other parts of the solution also include a bulk print facility where IM2014 delivers print commands to numerous bulk printers.

IM2014 can either reside on dedicated servers or in a virtual environment as is the case here. Resilience was a priority and a robust communications specification was developed – including testing criteria – between Conveyor Networks and the retailers’ IT teams. Every module of IM2014 was rigorously tested as was the integration into the retailer’s network. Conveyor Networks can remotely access the system to address any issues and see exactly what the customer can.

IM2014 drives volumes of over 6,000 units per hour, 24/7, for this retailer and can be interrogated at any time for a real time status report on the outbound warehouse operations. It is capable of handling even larger volumes related to appropriate automation needs.