Shuttle system boosts storage density

Carhartt WIP supplies 70 of its own retail stores and eleven outlet stores as well as online sales through an omni-channel strategy from its central logistics centre.

SSI Schaefer extended the storage capacity of the Carhartt WIP logistics centre and increased the process efficiency of made-to-order production for various distribution channels, with optimised material flows and modern system technology. The existing automated shipping buffer was extended and connected to the new system.

SSI Schaefer implemented a fully automated 5-aisle Cuby shuttle system with about 35,000 carton storage locations, a pre-zone and a high-speed loop in the add-on building, which exceeds 4,000 sq m. The dynamic and scalable storage system is operated by ten lifts. A potential expansion by three aisles is already considered in the installation layout. To guarantee sequencing of source cartons and consistent material supply of the eight connected picking locations, SSI Schaefer installed eight sequencing towers with 2 x 23 transfer locations each. An optional expansion by up to four towers for this automation area is already included in the installation layout. The picking locations are equipped with Put to Light technology and integrated into the system concept and material flows.

The new 1.6 km conveying system supplies 20 new packing work stations, a semi-automated returns work station and eleven special handling work stations for value-added services (VAS). Additionally, it is connected to the material flows of the already existing system. The existing system will be modified as well: SSI Schaefer extended the 8-aisle miniload by two aisles with 9,800 storage locations. For further process support, SSI Schaefer also integrates a wide range of handling systems into the new conveying system, such as automatic carton openers and erectors, tape carton sealers, scanners and label applicators.

Warehouse management system WAMAS has been implemented in the WIP logistics centre for warehouse management and process control. Material flow structures for B2B shipping remain intact, while SSI Schaefer has restructured the material flow for B2C shipping, returns handling and the special handling area (VAS).

For more information, visit www.ssi-schaefer.com