Starting from goods arrivals incoming goods shipments must be identified and booked to perfection and then placed in the right storage pocket in warehouse totes with up to 8 divisions. The goods pharmacy centre number is first scanned, followed by entry of the batch number on the package, the use-by date and the quantity. Meanwhile the system brings a suitable warehouse tote up ready onto the counting scales while the overhead light display projects a guiding light cone on the correct tote storage pocket. The tote can now either be stored or it runs on non-stop to a picking zone.

The automatic carton warehouse (ACH) is fitted with twin nine meter high stacker cranes (RBG) type Mustang creating space for some 35,000 totes. The two RBGs prepare the supply goods for the shaft automatic picker A-Frames on two retrieval levels and remove the empty totes.

Placing of the goods in the correct A-Frame shaft is monitored through use of a light control and a scanner. The ejector at each shaft can catapult up to six packages per second onto the belt that passes through the shaft rows arched above it in the form of a giant letter ‘A’.

When no article is needed at the A-Frame the order tote is conveyed straight past the A-Frames on a bypass transport system direct to the B and C picking zone preparation positions. The B and C automatic pickers are supplied from a total of 17 warehouse blocks. The LVS synchronizes the modules so that all the warehouse totes arrive at the picking zone preparation positions at the precise moment when the order totes arrive there. Temperature controlled pharmaceuticals can also be picked at the B zones, because the heat-sensitive tote goes right back to the protection of cold storage at very high speed after the pick.

C classification articles picking is also automated. One of the two ACH systems makes those goods totes ready that have contents intended for the beam type shelves. The warehouse personnel receive radio orders on their mobile wrist computers via the LVS. Batch tracking can be performed error-free via the warehouse management system since the pharmaceuticals from each batch are allocated to separate warehouse locations. As soon as an order is completed the tote is pushed back to the rear onto the discharge conveyor.

After picking is completed the order totes roll on to two closing and sealing machines that print out the delivery docket and place it in the dispatch tote. These machines also provide each tote with a dispatch label. Following on from this the order totes are hoop bound and transported onwards to dispatch. 2000 totes per hour are sorted for the truck delivery tours in three dispatch levels on a total of 54 gravity roller lines. The tour drivers pick up their tour goods from the target line and can immediately load their delivery trucks for the road.