Less Touch, Low Cost Multi-Use Sortation
Using a BG Pouch System installed in unused overhead space, single items can be buffered, sorted and sequenced to automate the order handling and returns processes with a capacity of over 10,000 items/hour. The combination of benefits enables the logistics operators to achieve handling with very few manual item touches, a higher throughput and very little use of floor-space.
As a simplified logistics process, pouch sortation increases efficiency by reducing the number of times that each item is touched in the fulfilment or distribution center. For returns handling, the need for less handling or touching is particularly critical.
The fulfilment or distribution center can streamline a number of handling processes by using the BG Pouch System; regular sorting after picking, batch sortation and intermediate storage handling of returned items.
The common denominator is flexible automation which enables each of these logistics processes to be completed with less manual handling. In addition to increased handling efficiency, the operational cost is reduced for sortation and returns handling.
To ease the handling of items in the returns process each returned item is placed directly into a pouch rather than into regular storage. The pouch system is used as an intermediate buffer for items which are most likely to be re-sold according to data from the Warehouse Management System (WMS). Items which are not sold after a few days can be returned easily to shelf storage as part of an automatic housekeeping process which is run during low throughput periods.
Handling peaks can be flattened by using the pouch system for predictive picking of items before the days of peak demand. In this process, items which are pre-picked before a promotion or sale can be buffered individually in pouches inside the system. The moment the WMS registers a sale, the relevant items are moved from the buffer and immediately sorted for packing.
The BG Pouch System provides a dynamic buffer that works as a scalable interim storage. The dynamic buffer can also be used as support for the picking systems to reduce handling peaks.
Sorting for Sequenced Packing
Sorting items in specific sequences saves time for packing and shipping orders for specific customers or shops. The sequence for items to be packed and shipped can be determined by the cut-off or shipment time scheduled in the WMS.
The order can also be packed in the sequence that allows shop staff to unpack the items in the order that matches the design of the shop shelving.
Streamlined Returns
The returns process can be significantly simplified by using the dynamic buffer to handle returned items. The process eliminates the need for each item to go back into storage to be re-picked and transferred to shipping.
After being checked and labelled, the returned item is placed directly into a pouch. The pouch system becomes interim storage so that any single item can be released immediately for order fulfillment, packing and shipping.
The processed items and data are controlled and optimized with the straightforward integration of the Warehouse Management System (WMS), the BEUMER Warehouse Control System (WCS BG Flow), and the PLC system of the BG Pouch System.
Flexibility is the key which enables logistics operators to use a BG Pouch System to handle a wide range of items. Each pouch has the capacity to hold an item which weighs up to 7 kg and can physically fit into the pouch. These criteria mean that the pouch system can handle a wide range of items, including Garments on Hangers (GoH).
Each sortation matrix is capable of handling 10,000 pouches/hour and will provide an estimated 25% higher throughput per module than conventional pouch solutions. In a typical installation this would mean up to a 30% saving in floor space.
In fulfilment or distributions centers, the integration with other automated material handling systems, combined with the modularity of the pouch system, enables the level of automation to be adjusted to match individual requirements.
The modularity of the pouch system allows it to be simply scaled in capacity by adding one or more modules with very low additional investment. The benefit is that the system can grow in parallel to match the growth of the business.
The ability of the BG Pouch System to buffer, sort and sequence provides the operational flexibility to move operators to work on different processes. The staff will benefit by working across a more varied range of tasks and the logistics operators can optimize the use of staff. This level of flexibility could allow items for peaks to be picked in the morning for packing in the afternoon or during periods of low demand. The workstations are designed to provide maximum comfort and accessibility.
To ensure fast installation and minimize maintenance, the overhead BG Pouch System combines simplicity with a lean and modular build and is designed to use the height of the building.
