press release

SSI Schaefer Automates Office Depot Manchester

April 2008

SSI Schaefer has just completed the installation of a new distribution warehouse in Manchester for Office Depot. Using a sophisticated mix of automatic and semi-automatic picking, cutting edge picking strategies and warehouse systems with optimum space utilisation, the warehouse is now designed for a daily picking capacity of 35,000 cartons.

SSI Schaefer has enhanced the quality of delivery, time and cost benefits for the worldwide leading provider of office supplies and services. Within its 28,000 square metre distribution centre in Manchester, Office Depot chose the latest automated technology in warehousing and picking processes from SSI Schaefer to form the basis of ultimately, a smooth running, efficient warehouse.

Specialists in dynamic warehousing from SSI Schaefer were brought in to develop a customised logistics concept. Heading the project was David Hibbett, Group Development Manager at SSI Schaefer, he said: "The new distribution warehouse in Manchester was a first for the Office Depot Group that will serve as the basis for future distribution centres across the world."

With over 12,000 different products, including office supplies, machinery, computer software and PCs stored in the new distribution centre, SSI Schaefer has installed a system that ensures high availability and quick production. Central features of the system include a compact arrangement of picking areas, the 3.3 kilometre long state-of-the-art conveying system, an automatic picking system, a dynamic flow rack and an Automatic Storage and Retrieval System (ASRS).

The basic picking principle of all picking areas is paperless picking. For this purpose, the IT System creates a carton or tote order for paperless picking at the ordering stage. The cartons are then opened at one of the three installed carton erecting stations and made available, together with the totes, on separate buffer conveyors. A routing label with barcode is given to each tote, including relevant logo, to guide the transport units effectively round the complete order handling process.

Over 720 S-Pemat customised channels for storing small parts and automatic picking for small, fast-rotating products have been installed by SSI Schaefer. The S-Pemat system provides optimum storage and provision for the picking of small parts, while high quantities of different products can be stored in numerous adjacent channels. Separate storage and retrieval zones avoid any delays through the work flow and products on the picking side are permanently available moving downwards and picked according to the first-in-first-out principle. Pickers retrieve the products at the front where a large number of products are readily available.

A special feature installed within the S-Pemat by SSI Schaefer - a special pillow bag for picking and bundling small parts - means that small parts are filled into small plastic bags at the end of automatic picking, which not only ensures secure, user-friendly handling when compiling the order positions of a total order but also assures that the end customer can conveniently remove the products from the delivered carton.

For larger, faster rotating products the Office Depot distribution centre has a semi-automatic picking zone with a Pick by Light system. The system, which also has a dynamic flow rack that is replenished from the back with incoming original cartons, enables the pickers to access individual products controlled by 2,700 light signals while having both hands free. The dynamic flow racks are equipped with special take-away conveyors to remove packing material.

David Hibbett explained: "To achieve a dynamic throughput, picking areas can be extended. Higher picking quantities and reduced picking errors can be achieved because the picking locations and quantities are indicated by optic signals and picking must be unambiguously confirmed."

A second area with semi-automatic picking for slower rotating products was installed with two Pick to Tote picking stations for products picked directly into the shipping cartons. The ergonomically optimised workstations, which guarantee easy, stress-free picking, are just retrieval places, part of a 13 metre Automatic Storage and Retrieval System (ASRS). With 31 levels, on a base area of just 280 square metres, the system can accommodate up to 6,000 products in 10,000 storage locations. The performance of 150 double cycles per hour not only provides for efficient space utilisation thanks to the high storage density and use of the ceiling height, but also ensures faster, efficient picking processes. This way, up to 600 cartons per hour are handled at the two Pick to Tote stations.

At six available brochure insertion devices the ready order cartons automatically receive additional material, if required, before they are closed at one of the two carton closing machines and a shipping label is attached. The cartons are then transported on a conveyor to the goods-out area where they are diverted by a shoe sorter and roller switch sorter to one of the 23 shipping docks. Five of the docks are equipped with telescope conveyors to transport the cartons directly to the already waiting trucks.

David Hibbett continued: "Thanks to the individual combination of customised components from SSI Schaefer, the Office Depot distribution centre is now one of the most productive warehouses in Europe and has the most modern warehousing technology available in today�s market. The whole design takes into account the possible need for future expansion and the system has already fulfilled the requirements and expectations regarding enhanced delivery, quality and reliability from the 24-hour, reduced power consumption and shorter reaction times, Office Depot had in mind when commissioning SSI Schaefer."

www.ssi-schaefer.co.uk

Ends

Media Enquiries:

Charlotte Lockwood, Account Manager
Harvest Marketing Communications
Tel: 023 9244 9655
Email: [email protected]

Note to Editors:

SSI Schaefer is the UK�s leading storage and materials handling equipment solutions provider.

Based in Andover, Hampshire, the company, provider of shelving, racking, containers, workshop equipment, office furniture and waste management systems, has built its reputation on an unwavering commitment to excellence - in the people it chooses to serve, its customers and the products it brings to the market.

SSI Schaefer has developed a unique partnering approach, through which the company works hand in hand with their customers to develop, design and implement the most innovative yet cost effective solution for each project - regardless of its size.

Whether the needs is for a new shelving or racking system, additional storage space, a mezzanine floor or the completion of an automated distribution centre, SSI Schaefer prides itself on going the extra mile to fulfill and deliver the best solutions ... on time and to budget.

For further information:
SSI Schaefer - 01264 386600
Email: [email protected]
Web: www.ssi-schaefer.co.uk