Optimum performance for Mango

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SOLUTION AND MATERIAL FLOW 

One-Touch Receiving

In the goods-in area, SKU cartons are brought into the distribution centre using inbound lines directly from the lorries at the docks. Operators handle each carton only once when they load the SKU onto the extended conveyor inside the container. Up to 6,000 cartons per hour are received and transported to the automatic mini-load warehouse. In total, the automatic double stacked mini-load warehouse provides 850,000 storage positions for cartons of a wide range of sizes. The high-performance storage and retrieval machines (AS/R) can store and retrieve up to 6,500 cartons per hour.  

Order Fulfilment

The mini-load bulk storage feeds the shuttle picking engine via toting stations. This highly dynamic buffer transports totes to the order processing areas which are either based on sortation or picking workstations – depending on the order type:

• Cross-belt sorters are used to process most of the orders. Starting at 25,000 items per hour with low picking ratios and up to 30,000 items per hour with higher ratios thanks to TGW algorithms. These items are inducted at the ergonomic in-feed stations. The sorters transport individual items to chutes, where they are offloaded according to pre-cubing algorithms. At the end of the chutes, items are packed in order cartons.
• Prioritised orders, non-sortable items and slow-moving items are processed at high-performance picking workstations (goods-to-person workstations) 

Order consolidation and shipping

All orders coming either from the sorters or the goods-to-person workstations are consolidated in the automatic mini-load warehouse and from there are transported to the dispatch area. A linear sorter routes the order cartons to the designated lanes where 5,800 cartons per hour are loaded into lorries. 

HIGHLIGHTS