Batch Picking Cart Solution

Jan 26, 2024 | Solutions - By Function, Solutions - by Product

Solutions

Batch Picking Cart Solution

Batch picking, sometimes referred to as cluster picking, increases the efficiency of distribution center operations by enabling an individual picker to pick multiple orders with one trip through the picking area.

Batch picking solution combines the best features of pick-to-light, put-to-light, voice, and wireless barcode scanning technologies into a single cart-based solution that yields significant increases in both the speed and accuracy of piece picking.

Pick Smarter, Not Harder

This very flexible technology reduces walking with its batching of orders enabling the completion of up to 50 orders in one trip. We use AI-technology and advanced mathematical models to calculate the shortest route between all items on the pick list. This provides huge time savings and reduces the wear and tear on equipment.

Want to learn more about our Batch Picking Cart Solutions?

System Overview

Voice guides the picker through the picking process.
Lights on product bays highlight pick locations and display pick quantities.
Lights on the cart highlight put locations and put quantities.
Wireless barcode scanning is an alternative to light-directed picking to confirm that the right product was picked.
The entire process is orchestrated by a tablet PC without the need for continuous connectivity to a host computer.

Benefits

Pickers work in a hands-free, heads-up mode
Fast, accurate order fulfillment
Easy to interface to customer’s WMS
Reduces or eliminates the need for auditing and packing
Minimizes travel time in the DC to pick products
Flexible reconfiguration to meet changing business needs
Easy to learn, easy to use, and easy to maintain
Low-cost entry point with incremental expansion path
Excellent ROI with short pay-back period

Ecommerce Fulfillment

Sep 22, 2023 | Solutions - By Function

Solutions

Ecommerce Fulfillment

In the dynamic world of Ecommerce Fulfillment is a critical element that can make or break a brand’s reputation. As online shopping continues to gain traction globally, e-commerce companies face unique challenges in meeting customer demands for speedy, accurate, and cost-effective order fulfillment. To navigate these challenges and stay competitive, the role of automation has emerged as a transformative force in e-commerce fulfillment.

Challenges in E-commerce Fulfillment:

The rise of e-commerce has presented a set of complex challenges that require innovative solutions. Here are some of the key challenges facing e-commerce fulfillment:

Fluctuating Demand: E-commerce businesses often experience erratic spikes in order volumes, particularly during peak seasons or promotional events. These fluctuations can overwhelm traditional fulfillment processes and lead to inefficiencies.
Inventory Management Complexity: Managing inventory across multiple sales channels while ensuring real-time accuracy is a complex task prone to errors. Inaccurate stock levels can result in overselling or stockouts, damaging customer trust.
Order Accuracy: In the e-commerce realm, order accuracy is paramount. Any mistakes in order fulfillment, such as shipping incorrect items or omitting items, can lead to costly returns and dissatisfied customers.
Swift Delivery Expectations: Customer expectations for rapid, reliable, and cost-effective delivery have risen significantly. Meeting these demands while controlling shipping costs remains an ongoing challenge.
Labor Shortages: Attracting and retaining skilled labor for e-commerce fulfillment, particularly during peak periods, is a continual hurdle. Labor shortages can lead to slower order processing and decreased efficiency.

The Transformative Power of Automation:

Automation technologies are at the heart of the e-commerce fulfillment industry’s efforts to overcome these challenges. Let’s explore the various facets of automation and how they are reshaping the landscape:

Warehouse Management Systems (WMS): A robust WMS is the central nervous system of modern fulfillment centers. It offers real-time inventory visibility, optimizes order picking routes, and automates inventory replenishment. This streamlines operations and reduces errors.

Robotic Process Automation (RPA): RPAs are employed to automate repetitive, rule-based tasks, such as data entry and order processing. By doing so, they enhance accuracy and speed while reducing labor costs.

Goods-to-Person (GTP) Systems: GTP systems transport items directly to warehouse workers, significantly reducing travel time. These systems use conveyors, shuttles, or robots to transport products to order pickers, improving efficiency.

Sortation Systems: Sortation systems automate the process of sorting and routing items to their designated shipping destinations. This minimizes manual handling and accelerates order fulfillment.

Automated Guided Vehicles (AGVs): AGVs are autonomous robots that handle tasks like moving goods from storage to picking stations. They reduce the need for manual labor and enhance efficiency.

Collaborative Robots (Cobots): Cobots work alongside human employees, assisting with tasks that require precision and consistency. This not only improves order accuracy but also increases overall productivity.

Machine Learning and AI: Machine learning algorithms analyze historical sales data and customer behavior to predict demand accurately. This enables better inventory management and optimization.

Automation in Action: Enhancing Efficiency in Fulfillment Centers

Demand Forecasting: Automation solutions, powered by machine learning algorithms, analyze extensive datasets to predict demand patterns accurately. This foresight enables fulfillment centers to allocate resources efficiently and maintain optimal stock levels.

Inventory Management: Advanced automation technologies, including WMS and RFID systems, provide real-time inventory visibility. Automation triggers replenishment orders when inventory levels drop, reducing the risk of stockouts.

Order Picking: Goods-to-Person (GTP) systems, AGVs, and cobots dramatically reduce travel time for order pickers. Implementing wave picking strategies, which batch similar orders together, further boosts productivity.

Quality Control: Machine vision systems are employed to inspect products for defects and errors during order fulfillment. This minimizes errors and reduces the likelihood of returns, ensuring order accuracy.

Sortation and Packaging: Integrated sortation systems and automated packaging solutions streamline the final stages of order fulfillment. Automated packaging not only reduces waste but also ensures consistent packaging quality.

Conclusion: The Future of E-commerce Fulfillment

In the e-commerce fulfillment industry, automation has emerged as a catalyst for transformative change. These solutions not only address the challenges of demand variability, complex inventory management, order accuracy, swift delivery, and labor shortages but also position fulfillment centers for sustained growth and success in an ever-evolving market. As e-commerce continues to redefine the retail landscape, those who embrace automation are poised to thrive and lead the charge into the future of online shopping. Automation is not merely a tool; it’s a strategic imperative that is reshaping e-commerce

Garment on Hanger (GOH)

Sep 22, 2023 | Solutions - By Function

Solutions

Garment on Hanger (GOH)

In the dynamic world of fashion retail, efficiency is paramount. The handling and delivery of clothing items on hangers require precision and care, making Automated Garment on Hanger (GOH) systems a difference maker for fulfillment centers. The GOH system is an overhead storage, transport,

and sortation system for fast and easy storage, retrieval, sortation, and consolidation of customer orders.

ABCO Systems has a complete product range for all GOH transportation and sortation requirements — for example, pin conveyor, clip conveyor, unisort, and manual slick rail. The modular design of these systems easily enables different functionalities, such as transportation, accumulation, decline/incline, and sortation.

SORT, TRANSPORT, ACCUMULATE, AND SHIP GARMENTS ON HANGERS FAST

This is your life: You want to satisfy your e-Commerce customers with fast delivery and your stores with aisle ready shipments; your business is growing but you have no room to expand; you cannot find good labor.

The (GOH) overhead system can help.

With the GOH system you can

Get orders out the door fast
Grow in your existing space
Reduce labor costs

Conveyor-Based GOH Systems:

Overhead Conveyor Systems: These systems consist of a network of overhead tracks, hooks, and hangers. GOH items are suspended from these hooks, allowing for smooth transportation throughout the fulfillment center. Overhead conveyor systems are efficient for space optimization and gentle handling of garments while maintaining open floors.

Floor-Mounted Conveyor Systems: Similar to overhead systems, floor-mounted conveyors use a network of tracks, but the hangers move along the floor. These systems are suitable for fulfillment centers with height limitations.

AS/RS-Based GOH Systems:

Automated Storage and Retrieval Systems (AS/RS): AS/RS technology uses automated cranes or shuttles to retrieve and store GOH inventory in high-density racks. It maximizes vertical space utilization, making it ideal for facilities with limited floor space.

GOH Carousel Systems:

Vertical Carousel Systems: Vertical carousels consist of rotating shelves that store GOH items. When an order is placed, the carousel rotates to present the needed garments, minimizing the distance workers need to travel.

Robotic GOH Systems:

Robotic GOH Handlers: These systems deploy advanced robotic arms equipped with grippers and sensors to handle GOH items. Robots navigate the fulfillment center, picking garments with precision. They reduce manual labor and enhance order accuracy.

GOH Storage and Retrieval Solutions:

Static GOH Racks: While not fully automated, static GOH racks provide efficient storage and retrieval. Garments are hung on racks equipped with wheels, making them easy to move within the facility.

Dynamic GOH Storage and Retrieval: Dynamic solutions combine conveyors, elevators, and storage buffers to optimize GOH storage and retrieval. These systems ensure garments are easily accessible and can be retrieved efficiently for order fulfillment.

GOH Sorting and Packing Systems:

Sortation and Packing Systems: Automated sortation systems identify and route GOH items to their designated packing stations. This minimizes manual handling and reduces errors during packing. Some systems even automate labeling and packing slip insertion.

GOH Quality Control Systems:

Machine Vision Inspection: Machine vision systems use cameras and advanced image processing to inspect GOH items for defects or damage. Items that don’t meet quality standards are automatically flagged for further inspection or removal from orders.

Customized GOH Systems:

Tailored Solutions: Some fulfillment centers opt for customized GOH systems tailored to their unique needs. These solutions are designed to optimize operations and address specific challenges.

Speak to an ABCO Systems Engineer today!

Automated Garment on Hanger (GOH) systems are reshaping the fashion fulfillment landscape, offering diverse solutions to address unique challenges. From conveyor-based and AS/RS systems to robotic handlers, fashion retailers have a wide array of tools at their disposal. As the fashion industry continues to evolve, embracing these innovations ensures fulfillment centers can meet customer demands, reduce errors, and provide a seamless shopping experience.

Solution Mezzanines

Sep 22, 2023 | Solutions - By Function

Solutions

Mezzanines

Solution Mezzanines

Structural Steel Mezzanines: These solution mezzanines are supported by a robust framework of structural steel columns and beams. They offer exceptional strength and durability, making them ideal for heavy-duty applications like industrial warehouses and manufacturing facilities.

Multi-Level Mezzanines: For facilities with significant vertical space, multi-level mezzanines offer a practical solution to maximize space utilization. They consist of multiple tiers or levels connected by stairs or lifts, ideal for distribution centers and logistics operations.

Office Mezzanines: Offices often need to expand workspace without relocating. Office mezzanines provide the perfect solution, offering additional office space above an existing floor, complete with amenities like HVAC, electrical, and networking.

Production Mezzanines: Manufacturing and production facilities require efficient use of space for equipment and assembly lines. Production mezzanines can house machinery, workstations, and assembly areas, optimizing workflow.

Mezzanine Alternatives

Rack-Supported Mezzanines: In these mezzanines, the storage racks themselves act as the supporting structure for the platform above. This efficient design maximizes both storage space and usable floor space beneath.

Shelving-Supported Mezzanines: This type of mezzanine incorporates shelving units as the foundation for the elevated platform. It’s suitable for storage-intensive environments where easy access to goods is essential, such as distribution centers and retail stockrooms.

Deck-over Mezzanines: These mezzanines are designed to create additional workspace or storage above an existing office or production area. They feature a smooth deck surface, making them suitable for offices, breakrooms, or production lines.

Custom Mezzanines: Sometimes, standard mezzanine designs don’t quite fit the unique needs of a facility. Custom mezzanines are designed from the ground up, tailored to your specific requirements, layout, and industry.

Speak to an ABCO Systems Engineer about what solution makes the most sense for your operation.

The world of mezzanines is as diverse as the industries they serve. Whether you’re looking to expand storage, create office space, or enhance your retail displays, there’s a mezzanine solution tailored to your needs. Mezzanines offer a cost-effective and flexible way to unlock the untapped potential of your existing space. By choosing the right type of mezzanine for your facility, you can elevate not only your physical space but also your operational efficiency and overall productivity. Don’t just expand your square footage; elevate your possibilities with mezzanines

Microfulfillment

Sep 22, 2023 | Solutions - By Function

Solutions

Microfulfillment

Microfulfillment Solutions

In today’s fast-paced world of e-commerce, the key to success lies in efficient order fulfillment and delivery. Micro-Fulfillment automation has emerged as a game-changer, offering a strategic approach to address the challenges of rapid online order growth and the demand for quick deliveries. In this comprehensive guide, we will explore the concept of Micro-fulfillment automation and its transformative impact on the e-commerce landscape.

Understanding Micro-Fulfillment Automation:

Micro-Fulfillment refers to the process of fulfilling online orders from smaller, strategically located fulfillment centers, often within urban areas. These centers are designed to be highly automated, allowing for swift order processing and last-mile delivery. The core components of Micro-fulfillment automation include:

Compact Fulfillment Centers: Micro-Fulfillment centers are compact and strategically placed in proximity to densely populated areas. This proximity reduces delivery distances and enables quicker order delivery.

Automated Storage and Retrieval Systems (AS/RS): AS/RS technology is at the heart of Micro-Fulfillment automation. It includes robotic systems that retrieve products from dense storage structures, ensuring efficient space utilization.

Goods-to-Person (GTP) Systems: GTP systems bring products directly to human operators, reducing the time spent searching for items in a warehouse. This automation streamlines order picking and increases productivity.

Order Consolidation: Automated systems consolidate multiple orders into a single package efficiently. This reduces packaging waste and optimizes the last-mile delivery process.

Benefits of Micro-fulfillment Automation:

Micro-fulfillment automation offers a range of benefits that are reshaping the e-commerce industry:

Speed and Efficiency: Micro-Fulfillment centers are designed for speed. Automated systems enable rapid order processing, reducing the time from order placement to delivery.

Cost-Effectiveness: By optimizing space and streamlining operations, Micro-Fulfillment centers reduce labor and real estate costs. These cost savings can be passed on to consumers.

Improved Inventory Management: AS/RS and inventory tracking systems ensure accurate inventory counts, minimizing stockouts and overstock situations.

Sustainability: Micro-Fulfillment’s efficient order consolidation and reduced delivery distances contribute to environmental sustainability by minimizing carbon emissions and packaging waste.

Enhanced Customer Experience: Faster order fulfillment and shorter delivery times result in a better customer experience, leading to increased customer loyalty.

Applications of Micro-Fulfillment Automation:

Micro-fulfillment automation is being applied across various industries and use cases:

Grocery Retail: Micro-Fulfillment centers are transforming the grocery industry, enabling retailers to offer same-day or even one-hour delivery services.

Pharmaceuticals: Micro-Fulfillment is being used to provide rapid prescription fulfillment and medical supply distribution.

Fashion Retail: E-commerce fashion retailers are leveraging Micro-Fulfillment to offer quick delivery of clothing and accessories.

Electronics and Gadgets: Retailers of electronics and gadgets are using Micro-Fulfillment to meet the demands of tech-savvy consumers.

Challenges and Considerations:

While Micro-fulfillment automation holds immense promise, it also presents challenges that businesses must address:

High Initial Investment: Implementing Micro-Fulfillment automation requires a significant upfront investment in technology and infrastructure.

Space Constraints: Securing suitable urban locations for Micro-Fulfillment centers can be challenging due to space constraints and zoning regulations.

Integration with Existing Systems: Ensuring seamless integration with existing e-commerce platforms and supply chain systems is crucial for success.

Labor Transition: Transitioning from manual labor to automation may require retraining or reallocation of the workforce.

Speak to an ABCO Systems Automation Experts

Micro-Fulfillment automation is reshaping the e-commerce landscape, offering an efficient and sustainable solution to meet the demands of today’s online shoppers. By strategically placing compact fulfillment centers, leveraging AS/RS technology, and optimizing order consolidation, businesses are redefining the speed and efficiency of order fulfillment. As the e-commerce industry continues to evolve, Micro-Fulfillment automation will play a pivotal role in meeting customer expectations for rapid delivery and superior service.

MRO Operations

Sep 22, 2023 | Solutions - By Function

Solutions

MRO Operations

In the realm of industrial maintenance, repair, and MRO Operations, efficiency is the linchpin of success. MRO operations encompass a wide range of tasks critical to maintaining equipment and facilities, from routine maintenance to emergency repairs. To meet the demands of today’s fast-paced industrial landscape, MRO operations automation has emerged as a transformative force.

Understanding Maintenance, Repair, MRO Operations Automation:

Maintenance, Repair, Operations(MRO) refers to the process of fulfilling online orders from smaller, strategically located fulfillment centers, often within urban areas. These centers are designed to be highly automated, allowing for swift order processing and last-mile delivery. The core components of Micro-fulfillment automation include:

Compact Fulfillment Centers: Maintenance, Repair, Operations(MRO) centers are compact and strategically placed in proximity to densely populated areas. This proximity reduces delivery distances and enables quicker order delivery.

Automated Storage and Retrieval Systems (AS/RS): AS/RS technology is at the heart of Maintenance, Repair, Operations(MRO) automation. It includes robotic systems that retrieve products from dense storage structures, ensuring efficient space utilization.

Order Consolidation: Automated systems consolidate multiple orders into a single package efficiently. This reduces packaging waste and optimizes the last-mile delivery process.

Understanding MRO Operations Automation:

Operations automation refers to the use of advanced technologies and systems to streamline and optimize maintenance, repair, and operations tasks. These tasks include equipment inspections, parts replacement, inventory management, and more. The core components of operations automation encompass:

Predictive Maintenance: Predictive maintenance utilizes data analytics and sensor technology to predict equipment failures before they occur. By monitoring equipment conditions in real-time, maintenance teams can perform targeted repairs, reducing downtime and costs.
Inventory Management: Automated inventory management systems track MRO parts and supplies in real-time, ensuring that the right parts are available when needed. This minimizes stockouts and overstock situations, optimizing inventory carrying costs.
Work Order Management: Automation streamlines work order creation, assignment, and tracking. Maintenance teams can access work orders digitally, ensuring that tasks are completed efficiently and on schedule.
Asset Management: Asset management systems track the entire lifecycle of equipment and facilities, from procurement to disposal. Automation improves asset visibility, maintenance history tracking, and equipment performance analysis.
Mobile Maintenance Apps: Mobile apps enable maintenance personnel to access work orders, inventory information, and equipment data from the field, improving responsiveness and on-the-job efficiency.

Benefits of MRO Operations Automation:

MRO operations automation delivers a host of advantages that are revolutionizing industrial maintenance:

Reduced Downtime: Predictive maintenance and real-time monitoring minimize unexpected equipment breakdowns, reducing costly downtime.
Cost Savings: Optimized inventory management and efficient work order processes result in cost savings by minimizing excess inventory and overtime labor.
Enhanced Safety: Automation reduces the need for manual inspections in hazardous environments, improving safety for maintenance personnel.
Improved Compliance: Automation ensures that maintenance tasks are performed according to regulatory standards and industry best practices, reducing compliance risks.
Data-Driven Decisions: Automation provides actionable data insights, enabling better decision-making for equipment replacement, repairs, and upgrades.

Applications of MRO Operations Automation:

MRO operations automation is transforming industries and use cases across the board:

Manufacturing: In manufacturing facilities, operations automation ensures that machinery runs smoothly, minimizing production downtime.
Utilities: Power plants and utility companies leverage automation to maintain critical infrastructure and reduce service interruptions.
Transportation: Airlines, railways, and logistics companies use automation to keep fleets in peak condition, optimizing safety and reliability.
Healthcare: Hospitals and medical facilities automate operations to ensure that essential medical equipment is always ready for use.
Facility Management: Commercial real estate and facility management companies use automation to maintain buildings and optimize energy consumption.

Challenges and Considerations:

While operations automation offers numerous benefits, businesses must address certain challenges:

Integration Complexity: Integrating automation systems with existing MRO processes and software can be complex and require specialized expertise.
Data Security: Handling sensitive maintenance data requires robust cybersecurity measures to protect against data breaches.
Initial Investment: Implementing automation solutions may require a significant initial investment in technology and training.
Change Management: Employees may require training and support to adapt to new automation processes.

Conclusion: A New Era of Efficiency in Operations

Operations automation is ushering in a new era of efficiency in industrial maintenance. By harnessing the power of predictive maintenance, inventory optimization, and work order automation, businesses are reducing downtime, cutting costs, and improving safety. As industries evolve in a world where downtime is costly and data-driven decisions are paramount, operations automation is no longer an option; it’s a strategic necessity. Embracing this transformative technology is not just a competitive advantage; it’s the key to maintaining a competitive edge in the dynamic landscape of industrial maintenance.

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